Aero engines are made up of a large number of blades which are subject to wear and damage. They are expensive and must be repaired wherever possible. Engines also have small components which are required in small numbers that need to be developed rapidly. The first part of this research work focuses on developing a robust automated blade repair method using robotic welding. Optimal weld parameters were developed for build-up of edges having different thicknesses. Samples with varying Current and varying travel speed were produced and their micro hardness values were compared. Blade profiles were welded upon. The second part involves a methodology for producing small components using rapid prototyping (RP) techniques. This part involves use of 3D robotic welding for layered manufacturing. Tensile samples produced using the metal RP method were tested and results were found to be well above the minimum cast specifications for the given material.

An accelerated high cycle fatigue testing approach is presented to determine the fatigue endurance limit of materials at high frequencies. Base excitation of a tapered plaque driven into a high frequency resonance mode allows the test to be completed in a significantly shorter time. This high cycle fatigue testing is performed using the tracked sine resonance search and dwell strategy. The controller monitors the structural health during the test. Any change in the dynamic response indicates crack initiation in the material. In addition, a shape optimization finite element model is conducted for the design of the tapered plaques. An integrated neural (Neural-Network) genetic (NSGA_II) optimization technique is implemented to carry out the shape optimization for this component. This process results in a significant reduction in the computational cost. A Pareto set is then produced that meets the designer’s requirements and provides the decision maker several alternatives to choose from.

The effect of rotation on flow in a gas turbine blade cooling duct model is investigated experimentally. The present work consists of velocity measurements at different locations in a test section with a 180° bend with ribs on one wall. Three geometric rib parameters are considered; rib-rib spacing, rib orientation angle and rib blockage ratio. PIV is used for flow visualization and analysis. Along with the clean duct measurements, ribs with blockage ratios, b/h, of 0.25 and 0.125 were considered. The b/h = 0.25 cases have been comprehensively analyzed while the b/h = 0.125 cases have been studied at the post-bend region of the duct only. Reynolds number considered is in the range of approximately 5000-40,000 and the rotation speed is varied for a rotation number from 0 to 7. It is observed that rotation has a significant effect on secondary flows within the rotating duct. For blockage ratio, b/h = 0.25, at a constant Re and Ro, the RMS of fluctuations of velocity do not show large spatial variations with ribs or rib orientations. At higher Re, the value decreases in comparison to the low Re cases. The kinetic energy of fluctuations increases due to the presence of ribs, indicating better heat transfer for the ribbed duct, but do not show large variations with rib orientation angle. The fluctuations and kinetic energy show maximum values at the post-bend regions of the duct. The velocity fields and PDFs show a possible cause for e°cient heat transfer for the 45° rib arrangement as compared with the 90° rib cases. At high Ro, the absolute value of circulation has a large increase at the post-bend and thereafter there is a gradual decay at the exit for all cases. The ribs with blockage ratio of b/h = 0.125 showed no marked changes in circulation with changes in rib orientation angle, thus implying that the rib blockage plays a role in the generation of secondary flows, particularly in conjunction with rotation.

A model of a gas turbine blade cooling channel equipped with turbulators and a backward facing step geometry was examined. Up to four turbulators oriented cross-stream and inclined 45° to the flow direction were mounted in the channel. The blockage ratio b/H of the turbulators and the height h/H of the backward facing step was 0:125 and 0:14 respectively. The number of turbulators as well as their size was varied. In a preliminary investigation, hot-wire and pressure measurements were taken for three different Reynolds numbers (5,000, 12,000, 18,000)in the center plane of the test section. Subsequently, particle image velocimetry (PIV) measurements were made on the same geometries. Results of PIV measurements for a Reynolds number range of Reb=600 to 5,000 for the turbulators and Reh=1,500 to 16,200 for the backward facing step are presented, where Reynolds numbers are based on turbulator height b and step height h, respectively. Plots of the velocity field, vorticity, reverse flow probability and RMS velocity are shown. The focus is on the steady flow behavior but also the unsteadiness of the flow is discussed in one section. Also reattachment lengths were obtained and compared among the various turbulator arrangements and the backward facing step geometry. It was found that the flow becomes periodic after three or four ribs. For one turbulator, a very large separation region was observed. The magnitude of the skin friction factor was found to be the highest for two ribs. If the first rib is replaced by a smaller rib, the skin friction factor becomes the lowest for this case. Compared to the backward facing step, the flow reattaches earlier for multiple turbulators. A dependency of reattachment length on Reynolds number was not observed.

The flow field around a low pressure turbine blade is examined using smoke-wire flow visualization, static surface pressure measurements, and particle image velocimetry (PIV). The purpose of the experimental study is to investigate the transition and separation characteristics on low pressure turbine blades under low Reynolds number (Re) and varying freestream turbulence intensity (FSTI). A cascade model consisting of 6 Pratt andamp; Whitney PAK-B low pressure turbine blades was examined in a wind tunnel using PIV and flow visualization. Smoke-wire visualization was performed for test section exit angles of 93°, 95°, and 97°, in the range Re = 3 · 104 to 9 · 104 and three levels of FSTI varied with a passive grid. The locations of separation and transition were determined to be approximately 45% and 77% of the suction surface length, respectively, based upon the smoke stream lines observed in the images, and appear to be independent of Re, turning angle, and FSTI. The maximum size of the separation bubble was found to decrease with increasing Re, turning angle, and FSTI. PIV images from three camera views were processed for an exit angle of 95° and a Re range of 3:0 · 104 to 30:0 · 104 and three levels of FSTI. Velocity, vorticity, and reversed flow probability field plots were generated along with velocity, vorticity, and RMS velocity profiles. The point of separation point was determined to be from 63% SSL to 67% SSL. The area of reversed flow was computed for each image pair from camera views 1 and 3, as an approxiamtion of the relative size of the separation region. For low Re and FSTI cases the area was much larger than for higher FSTI cases at any Re. The raw PIV images include some of the rst clear pictures of the turbulent flow structures forming in the unsteady shear layer over the suction surface of low pressure turbine blades. Several movies are compiled that show how the geometry and location of the shear layer evolve in time for a given set of flow conditions.

