Transient liquid-crystal technique used to produce high-resolution convective heat-transfer-coefficient maps

In this transient technique the preheated isothermal model wall simulates the classic one-dimensional, semi-infinite wall heat transfer conduction problem. By knowing the temperature of the air flowing through the model, the initial temperature of the model wall, and the surface cooling rate measured at any location with time (using the fast-response liquid-crystal patterns recorded on video tape), the heat transfer coefficient can be calculated for the color isothermal pattern produced. Although the test was run transiently, the heat transfer coefficients are for the steady-state case. The upstream thermal boundary condition was considered to be isothermal. This transient liquid-crystal heat-transfer technique was used in a transient air tunnel in which a square-inlet, 3-to-1 exit transition duct was placed. The duct was preheated prior to allowing room temperature air to be suddenly drawn through it. The resulting isothermal contours on the duct surfaces were revealed using a surface coating of thermochromic liquid crystals that display distinctive colors at particular temperatures. A video record was made of the temperature and time data for all points on the duct surfaces during each test. The duct surfaces were uniformly heated using two heating systems: the first was an automatic temperature-controlled heater blanket completely surrounding the test duct like an oven, and the second was an internal hot-air loop through the inside of the test duct. The hot-air loop path was confined inside the test duct by insulated heat dams located at the inlet and exit ends of the test duct. A recirculating fan moved hot air into the duct inlet, through the duct, out of the duct exit, through the oven, and back to the duct inlet. The temperature nonuniformity of the test duct model wall was held very small. Test results are reported for two inlet Reynolds numbers of 200,000 and 1,150,000 (based on the square-inlet hydraulic diameter) and two free-stream turbulence intensities of about 1 percent, which is typical of wind tunnels, and up to 20 percent (using a grid), which is typical of real engine conditions

Heat transfer measurements from a NACA 0012 airfoil in flight and in the NASA Lewis icing research tunnel

Local heat transfer coefficients from a smooth and roughened NACA 0012 airfoil were measured using a steady state heat flux method. Heat transfer measurements on the specially constructed 0.533 meter chord airfoil were made both in flight on the NASA Lewis Twin Otter Research Aircraft and in the NASA Lewis Icing Research Tunnel (IRT). Roughness was obtained by the attachment of small, 2 mm diameter, hemispheres of uniform size to the airfoil surface in four distinct patterns. The flight data was taken for the smooth and roughened airfoil at various Reynolds numbers based on chord in the range of 1.24x10(exp 6) to 2.50x10(exp 6) and at various angles of attack up to 4 degrees. During these flight tests the free stream velocity turbulence intensity was found to be very low (less than 0.1 percent). The wind tunnel data was taken in the Reynolds number range of 1.20x10(exp 6) to 4.52x10(exp 6) and at angles of attack from -4 degrees to +8 degrees. The turbulence intensity in the IRT was 0.5 to 0.7 percent with the cloud making spray off. Results for both the flight and tunnel tests are presented as Frossling number based on chord versus position on the airfoil surface for various roughnesses and angle of attack. A table of power law curve fits of Nusselt number as a function of Reynolds number is also provided. The higher level of turbulence in the IRT versus flight had little effect on heat transfer for the lower Reynolds numbers but caused a moderate increase in heat transfer at the higher Reynolds numbers. Turning on the cloud making spray air in the IRT did not alter the heat transfer. Roughness generally increased the heat transfer by locally disturbing the boundary layer flow. Finally, the present data was not only compared with previous airfoil data where applicable, but also with leading edge cylinder and flat plate heat transfer values which are often used to estimate airfoil heat transfer in computer codes

Convective heat transfer measurements from a NACA 0012 airfoil in flight and in the NASA Lewis Icing Research Tunnel

Local heat transfer coefficients were measured on a smooth and roughened NACA 0012 airfoil. Heat transfer measurements on the 0.533 m chord airfoil were made both in flight on the NASA Lewis Twin Otter Icing Research Aircraft and in the NASA Lewis Icing Research Tunnel (IRT). Roughness was obtained by the attachment of uniform 2 mm diameter hemispheres to the airfoil surface in 4 distinct patterns. Flight data were taken for the smooth and roughened airfoil at various Reynolds numbers based on chord in the range 1.24 to 2.50 x 10(exp 6) and at various angles of attack up to 4 deg. During these flight tests, the free stream velocity turbulence intensity was found to be very low (less than 0.1 percent). Wind tunnel data were acquired in the Reynolds number range 1.20 to 4.25 x 10(exp 6) and at angles of attack from -4 to 8 deg. The turbulence intensity in the IRT was 0.5 to 0.7 percent with the cloud generating sprays off. A direct comparison was made between the results obtained in flight and in the IRT. The higher level of turbulence in the IRT vs. flight had little effect on the heat transfer for the lower Reynolds numbers but caused a moderate increase in heat transfer at the high Reynolds numbers. Roughness generally increased the heat transfer

