Int. J. Turbomach. Propuls. Power, Volume 9, Issue 2 (June 2024) – 12 articles

Erosion damage can occur in fans and blowers during industrial processes, cooling, and mine ventilation. This study focuses on investigating erosion caused by particulate air flows in a centrifugal fan with forward-inclined blades. This type of fan is particularly vulnerable to erosion due to its radial flow component and flow recirculation. The flow field was solved separately, and the data transferred to the particle trajectory and erosion code. This in-house code implements the Lagrangian approach and the random walk algorithm, including statistical descriptions of particle sizes, release positions, and restitution factors. The study involved two types of dust particles, with a concentration between 100 and 500 μg/m³: The first type is the Saharan (North Africa) dust, which has a finer size between 0.1 and 100 microns. The second type is the Coarse Arizona Road Dust, also known as AC-coarse dust, which has a larger size ranging from 1 to 200 microns. The complex flow conditions within the impeller and scroll, as well as the concentration and size distribution of particles, are shown to affect the paths, impact conditions, and erosion patterns. The outer wall of the scroll is most heavily eroded due to high-impact velocities by particles exiting the impeller. Erosion is more pronounced on the pressure side of the full blades compared to the splitters and casing plate. The large non-uniformities of erosion patterns indicate a strong dependence with the blade position around the scroll. Therefore, the computed eroded mass is cumulated and averaged for all the surfaces of components. These results provide useful insights for monitoring erosion wear in centrifugal fans and selecting appropriate coatings to extend the lifespan. Full article

An experiment-supported simulation process chain is set up to perform numerical forced response analyses on a transonic high-pressure compressor front stage at varying operating conditions. A wake generator is used upstream of the rotor to excite a specific resonance within the operating range of the compressor. Thereby, extensive aerodynamic and structural dynamic experimental data, obtained from state-of-the-art rig testing at the Transonic Compressor Darmstadt test facility at the Technical University of Darmstadt, are used to validate numerical results and ensure realistic boundary conditions. In the course of this, five-hole-probe measurements at steady operating conditions close to the investigated resonance enable a validation of the steady aerodynamics. Subsequently, numerically obtained aeroelastic quantities, such as resonance frequency, and damping, as well as maximum alternating blade stresses and tip deflections, are compared to experimental blade tip timing data. Experimental trends in damping can be confirmed and better explained by considering numerical results regarding the aerodynamic wall work density and secondary flow phenomena. The influence of varying loading conditions on the resonance frequency is not observed as distinctly in numerical, as in experimental results. Generally, alternating blade stresses and deflections appear to be significantly lower than in the experiments. However, similar to the aerodynamic damping, numerical results contribute to a better understanding of experimental trends. The successive experimental validation shows the capabilities of the numerical forced response analysis setup and enables the highlighting of challenges and identification of potential further adaptations. Full article

The deposition of combustion residues in the nozzle ring (NR) of a turbocharger turbine stage changes the NR geometry significantly in a random manner. The resultant complex and highly asymmetric geometry induces low engine order (LEO) excitation, which may lead to resonance excitation of rotor blades and high cycle fatigue (HCF) failure. Therefore, a suitable prediction workflow is of great importance for the design and validation phases. The prediction of LEO excitation is, however, computationally expensive as high-fidelity, full annulus CFD models are required. Previous investigations showed that a steady-state computational model consisting of the volute, the NR, and a radial extension is suitable to reduce the computational costs massively and to qualitatively predict the level of LEO forced response. In the current paper, the aerodynamic excitation of 69 real contaminated NRs is analyzed using this simplified approach. The results obtained by the simplified simulation model are used to select 13 contaminated NR geometries, which are then simulated with a model of the entire turbine stage, including the rotor, in a transient time-marching manner to provide high-fidelity simulation results for the verification of the simplified approach. Furthermore, two contamination patterns are analyzed in a more detailed manner regarding their aerodynamic excitation. It is found that the simplified model can be used to identify and classify contamination patterns that lead to high blade vibration amplitudes. In cases where transient effects occurring in the rotor alter the harmonic pressure field significantly, the ability of the simplified approach to predict the LEO excitation is not sufficient. Full article