Alleviating loads on a wind turbine blades would allow a reduction in weight, and potentially increase the size and lifespan of rotors. Trailing edge flaps are one technology proposed for changing the aerodynamic characteristics of a blade in order to limit the transformation of freestream wind fluctuations into load fluctuations within the blade structure. An instrumented wind turbine test rig and rotor were developed to enable a wide-range of experimental set-ups for such investigations. The capability of the developed system was demonstrated through a study of the effect of stationary trailing edge flaps on blade load and performance. The investigation focused on measuring the changes in flapwise bending moment and power production for various trailing edge flap parameters. The blade was designed to allow accurate instrumentation and customizable settings, with a design point within the range of wind velocities in a large open jet test facility. The wind facility was an open circuit wind tunnel with a maximum velocity of 11m/s in the test area. The load changes within the blade structure for different wind speeds were measured using strain gauges as a function of flap length, location and deflection angle. The blade was based on the S833 airfoil and is 1.7 meters long, had a constant 178mm chord and a 6o pitch. The aerodynamic parts were 3D printed using plastic PC-ABS material. The total loading on the blade showed higher reduction when the flap was placed further away from the hub and when the flap angle (pitching towards suction side) was higher. The relationship between the load reduction and deflection angle was roughly linear as expected from theory. The effect on moment was greater than power production with a reduction in moment up to 30% for the maximum deflection angle compared to 6.5% reduction in power for the same angle. Overall, the experimental setup proved to be effective in measuring small changes in flapwise bending moment within the wind turbine blade.

Aero engines are made up of a large number of blades which are subject to wear and damage. They are expensive and must be repaired wherever possible. Engines also have small components which are required in small numbers that need to be developed rapidly. The first part of this research work focuses on developing a robust automated blade repair method using robotic welding. Optimal weld parameters were developed for build-up of edges having different thicknesses. Samples with varying Current and varying travel speed were produced and their micro hardness values were compared. Blade profiles were welded upon. The second part involves a methodology for producing small components using rapid prototyping (RP) techniques. This part involves use of 3D robotic welding for layered manufacturing. Tensile samples produced using the metal RP method were tested and results were found to be well above the minimum cast specifications for the given material.

A modular structural design methodology for composite blades is developed. This design method can be used to design composite rotor blades with sophisticate geometric cross-sections. This design method hierarchically decomposed the highly-coupled interdisciplinary rotor analysis into global and local levels. In the global level, aeroelastic response analysis and rotor trim are conduced based on multi-body dynamic models. In the local level, variational asymptotic beam sectional analysis methods are used for the equivalent one-dimensional beam properties. Compared with traditional design methodology, the proposed method is more efficient and accurate. Then, the proposed method is used to study three different design problems that have not been investigated before. The first is to add manufacturing constraints into design optimization. The introduction of manufacturing constraints complicates the optimization process. However, the design with manufacturing constraints benefits the manufacturing process and reduces the risk of violating major performance constraints. Next, a new design procedure for structural design against fatigue failure is proposed. This procedure combines the fatigue analysis with the optimization process. The durability or fatigue analysis employs a strength-based model. The design is subject to stiffness, frequency, and durability constraints. Finally, the manufacturing uncertainty impacts on rotor blade aeroelastic behavior are investigated, and a probabilistic design method is proposed to control the impacts of uncertainty on blade structural performance. The uncertainty factors include dimensions, shapes, material properties, and service loads.

This study investigates the manifestation of geometric features of turbine blades in signatures of non-optical time of arrival (ToA) probes. The approach enables an evaluation of the various signal characteristics used for defining ToA for a range of airfoil geometries and provides knowledge about additional waveform characteristics. The objective of this research is to increase the accuracy of microwave ToA probes by gaining a better understanding of the microwave signals in five steps. Firstly, ToA definitions used in the past are compared. Considering accuracy, computational effort, and versatility, the constant fraction crossing definition is found to be the most accurate. Secondly, an experimental apparatus capable of measuring airfoil ToA with microwave probes and optical probes as a reference is designed and built. As a third step, a catalog of 16 turbine blade geometries is developed. Fourthly, the signatures of these turbine blades are acquired using both the optical and the microwave probes. Finally, the impact of the geometric effects on the signatures is evaluated. The quality of the microwave results is found to be highly dependent on the polarization of the microwaves. Analysis of the time domain signal shows that decreasing the blade width, increasing the chord angle, or incorporating a blade tip pocket or a varying cross-section leads to a decrease in the amplitude of the peak caused by the blade. Increasing the blade width and incorporating a chord angle leads to an increase in peak width. A frequency domain analysis is conducted on the microwave signals and verified using a synthetic signal. This analysis confirms the findings from the time domain analysis. The time domain analysis of the laser measurements shows that the spatial resolution of the laser is much higher than that of the microwave sensor. Consequently, the signal acquired with the optical setup provides a good means of defining the blade ToA. The knowledge gained in this study about the sensor and its interaction with passing blade tips of varying geometry can be used to enhance the understanding of microwave ToA measurements. This knowledge provides further insight into airfoil and engine health.

Thesis (M.S.)--University of Michigan, 1971.