High Reynolds number and turbulence effects on aerodynamics and heat transfer in a turbine cascade

Experimental data on pressure distribution and heat transfer on a turbine airfoil were obtained over a range of Reynolds numbers from 0.75 to 7.5 x 10 exp 6 and a range of turbulence intensities from 1.8 to about 15 percent. The purpose of this study was to obtain fundamental heat transfer and pressure distribution data over a wide range of high Reynolds numbers and to extend the heat transfer data base to include the range of Reynolds numbers encountered in the Space Shuttle main engine (SSME) turbopump turbines. Specifically, the study aimed to determine (1) the effect of Reynolds number on heat transfer, (2) the effect of upstream turbulence on heat transfer and pressure distribution, and (3) the relationship between heat transfer at high Reynolds numbers and the current data base. The results of this study indicated that Reynolds number and turbulence intensity have a large effect on both the transition from laminar to turbulent flow and the resulting heat transfer. For a given turbulence intensity, heat transfer for all Reynolds numbers at the leading edge can be correlated with the Frossling number developed for lower Reynolds numbers. For a given turbulence intensity, heat transfer for the airfoil surfaces downstream of the leading edge can be approximately correlated with a dimensionless parameter. Comparison of the experimental results were also made with a numerical solution from a two-dimensional Navier-Stokes code

Heat Transfer Measurements for a Film Cooled Turbine Vane Cascade

Experimental heat transfer and pressure measurements were obtained on a large scale film cooled turbine vane cascade. The objective was to investigate heat transfer on a commercial high pressure first stage turbine vane at near engine Mach and Reynolds number conditions. Additionally blowing ratios and coolant density were also matched. Numerical computations were made with the Glenn-HT code of the same geometry and compared with the experimental results. A transient thermochromic liquid crystal technique was used to obtain steady state heat transfer data on the mid-span geometry of an instrumented vane with 12 rows of circular and shaped film cooling holes. A mixture of SF6 and Argon gases was used for film coolant to match the coolant-to-gas density ratio of a real engine. The exit Mach number and Reynolds number were 0.725 and 2.7 million respectively. Trends from the experimental heat transfer data matched well with the computational prediction, particularly for the film cooled case

Measurements and computational analysis of heat transfer and flow in a simulated turbine blade internal cooling passage

Visual and quantitative information was obtained on heat transfer and flow in a branched-duct test section that had several significant features of an internal cooling passage of a turbine blade. The objective of this study was to generate a set of experimental data that could be used to validate computer codes for internal cooling systems. Surface heat transfer coefficients and entrance flow conditions were measured at entrance Reynolds numbers of 45,000, 335,000, and 726,000. The heat transfer data were obtained using an Inconel heater sheet attached to the surface and coated with liquid crystals. Visual and quantitative flow field results using particle image velocimetry were also obtained for a plane at mid channel height for a Reynolds number of 45,000. The flow was seeded with polystyrene particles and illuminated by a laser light sheet. Computational results were determined for the same configurations and at matching Reynolds numbers; these surface heat transfer coefficients and flow velocities were computed with a commercially available code. The experimental and computational results were compared. Although some general trends did agree, there were inconsistencies in the temperature patterns as well as in the numerical results. These inconsistencies strongly suggest the need for further computational studies on complicated geometries such as the one studied

Toward Cooling Uniformity: Investigation of Spiral, Sweeping Holes, and Unconventional Cooling Paradigms

