In a gas turbine engine, turbine blades are exposed to temperatures above their melting point. Film-cooling and internal cooling techniques can prolong blade life and allow for higher engine temperatures. This study examines a novel cooling technique called a microcircuit, which combines internal convection and pressure side injection on a turbine blade tip. Holes on the tip called dirt purge holes expel dirt from the blade, so other holes are not clogged. Wind tunnel tests are used to observe how effectively dirt purge and microcircuit designs cool the tip. Tip gap size and blowing ratio are varied for different tip cooling configurations. Results show that the dirt purge holes provide significant film cooling on the leading edge with a small tip gap. Coolant injected from these holes impacts the shroud and floods the tip gap reducing tip leakage flow. With the addition of a microcircuit, coolant is delivered to a larger area of the tip. In all cases, cooling levels are higher for a small tip gap than a large tip gap. Increased blowing ratio does not have a dramatic effect on microcircuit film-cooling at the midchord but does improve internal cooling from the microcircuit. While the combined dirt purge holes and microcircuit cool the leading edge and midchord areas, there remains a small portion of the trailing edge that is not cooled. Also, results suggest that blowing from the microcircuit diminishes the tip leakage vortex. Overall, the microcircuit appears to be a feasible method for prolonging blade life. / Master of Science

Cooling of turbine parts in a gas turbine engine is necessary for operation as the temperature of combustion gases is higher than the melting temperature of the turbine materials. The gap between rotating turbine blades and the stationary shroud provides an unintended flow path for hot gases. Gases that flow through the tip region cause pressure losses in the turbine section and high heat loads to the blade tip. This thesis studies the heat transfer on an innovative tip geometry intended to help reduce aerodynamic losses. The blade tip has a depression (shelf) on the tip surface along much of the pressure side of the blade and film-cooling holes along the depression. This research experimentally measured the effect of the shelf, coolant flow and tip gap on heat transfer on the blade tip. Stationary experiments were performed in a low speed wind tunnel on a linear cascade with two different tip gaps and multiple coolant flow rates through the film-cooling holes. Tests showed that baseline Nusselt numbers on the tip surface were reduced with the shelf tip compared with a flat tip. Measurements indicated that film-cooling was more effective with a small tip gap than with a large tip gap. Experimental and computational results demonstrated a lack of coolant spreading that was detrimental to regions between the film-cooling holes. While the coolant was effective on the blade tip, the leading and trailing edge regions were found to have high heat transfer coefficients with little available cooling. / Master of Science

This degree project in applied physics studies the tip gap flows over the rotor blades of a high-pressure turbine. The rotor blade used in the study has an improved design that utilizes both a cavity tip and an uneven profiling to reduce turbine loss. The designed rotor blade is shown to admit a 21% lower leakage mass flow rate across the tip gap than a reference rotor blade with a flat tip. By studying the designed rotor blade using transient CFD, the flow field of the tip gap region has been studied through one blade passage. The flow field characteristics of particular interest are the leakage mass flow rate across the tip gap region, which is proportional to turbine loss, and the characteristic vortices that reside within the cavity tip. By using post-processing scripts, the leakage mass flow rate has been calculated for every time step across one blade passage, showing a strong time dependence. The characteristic vortices are found using two different vortex detection algorithms, and their respective vorticity magnitude is shown to depend on the leakage mass flow rate. The simulation shows that the vorticity magnitude is increasing above a threshold of leakage mass flow rate, and that it is decreasing under this threshold. This effect is shown to destabilize the leakage mass flow rate, increasing its amplitude over its period of one blade passage.

