Quantifying ageing effects in thermochromic liquid crystal thermography as applied to transient convective heat transfer experiments

Thermochromic liquid crystal (TLC) thermography is used in transient heat transfer experiments to determine distributions of convective heat transfer coefficient (HTC) inside models of internally cooled gas turbine engine components. As these components become more geometrically complex, the application of TLC thermography becomes increasingly challenging and additional sources of experimental uncertainty grow to be significant. The present work quantifies the uncertainties introduced by TLC ageing using a state-of-the-art imaging system and a new postprocessing methodology that are optimised for the intensity-based method of analysing TLC data. A coating comprising multiple TLCs with different active temperature ranges is considered and subject to 33 repeated thermal cycles. These repeated cycles are shown to increase the random and systematic uncertainties in the TLC measurements, resulting in consequent increases in the uncertainties associated with calculated HTCs. Increases in systematic uncertainty are caused by reflectance in the measured wavelength band moving to different temperatures, while increases in random uncertainty are related to changes in individual crystals or crystal clusters with ageing. Approaches to calibrating out increases in systematic uncertainty are proposed and recommended, but increases in random uncertainty will always persist unless the TLC coating is removed and reapplied

Stagnation temperature measurement using thin-film platinum resistance sensors

The measurement of stagnation temperature in high-speed flows is an important aspect of gas turbine engine testing. The ongoing requirement to improve the accuracy of such measurements has led to the development of probe systems that use a thin-film platinum resistance thermometer (PRT) as the sensing element. For certain aspects of engine testing this type of sensing device potentially offers superior measurement performance to the thermocouple, the temperature sensor of choice in most gas turbine applications. This paper considers the measurement performance of prototype PRT-based stagnation temperature probes, up to high-subsonic flow conditions, using passively aspirated probe heads. The relatively poor temperature recovery performance of a simply constructed probe has led to the development of a new design that is intended to reduce the impact of thermal conduction within the probe assembly. The performance of this so-called dual-skin probe has been measured through a series of tests at a range of Mach numbers, incidence angles and Reynolds numbers. The data reveal that a high probe recovery factor has been achieved with this device, and that the application of this design to engine tests would yield the measurement performance benefits of the PRT whilst requiring small levels of temperature recovery compensation

Combination probes for stagnation pressure and temperature measurements in gas turbine engines

During gas turbine engine testing, steady-state gas-path stagnation pressures and temperatures are measured in order to calculate the efficiencies of the main components of turbomachinery. These measurements are acquired using fixed intrusive probes, which are installed at the inlet and outlet of each component at discrete point locations across the gas-path. The overall uncertainty in calculated component efficiency is sensitive to the accuracy of discrete point pressures and temperatures, as well as the spatial sampling across the gas-path. Both of these aspects of the measurement system must be considered if more accurate component efficiencies are to be determined. High accuracy has become increasingly important as engine manufacturers have begun to pursue small gains in component performance, which require efficiencies to be resolved to within less than ±1%. This article reports on three new probe designs that have been developed in a response to this demand. The probes adopt a compact combination arrangement that facilitates up to twice the spatial coverage compared to individual stagnation pressure and temperature probes. The probes also utilise novel temperature sensors and high recovery factor shield designs that facilitate improvements in point measurement accuracy compared to standard Kiel probes used in engine testing. These changes allow efficiencies to be resolved within ±1% over a wider range of conditions than is currently achievable with Kiel probes

Impact of flow unsteadiness on steady-state gas-path stagnation temperature measurements

Steady-state stagnation temperature probes are used during gas turbine engine testing as a means of characterising turbomachinery component performance. The probes are located in the high-velocity gas-path, where temperature recovery and heat transfer effects cause a shortfall between the measured temperature and the flow stagnation temperature. To improve accuracy, the measurement shortfall is corrected post-test using data acquired at representative Mach numbers in a steady aerodynamic calibration facility. However, probes installed in engines are typically subject to unsteady flows, which are characterised by periodic variations in Mach number and temperature caused by the wakes shed from upstream blades. The present work examines the impact of this periodic unsteadiness on stagnation temperature measurements by translating probes between jets with dissimilar Mach numbers. For conventional Kiel probes in unsteady flows, a greater temperature measurement shortfall is recorded compared to equivalent steady flows, which is related to greater conductive heat loss from the temperature sensor. This result is important for the application of post-test corrections, since an incorrect value will be applied using steady calibration data. A new probe design with low susceptibility to conductive heat losses is therefore developed, which is shown to deliver the same performance in both steady and unsteady flows. Measurements from this device can successfully be corrected using steady aerodynamic calibration data, resulting in improved stagnation temperature accuracy compared to conventional probe designs. This is essential for resolving in-engine component performance to better than +/-0.5% across all component pressure ratios

