HOST turbine heat transfer subproject overview

The experimental part of the turbine heat transfer subproject consists of six large experiments, which are highlighted in this overview, and three of somewhat more modest scope. One of the initial efforts was the stator airfoil heat transfer program. The non-film cooled and the showerhead film cooled data have already been reported. The gill region film cooling effort is currently underway. The investigation of secondary flows in a 90 deg curved duct, was completed. The first phase examined flows with a relatively thin inlet boundary layer and low free stream turbulence. The second phase studied a thicker inlet boundary layer and higher free stream turbulence. A comparison of analytical and experimental cross flow velocity vectors is shown for the 60 deg plane. Two experiments were also conducted in the high pressure facility. One examined full coverage film cooled vanes, and the other, advanced instrumentation. The other three large experimental efforts were conducted in a rotation reference frame. An experiment to obtain gas path airfoil heat transfer coefficients in the large, low speed turbine was completed. Single-stage data with both high and low-inlet turbulence were taken. The second phase examined a one and one-half stage turbine and focused on the second vane row. Under phase 3 aerodynamic quantities such as interrow time-averaged and rms values of velocity, flow angle, inlet turbulence, and surface pressure distribution were measured

Review and assessment of the HOST turbine heat transfer program

The objectives of the HOST Turbine Heat Transfer subproject were to obtain a better understanding of the physics of the aerothermodynamic phenomena occurring in high-performance gas turbine engines and to assess and improve the analytical methods used to predict the fluid dynamics and heat transfer phenomena. At the time the HOST project was initiated, an across-the-board improvement in turbine design technology was needed. Therefore, a building-block approach was utilized, with research ranging from the study of fundamental phenomena and analytical modeling to experiments in simulated real-engine environments. Experimental research accounted for 75 percent of the project, and analytical efforts accounted for approximately 25 percent. Extensive experimental datasets were created depicting the three-dimensional flow field, high free-stream turbulence, boundary-layer transition, blade tip region heat transfer, film cooling effects in a simulated engine environment, rough-wall cooling enhancement in a rotating passage, and rotor-stator interaction effects. In addition, analytical modeling of these phenomena was initiated using boundary-layer assumptions as well as Navier-Stokes solutions

Experience with advanced instrumentation in a hot section cascade

The Lewis Research Center gas turbine Hot Section Test Facility was developed to provide a real engine environment with known boundary conditions for the aerothermal performance evaluation and verification of computer design codes. This verification process requires experimental measurements in a hostile environment. The research instruments used in this facility are presented, and their characteristics and how they perform in this environment are discussed. The research instrumentation consisted of conventional pressure and temperature sensors, as well as thin-film thermocouples and heat flux gages. The hot gas temperature was measured by an aspirated temperature probe and by a dual-element, fast-response temperature probe. The data acquisition mode was both steady state and time dependent. These experiments were conducted over a wide range of gas Reynolds numbers, exit gas Mach numbers, and heat flux levels. This facility was capable of testing at temperatures up to 1600 K, and at pressures up to 18 atm. These corresponded to an airfoil exit Reynolds number range of 0.5 x 10(6) to 2.5 x 10(6) based on the airfoil chord of 5.55 cm. The results characterize the performance capability and the durability of the instrumentation. The challenge of making measurements in hostile environments is also discussed. The instruments exhibited more than adequate durability to achieve the measurement profile. About 70 percent of the thin-film thermocouples and the dual-element temperature probe survived several hundred thermal cycles and more than 35 hr at gas temperatures up to 1600 K. Within the experimental uncertainty, the steady-state and transient heat flux measurements were comparable and consistent over the range of Reynolds numbers tested

A high heat flux experiment for verification of thermostructural analysis

A major concern in advancing the state of the art technologies for hypersonic vehicles is the development of an aeropropulsion system capable of handling the high heat fluxes during flight. The leading edges of such systems must not only tolerate the maximum heating rates, but must also minimize distortions to the flow field due to excessive blunting and/or thermal warping of the compression surface to achieve the high inlet performance required. A combined analytical and experimental effort to study the aerothermodynamic loads on actively cooled structures for hypersonic applications was established. A hydrogen/oxygen rocket engine was modified to establish a high enthalpy high heat flux environment. The facility provides heat flux levels from about 200 up to 10000 Btu/sq ft/sec. Cross flow and parallel flow regeneratively cooled model can be tested and analyzed by using cooling fluids of water and hydrogen. Results are presented of the experiment and the characteristics of the Hot Gas Test Facility. The predicted temperature results of the cross flow model are compared with the experimental data on the first monolithic specimens and are found to be in good agreement. Thermal stress analysis results are also presented