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Turbine airfoils are exposed to the hottest temperatures in the gas turbine with temperatures typically exceeding the melting point of the blade material. Cooling methods investigated in this computational study included parasitic cooling flow losses, which are inherent to engines, and microcircuit channels. Parasitic losses included dirt purge holes, located along the blade tip, and platform leakage flow, which result from gaps between various turbine components. Microcircuits are a novel cooling technique involving small air passages placed near the airfoil surface to enhance internal cooling. This study evaluated the benefit of external film-cooling flow exhausted from strategically placed microcircuits. Along the blade tip, predictions showed mid-chord cooling was independent of the blowing from microcircuit exits. The formation of a pressure side vortex was found to develop for most microcircuit film-cooling cases. Significant leading edge cooling was obtained from coolant exiting from dirt purge holes with a small tip gap while little cooling was seen with a large tip gap. Along the blade platform, the migration of coolant from the front leakage was shown to cool a considerable part of the platform. Several hot spots were predicted along the platform, which were circumvented through the placement of microcircuit channels. Ingestion of hot mainstream gas was predicted along the aft portion of the gutter and agreed with distress exhibited by actual gas turbine engines. / Master of Science

This thesis presents the results of a study performed in the Virginia Tech low speed linear cascade wind tunnel operating at a Reynolds number of 382,000 designed to model an axial compressor rotor. To simulate the flow created by the junction of a set of inlet guide vanes and the compressor casing, vortex generators were glued to a moving end wall. In this investigation, the tip clearance was varied from 0.83% to 12.9% chord. Measurements of the midspan and the tip blade loading were made using static pressure taps. The tip loading shows that the minimum suction surface pressure coefficient increases in magnitude linearly up to a tip clearance of 7.9% chord. Unsteady pressure was measured on the pressure and suction surfaces at the tip of two cascade blades using an array of 23 microphones mounted subsurface. These measurements reveal that the unsteady pressure at the blade tip is a linear function of tip clearance height. The instantaneous pressure shows that the surface pressure at the blade tip has the same character regardless of whether or not the blade is disturbed by the inflow vortices. This suggests that the vortex generators simply stimulate and organize the existing response of the blade. Single sensor hot-wire measurements were made within the tip clearance on the suction side of the blade 1mm from the tip gap exit. These measurements show that the mass flux through the tip clearance is closely related to the pressure difference across the tip gap. / Master of Science

<p>In the development of turbo machinery components it's desirable to not spend more time than necessary when setting up aero-thermal calculations to investigate uncertainties in the design. This report aims to describe general thoughts used in the development of an ICEM-mesh script and the possible configurations in the script file which enables the user to build mesh-grids with/without clearance gap at the hub and/or shroud for different blade geometries. It also aims to illustrate the performance analysis made on the Vinci LH2 turbine, a next generation upper stage engine to the Ariane 5 rocket, in which the effect of the tip gap size on the efficiency has been studied.</p><p>The calculations made have shown good agreement with experimental data. The efficiency loss due to the mixing of fluid where leakage flow passes the tip gap, which results in growth of a strong vortex, and the fluid passing the blade tip, with almost no work extracted from it, has shown a quite linear efficiency dependence depending on the tip gap size.</p>

In the development of turbo machinery components it's desirable to not spend more time than necessary when setting up aero-thermal calculations to investigate uncertainties in the design. This report aims to describe general thoughts used in the development of an ICEM-mesh script and the possible configurations in the script file which enables the user to build mesh-grids with/without clearance gap at the hub and/or shroud for different blade geometries. It also aims to illustrate the performance analysis made on the Vinci LH2 turbine, a next generation upper stage engine to the Ariane 5 rocket, in which the effect of the tip gap size on the efficiency has been studied. The calculations made have shown good agreement with experimental data. The efficiency loss due to the mixing of fluid where leakage flow passes the tip gap, which results in growth of a strong vortex, and the fluid passing the blade tip, with almost no work extracted from it, has shown a quite linear efficiency dependence depending on the tip gap size.