The accurate prediction of rotating stall inception is critical for determining the stable operating regime of a compressor. Among the two widely accepted pathways to stall, namely, modal and spike, the former is plausibly believed to originate from a global linear instability, and experiments have partially confirmed it. As for the latter, recent computational and experimental findings have shown it to exhibit itself as a rapidly amplified flow perturbation. However, rigorous analysis has yet to be performed to prove that this is due to global linear instability. In this work, an eigenanalysis approach is used to investigate the rotating stall inception of a transonic annular cascade. Steady analyses were performed to compute the performance characteristics at a given rotational speed. A numerical stall boundary was first estimated based on the residual convergence behavior of the steady solver. Eigenanalyses were then performed for flow solutions at a few near-stall points to determine their global linear stability. Once the relevant unstable modes were identified according to the signs of real parts of eigenvalues, they were examined in detail to understand the flow destabilizing mechanism. Furthermore, time-accurate unsteady simulations were performed to verify the obtained eigenvalues and eigenvectors. The eigenanalysis results reveal that at the rotating stall inception condition, multiple unstable modes appear almost simultaneously with a leading mode that grows most rapidly. In addition, it was found that the unstable modes are continuous in their nodal diameters, and are members of a particular family of modes typical of a dynamic system with cyclic symmetries. This is the first time such an interesting structure of the unstable modes is found numerically, which to some extent explains the rich and complex results constantly observed from experiments but have never been consistently explained. The verified eigenanalysis method can be used to predict the onset of a rotating stall with a CPU time cost orders of magnitude lower than time-accurate simulations, thus making compressor stall onset prediction based on the global linear instability approach feasible in engineering practice. Full article

The present contribution is in direct continuation of previous work which aimed at demonstrating the possible benefit of the unsteady feeding of turbines. Some numerical analyses of the flow inside a skeletal cascade revealed that instantaneous overloading occurs on the blades. However, such an academic case is far from a realistic configuration. The present paper investigates the influence of a simplified thickness distribution to check whether the instantaneous benefit is still observed. Based on numerical simulations, an analysis of the physical origin of the overloading is proposed on a single blade. It results in the choice of a triangular thickness distribution, which should promote the physical phenomena responsible for the overloading. A parametric study of such a distribution demonstrates that it is possible to obtain instantaneous performance very close to the optimum of the flat plate. Conclusions drawn from the single-blade analysis are extended to cascades and stator–rotor configurations and show an increase in the complexity of physical phenomena. Ultimately, the aim is to optimize the geometric shape to obtain maximum overloading. Consequently, the same type of study was carried out for the expansion phase, and similar results were obtained. Full article

In rotating detonation engines the turbine inlet conditions may be transonic with unprecedented unsteady fluctuations. To ensure an acceptable engine performance, the turbine passages must be suited to these conditions. This article focuses on designing and characterizing highly diffusive turbine vanes to operate at any inlet Mach number up to Mach 1. First, the effect of pressure loss on the starting limit is presented. Afterward, a multi-objective optimization with steady RANS simulations, including the endwall and 3D vane design is performed. Compared to previous research, significant reductions in pressure loss and stator-induced rotor forcing are obtained, with an extended operating range and preserving high flow turning. Finally, the influence of the inlet boundary layer thickness on the vane performance is evaluated, inducing remarkable increases in pressure loss and downstream pressure distortion. Employing an optimization with a thicker inlet boundary layer, specific endwall design recommendations are found, providing a notable improvement in both objective functions. Full article

Alongside the capability to simulate rotor–stator interactions, a central aspect within the development of frequency-domain methods for turbomachinery flows is the ability of the method to accurately predict rotor–rotor and stator–stator interactions on a single-passage domain. To simulate such interactions, state-of-the-art frequency-domain approaches require one fundamental interblade phase angle, and therefore it can be necessary to resort to multi-passage configurations. Other approaches neglect the cross-coupling of different harmonics. As a consequence, the influence of indexing on the propagation of the unsteady disturbances is not captured. To overcome these issues, the harmonic balance approach based on multidimensional Fourier transforms in time, recently introduced by the authors, is extended in this work to account for arbitrary interblade phase angle ratios on a single-passage domain. To assess the ability of the approach to simulate the influence of indexing on the steady, as well as on the unsteady, part of the flow, the proposed extension is applied to a modern low-pressure fan stage of a civil aero engine under the influence of an inhomogeneous inflow condition. The results are compared to unsteady simulations in the time-domain and to state-of-the-art frequency-domain methods based on one-dimensional discrete Fourier transforms. Full article

Wall proximity affects the accuracy of pressure probe measurements with a particularly strong impact on multi-hole probes. The wall-related evolution of the calibration of two hemispheric L-shaped 3D-printed five-hole probes was investigated in a low-speed wind tunnel. Pressure measurements and 2D particle image velocimetry were performed. The wall proximity causes the probe to measure a flow diverging from the wall, whereas the boundary layer causes the probe to measure a velocity directed towards the wall. Both angular calibration coefficients are affected in different manners. The error in angle measurement can reach 7°. These errors can be treated as calibration information. Acceleration caused by blockage is not the main reason for the errors. Methods to perform measurements closer to the wall are suggested. Full article