Surface infrared thermography, hotwire anemometry, and thermocouple surveys were performed on two new film cooling hole geometries: spiral/rifled holes and fluidic sweeping holes. Ways to quantify the efficacy of novel cooling holes that are asymmetric, not uniformly spaced or that show variation from hole to hole are presented. The spiral holes attempt to induce large-scale vorticity to the film cooling jet as it exits the hole to prevent the formation of the kidney shaped vortices commonly associated with film cooling jets. The fluidic sweeping hole uses a passive in-hole geometry to induce jet sweeping at frequencies that scale with blowing ratios. The spiral hole performance is compared to that of round holes with and without compound angles. The fluidic hole is of the diffusion class of holes and is therefore compared to a 777 hole and square holes. A patent-pending spiral hole design showed the highest potential of the nondiffusion type hole configurations. Velocity contours and flow temperature were acquired at discreet cross-sections of the downstream flow field. The passive fluidic sweeping hole shows the most uniform cooling distribution but suffers from low span-averaged effectiveness levels due to enhanced mixing. The data was taken at a Reynolds number of 11,000 based on hole diameter and freestream velocity. Infrared thermography was taken for blowing ratios of 1.0, 1.5, 2.0, and 2.5 at a density ratio of 1.05. The flow inside the fluidic sweeping hole was studied using 3D unsteady RANS. A section on ideas for future work is included that addresses issues of quantifying cooling uniformity and provides some ideas for changing the way we think about cooling such as changing the direction of cooling or coupling acoustic devices to cooling holes to regulate frequency

Fluidic Actuation for Aeropropulsive Acoustic Improvements

Experiments were performed in NASAs SW-2 cascade facility to compare three trailing edge actuation concepts to a 3D airfoil section with no trailing edge treatment. At a Reynolds number of 105, trailing edge pulsed ejection using fluidic oscillator devices was shown to fill the momentum deficit in the wake more uniformly than other actuators tested, with expected benefits for tonal noise in engine fans. Furthermore, pulsed ejection was found to alter the acoustic signature of the wake to reduce broadband noise. In some locations in the wake, spectral components of velocity were found to be reduced by 2 to 5 dB across nearly all frequencies. Trailing edge pulsed ejection is established as a feasible concept to reduce both tonal and broadband noise emissions from aircraft engines

Measurements of Heat Transfer, Flow, and Pressures in a Simulated Turbine Blade Internal Cooling Passage

An experimental study was made to obtain quantitative information on heat transfer, flow, and pressure distribution in a branched duct test section that had several significant features of an internal cooling passage of a turbine blade. The objective of this study was to generate a set of experimental data that could be used for validation of computer codes that would be used to model internal cooling. Surface heat transfer coefficients and entrance flow conditions were measured at nominal entrance Reynolds numbers of 45,000, 335,000, and 726,000. Heat transfer data were obtained by using a steady-state technique in which an Inconel heater sheet is attached to the surface and coated with liquid crystals. Visual and quantitative flow-field data from particle image velocimetry measurements for a plane at midchannel height for a Reynolds number of 45,000 were also obtained. The flow was seeded with polystyrene particles and illuminated by a laser light sheet. Pressure distribution measurements were made both on the surface with discrete holes and in the flow field with a total pressure probe. The flow-field measurements yielded flow-field velocities at selected locations. A relatively new method, pressure sensitive paint, was also used to measure surface pressure distribution. The pressure paint data obtained at Reynolds numbers of 335,000 and 726,000 compared well with the more standard method of measuring pressures by using discrete holes

A Fully Non-Metallic Gas Turbine Engine Enabled by Additive Manufacturing Part I: System Analysis, Component Identification, Additive Manufacturing, and Testing of Polymer Composites

The research and development activities reported in this publication were carried out under NASA Aeronautics Research Institute (NARI) funded project entitled "A Fully Nonmetallic Gas Turbine Engine Enabled by Additive Manufacturing." The objective of the project was to conduct evaluation of emerging materials and manufacturing technologies that will enable fully nonmetallic gas turbine engines. The results of the activities are described in three part report. The first part of the report contains the data and analysis of engine system trade studies, which were carried out to estimate reduction in engine emissions and fuel burn enabled due to advanced materials and manufacturing processes. A number of key engine components were identified in which advanced materials and additive manufacturing processes would provide the most significant benefits to engine operation. The technical scope of activities included an assessment of the feasibility of using additive manufacturing technologies to fabricate gas turbine engine components from polymer and ceramic matrix composites, which were accomplished by fabricating prototype engine components and testing them in simulated engine operating conditions. The manufacturing process parameters were developed and optimized for polymer and ceramic composites (described in detail in the second and third part of the report). A number of prototype components (inlet guide vane (IGV), acoustic liners, engine access door) were additively manufactured using high temperature polymer materials. Ceramic matrix composite components included turbine nozzle components. In addition, IGVs and acoustic liners were tested in simulated engine conditions in test rigs. The test results are reported and discussed in detail