This dissertation presents the results from an experimental study of three-dimensional turbulent tip gap flow in a linear cascade wind tunnel with 3.3% chord tip clearance with and without moving endwall simulation. Experimental measurements have been completed in Virginia Tech low speed linear cascade wind tunnel. A 24" access laser-Doppler velocimeter (LDV) system was developed to make simultaneous three-velocity-component measurements. The overall size of the probe is 24"à 37"à 24"and measurement spatial resolution is about 100 μm. With 24" optical access distance, the LDV probe allows measurements to be taken from the side of the linear cascade tunnel instead of through the bottom of the tunnel floor. The probe has been tested in a zero-pressure gradient two-dimensional turbulent boundary layer. Experimental measurements (oil flow visualization, pressure measurement, and LDV measurement) for the stationary wall captured the major flow structures of the tip leakage flow in the linear compressor cascade, such as tip leakage vortex, tip leakage vortex separation and tip separation vortex. Large velocity gradients in the tip leakage vortex separation, tip leakage vortex, and tip separation vortex regions generate large production of the Reynolds stresses and turbulent kinetic energy. One of the most interesting features of the tip leakage flow is the bimodal velocity probability histograms of the v component due to the unsteady motion of the flow in the interaction region between the tip leakage vortex and tip leakage jet. The tip separation vortex, tip leakage vortex separation, and tip leakage vortex contain most of turbulent kinetic energy and generate the highest dissipation rate. Relative motion of the endwall significantly affects the tip gap flow structures, especially in the near wall region. Compared to the stationary wall case, velocity gradients in the near wall region for the moving wall case are much smaller and lower velocity gradients in the near wall region cause the low production of Reynolds stresses and turbulent kinetic energy. Similar to the stationary wall case, high Reynolds stresses and turbulent kinetic energy values are mainly located in the vicinity of the tip leakage vortex and tip separation vortex region. The bimodal velocity probability histograms of the v component are also found at the same locations. The tip separation vortex with most of the turbulent kinetic energy generates the highest dissipation rate. The dissipation rate in the tip leakage vortex region is reduced with the decrease of turbulent kinetic energy under the moving wall effect. / Ph. D.

This thesis presents some results from an experimental study of three-dimensional turbulent tip gap flows in the linear cascade wind tunnel, for two different tip gap clearances (t/c=1.65% and 3.3%). The experiments focus on near-wall flow field measurements for the stationary wall and moving wall, and static pressure measurement on the low end-wall for the stationary wall case. The representative flows were pressure driven, three-dimensional turbulent boundary layers in the linear cascade tunnel for the stationary wall case, and the combination of the pressure driven and shear driven flow for the moving wall case. Several experimental techniques are used in the studies: a three-orthogonal-velocity-component fiber-optic laser Doppler anemometer (3D-LDA) system, surface oil flow visualization, and a scanivalve system for static pressure measurement through pressure ports on the end-wall. From the details of the oil flow visualization pattern on the end-wall, some features of the passage flow, cross flow, and the tip leakage vortex in this cascade flow were captured. Oil flow visualization on the blade surface reveals the reattachment of the tip leakage vortex on the blade surface. The static pressure results on the lower end-wall and mid-span of the blade show huge pressure drop on the lower end-wall from the pressure side to the suction side of the blade and from mid-span to the lower end wall. The end-wall skin friction velocity is calculated from near-wall LDA data and pressure gradient data using the near-wall momentum equation. The statistics of Reynolds stresses and triple products in two-dimensional turbulent boundary layer and three-dimensional turbulent boundary layer was examined using a velocity fluctuation octant analysis in three different coordinates (the wall collateral coordinates, the mid tip gap coordinates, and the local mean flow angle coordinates). The velocity fluctuation octant analysis for the two-dimensional turbulent boundary layer reveals that ejections of the low speed streaks outward from the wall and the sweeps of high speed streaks inward toward the wall are the dominant coherent motions. The octant analysis for the three-dimensional turbulent boundary layer in the tip gap shows that the dominant octant events are partially different from those in the two-dimensional turbulent boundary layer, but ejection and sweep motions are still the dominant coherent motions. For the three-dimensional turbulent boundary layer in the moving wall flow, the near-wall shear flow reinforces the sweep motion to the moving wall and weakens the out-ward ejection motion in the shear flow dominant region. Between the passage flow and the shear flow, is the interaction region of the high speed streaks and the low speed streaks. This is the first time that the coherent structure of the three-dimensional turbulent boundary in the linear cascade tip gap has been studied. / Master of Science