A unique high heat flux facility for testing hypersonic engine components

A major concern in advancing the state-of-the-art technologies for hypersonic vehicles is the development of an aeropropulsion system capable of withstanding high thermal loads expected during hypersonic flights. Consequently, there is a need for experimental facilities capable of providing a high heat flux environment for testing compound concepts and verifying analyses. A hydrogen/oxygen rocket engine was developed to provide a high enthalpy/high heat flux environment for component evaluation. This Hot Gas Facility is capable of providing heat fluxes ranging from 200 (on flat surfaces) up to 8000 Btu per sq ft per sec (at a leading edge stagnation point). Gas temperatures up to 5500 R can be attained as well as Reynolds numbers up to 360,000 per ft. Test articles such as cowl leading edges, transpiration-cooled seals, fuel injectors, and cooled panel concepts can be evaluated with gaseous hydrogen as coolant. This facility and its configuration and test capabilities are discussed. Results from flow characterization experiments are also shown and their implications considered

Heat transfer in aerospace propulsion

Presented is an overview of heat transfer related research in support of aerospace propulsion, particularly as seen from the perspective of the NASA Lewis Research Center. Aerospace propulsion is defined to cover the full spectrum from conventional aircraft power plants through the Aerospace Plane to space propulsion. The conventional subsonic/supersonic aircraft arena, whether commercial or military, relies on the turbine engine. A key characteristic of turbine engines is that they involve fundamentally unsteady flows which must be properly treated. Space propulsion is characterized by very demanding performance requirements which frequently push systems to their limits and demand tailored designs. The hypersonic flight propulsion systems are subject to severe heat loads and the engine and airframe are truly one entity. The impact of the special demands of each of these aerospace propulsion systems on heat transfer is explored

Thermal/structural analyses of several hydrogen-cooled leading-edge concepts for hypersonic flight vehicles

The aerodynamic heating at high flight Mach numbers, when shock interference heating is included, can be extremely high and can exceed the capability of most conventional metallic and potential ceramic materials available. Numerical analyses of the heat transfer and thermal stresses are performed on three actively cooled leading-edge geometries (models) made of three different materials to address the issue of survivability in a hostile environment. These analyses show a mixture of results from one configuration to the next. Results for each configuration are presented and discussed. Combinations of enhanced internal film coefficients and high material thermal conductivity of copper and tungsten are predicted to maintain the maximum wall temperature for each concept within acceptable operating limits. The exception is the TD nickel material which is predicted to melt for most cases. The wide range of internal impingement film coefficients (based on correlations) for these conditions can lead to a significant uncertainty in expected leading-edge wall temperatures. The equivalent plastic strain, inherent in each configuration which results from the high thermal gradients, indicates a need for further cyclic analysis to determine component life

Hypersonic Engine Leading Edge Experiments in a High Heat Flux, Supersonic Flow Environment

A major concern in advancing the state-of-the-art technologies for hypersonic vehicles is the development of an aeropropulsion system capable of withstanding the sustained high thermal loads expected during hypersonic flight. Three aerothermal load related concerns are the boundary layer transition from laminar to turbulent flow, articulating panel seals in high temperature environments, and strut (or cowl) leading edges with shock-on-shock interactions. A multidisciplinary approach is required to address these technical concerns. A hydrogen/oxygen rocket engine heat source has been developed at the NASA Lewis Research Center as one element in a series of facilities at national laboratories designed to experimentally evaluate the heat transfer and structural response of the strut (or cowl) leading edge. A recent experimental program conducted in this facility is discussed and related to cooling technology capability. The specific objective of the experiment discussed is to evaluate the erosion and oxidation characteristics of a coating on a cowl leading edge (or strut leading edge) in a supersonic, high heat flux environment. Heat transfer analyses of a similar leading edge concept cooled with gaseous hydrogen is included to demonstrate the complexity of the problem resulting from plastic deformation of the structures. Macro-photographic data from a coated leading edge model show progressive degradation over several thermal cycles at aerothermal conditions representative of high Mach number flight

Summary of experimental heat-transfer results from the turbine hot section facility

Experimental data from the turbine Hot Section Facility are presented and discussed. These data include full-coverage film-cooled airfoil results as well as special instrumentation results obtained at simulated real engine conditions. Local measurements of airfoil wall temperature, airfoil gas-path static-pressure distribution, and local heat-transfer coefficient distributions are presented and discussed. In addition, measured gas and coolant temperatures and pressures are presented. These data are also compared with analyses from Euler and boundary-layer codes

Analysis of developing laminar flows in circular pipes using a higher-order finite-difference technique

A higher-order finite-difference technique is developed to calculate the developing-flow field of steady incompressible laminar flows in the entrance regions of circular pipes. Navier-Stokes equations governing the motion of such a flow field are solved by using this new finite-difference scheme. This new technique can increase the accuracy of the finite-difference approximation, while also providing the option of using unevenly spaced clustered nodes for computation such that relatively fine grids can be adopted for regions with large velocity gradients. The velocity profile at the entrance of the pipe is assumed to be uniform for the computation. The velocity distribution and the surface pressure drop of the developing flow then are calculated and compared to existing experimental measurements reported in the literature. Computational results obtained are found to be in good agreement with existing experimental correlations and therefore, the reliability of the new technique has been successfully tested