Heat transfer in an injector-scaled additively manufactured fuel passage

Knowledge of heat transfer in fuel wetted passages is important for informing injector design and life estimates due to the effects of temperature on fuel degradation. Future injectors will be manufactured using additive methods in an effort to reduce production costs and time, while also facilitating more agile design practices. Additive manufacturing (AM) is known to result in increased surface roughness compared to conventional manufacturing techniques, however limited data exist on how this roughness impacts heat transfer, particularly in liquid flows. This paper solves the inverse heat conduction problem for heat transfer coefficient in liquid flows through rough 90 deg channel bends typical of the pilot gallery in a lean direct-injection fuel spray nozzle. Heat transfer distributions across two rough surfaces are compared to an equivalent smooth surface. The two rough surfaces have different morphologies but have the same relative effective sand grain roughness which is matched to a prototype AM fuel injector. The sand grain roughness is predicted from a correlation that has been adapted for the high relative roughness scales characteristic of additively manufactured fuel passages. The effective sand grain roughness estimated from surface measurements of a prototype AM fuel gallery was ∼13% of the passage hydraulic diameter. For the two rough surfaces, the heat transfer enhancement is up to three times the smooth surface value for the straight section preceding the bend and up to four times around the bend. Heat transfer distributions across the two rough surfaces are similar, but the magnitudes differ by ∼17% depending on the surface morphology. This highlights the importance of the heat transfer effectiveness of surface features, which unlike the sand grain roughness is not matched for the two surfaces considered. Adjusting the data for differences in heat transfer effectiveness corrects the average heat transfer for the rough surfaces to within 7%.</p

Heat transfer and residence time in lean direct injection fuel galleries

In radially staged lean direct injection systems, pilot fuel plays an important role in cooling the mains fuel gallery in regions of the flight envelope where the mains fuel is stagnant. Under these conditions, managing wetted wall temperatures is vital to avoid the formation of carbonaceous particles, which become deposited on the surfaces of the fuel gallery and can lead to a deterioration in system performance. The prediction of wetted wall temperatures therefore represents an important aspect of the injector design phase. Such predictions are often based on injector thermal models, which tend to rely on the application of convective boundary conditions from empirical heat transfer correlations. The use of these correlations leads to questions over the accuracy of predicted wetted wall temperatures and therefore uncertainty over the probability of deposition. This paper seeks to improve on the current situation by applying the inverse conduction technique to determine heat transfer coefficients specific to the pilot fuel gallery. These heat transfer coefficients are crucial for determining wetted wall temperatures in the pilot and mains fuel galleries and principally govern the risk of deposition in the stagnant mains. The pilot heat transfer data is further examined alongside measurements of the pilot residence time distribution, which together control the risk of pilot deposition at low fuel flow rates. Both the heat transfer and residence time measurements demonstrate the opportunity for future fuel gallery design refinement and provide the supporting data to facilitate this.</div

Study of an effusion-cooled plate with high level of upstream fluctuation

The flow field and surface adiabatic coolant-film effectiveness (ACE) distribution of a combustor representative effusion cooling array with cylindrical cooling holes has been studied both experimentally and numerically. Both studies focus on the influence of inflow turbulence, especially the high inflow turbulence which is always present in the combustor environment but rarely studied in the literature. A fluctuating inflow at roughly 20% intensity level is generated in the wind tunnel, and distributions of ACE measured for blowing ratios (BR) between 1.8 and 4.1. For comparison, ACE distributions are also measured at a low inflow turbulence intensity of 5%. For further investigation on the mechanism of inflow turbulence effects, hybrid large eddy simulations (LES) are carried out at a BR of around 1.8 under both low and high inflow turbulence intensities. The fluctuating inflow is generated using the Synthetic Eddy Method (SEM) with similar turbulence intensity. The predicted surface ACE distributions of the 2 cases are compared with the measurements. More detailed studies of the flow field are carried out based on the numerical results. The effects of inflow fluctuation levels are studied by comparing various flow statistics between the low and high fluctuation cases. The formation of the coolant film is also studied based on the development of the coolant film thickness. The interaction between the upstream and downstream coolant jets is investigated by visualising the coolant jet centre trajectory, as well as analyzing the turbulence structures, spectra and coherence at selected positions. These analysis clearly show that the highly fluctuating inflow results in an enhanced mixing of the coolant and mainstream. In the high turbulence intensity case, this leads to wider span-wise and shorter stream-wise film coverage over the first few rows of the array. These effects diminish as soon as a thick coolant film is formed in the downstream, especially at high BR conditions