Unsteady component interaction represents a crucial topic in turbomachinery design and analysis. Combustor/turbine interaction is one of the most widely studied topics both using experimental and numerical methods due to the risk of failure of high-pressure turbine blades by unexpected deviation of hot flow trajectory and local heat transfer characteristics. Compressor/combustor interaction is also of interest since it has been demonstrated that, under certain conditions, a non-uniform flow field feeds the primary zone of the combustor where the high-pressure compressor blade passing frequency can be clearly individuated. At the integral scale, the relative motion between vanes and blades in compressor and turbine stages governs the aerothermal performance of the gas turbine, especially in the presence of shocks. At the inertial scale, high turbulence levels generated in the combustion chamber govern wall heat transfer in the high-pressure turbine stage, and wakes generated by low-pressure turbine vanes interact with separation bubbles at low-Reynolds conditions by suppressing them. The necessity to correctly analyze these phenomena obliges the scientific community, the industry, and public funding bodies to cooperate and continuously build new test rigs equipped with highly accurate instrumentation to account for real machine effects. In computational fluid dynamics, researchers developed fast and reliable methods to analyze unsteady blade-row interaction in the case of uneven blade count conditions as well as component interaction by using different closures for turbulence in each domain using high-performance computing. This research effort results in countless publications that contribute to unveiling the actual behavior of turbomachinery flow. However, the great number of publications also results in fragmented information that risks being useless in a practical situation. Therefore, it is useful to collect the most relevant outcomes and derive general conclusions that may help the design of next-gen turbomachines. In fact, the necessity to meet the emission limits defined by the Paris agreement in 2015 obliges the turbomachinery community to consider revolutionary cycles in which component interaction plays a crucial role. In the present paper, the authors try to summarize almost 40 years of experimental and numerical research in the component interaction field, aiming at both providing a comprehensive overview and defining the most relevant conclusions obtained in this demanding research field. Full article

The relationship between aerodynamic forcing and non-synchronous vibration (NSV) in axial compressors remains difficult to ascertain from experimental measurements. In this work, the relationship between casing pressure and blade vibration was investigated using experimental observations from a 1.5-stage axial compressor under off-design conditions. The wavenumber-dependent auto-spectral density (ASD) of casing pressure was introduced to aid in understanding the characteristics of pressure fluctuations that lead to the aeromechanical response. Specifically, the rotor blade’s natural frequencies and nodal diameters could be directly compared with the pressure spectra. This analysis indicated that the rotating disturbances coincided with the first bending (1B) and second bending (2B) vibration modes at certain frequencies and wavenumbers. The non-intrusive stress measurement system (NSMS) data showed elevated vibration amplitudes for the coincident nodal diameters. The amplitude of the wavenumber-dependent pressure spectra was projected onto the single-degree-of-freedom (SDOF) transfer function and was compared with the measured vibration amplitude. The results showed a near-linear relationship between the pressure and vibration data. Full article

Labyrinth seals are commonly used in turbomachinery in order to control leakage flows. Flutter is one of the most dangerous potential issues for them, leading to High Cycle Fatigue (HCF) life considerations or even mechanical failure. This phenomenon depends on the interaction between aerodynamics and structural dynamics; mainly due to the very high uncertainties regarding the details of the fluid flow through the component, it is very hard to predict accurately. In 2014, as part of the E-Break research project funded by the European Union (EU), an experimental campaign regarding the flutter behaviour of labyrinth seals was conducted at “Centro de Tecnologias Aeronauticas” (CTA). During this campaign, three realistic seals were tested at different rotational speeds, and the pressure ratio where the flutter onset appeared was determined. The test was reproduced using a linearised uncoupled structural-fluid methodology of analysis based on Computational Fluid Dynamics (CFD) simulations, with results only in moderate agreement with experimental data. A procedure to adjust the CFD simulations to the steady flow measurements was developed. Once this method was applied, the matching between flutter predictions and the measured data improved, but some discrepancies could still be found. Finally, a set of simulations to retain the influence of the external cavities was run, which further improved the agreement with the testing data. Full article

The manufacturing geometrical variability in axial compressors is a stochastic source of uncertainty, implying that the real geometry differs from the nominal design. This causes the real geometry to lose the ideal axial symmetry. Considering the aerofoils of a stator vane, the geometrical variability affects the flow traversing it. This impacts the downstream rotor, especially when considering the aeroelastic excitation forces. Optical surface scans coupled with a parametrisation method allow for acquiring the information relative to the real aerofoils geometries. The measured data are included in a multi-passage and multi-stage CFD setup to represent the mistuned flow. In particular, low excitation harmonics on the rotor vane are introduced due to the geometrical deviations of the upstream stator. The introduced low engine orders, as well as their amplitude, depend on the stator geometries and their order. A method is proposed to represent the phenomena in a reduced CFD domain, limiting the size and number of solutions required to probabilistically describe the rotor excitation forces. The resulting rotor excitation forces are reconstructed as a superposition of disturbances due to individual stator aerofoils geometries. This indicates that the problem is linear in the combination of disturbances from single passages. Full article