Research Papers

J. Eng. Gas Turbines Power. 2019;141(9):091001-091001-13. doi:10.1115/1.4043545.

Plasma actuators may be successfully employed as virtual control surfaces, located at the trailing edge (TE) of blades, both on the pressure and on the suction side, to control the aeroelastic response of a compressor cascade. Actuators generate an induced flow against the direction of the freestream. As a result, actuating on the pressure side yields an increase in lift and nose down pitching moment, whereas the opposite is obtained by operating on the suction side. A properly phased alternate pressure/suction side actuation allows to reduce vibration and to delay the flutter onset. This paper presents the development of a linear frequency domain reduced order model (ROM) for lift and pitching moment of the plasma-equipped cascade. Specifically, an equivalent thin airfoil model is used as a physically consistent basis for the model. Modifications in the geometry of the thin airfoil are generated to account for the effective chord and camber changes induced by the plasma actuators, as well as for the effects of the neighboring blades. The model reproduces and predicts correctly the mean and the unsteady loads, along with the aerodynamic damping on the plasma equipped cascade. The relationship between the parameters of the ROM with the flow physics is highlighted.

Commentary by Dr. Valentin Fuster
J. Eng. Gas Turbines Power. 2019;141(9):091002-091002-10. doi:10.1115/1.4043555.

Turbine attachments in the aero-engine are generally subjected to combined high and low cycle fatigue (CCF) loadings, i.e., low cycle fatigue (LCF) loading due to centrifugal and thermal loading stresses superimposed to the aerodynamically induced high cycle fatigue (HCF) loading. The primary focus of this study is to predict the crack growth life for the actual full-scale turbine attachment through experimentally examining the crack growth behavior under CCF loading at elevated temperature. The crack closure effect was first investigated by using the corner-notched (CN) specimen cut from the turbine attachment since the stress state of CN specimen is more similar to turbine attachment than compact tension (CT) specimen. Employing digital image correlation (DIC) technique, the level of crack closure of CN specimen was clarified under different stress ratios (R) for LCF loading. Afterward, a CCF crack growth model for the full-scale turbine attachment was proposed, which takes the crack closure effect, time-independent crack increment, and transient vibrational analysis into account. In order to verify the proposed method, a Ferris wheel system was established to conduct CCF test on the full-scale turbine attachment at elevated temperature. This study provides an effective methodology to predict the fatigue crack growth (FCG) life of full-scale turbine attachment under CCF loading.

Commentary by Dr. Valentin Fuster
J. Eng. Gas Turbines Power. 2019;141(9):091003-091003-10. doi:10.1115/1.4043430.

Radial inflow turbines, characterized by a low specific speed, are a candidate architecture for the supercritical CO2 Brayton cycle at small scale, i.e., less than 5 MW. Prior cycle studies have identified the importance of turbine efficiency to cycle performance; hence, well-designed turbines are key in realizing this new cycle. With operation at high Reynolds numbers, and small scales, the relative importance of loss mechanisms in supercritical CO2 turbines is not known. This paper presents a numerical loss investigation of a 300 kW low specific speed radial inflow turbine operating on supercritical CO2. A combination of steady-state and transient calculations is used to determine the source of loss within the turbine stage. Losses are compared with preliminary design approaches, and geometric variations to address high loss regions of stator and rotor are trialed. Analysis shows stage losses to be dominated by endwall viscous losses in the stator. These losses are more significant than predicted using gas turbine derived preliminary design methods. A reduction in stator–rotor interspace and modification of the blade profile showed a significant improvement in stage efficiency. An investigation into rotor blading shows favorable performance gains through the inclusion of splitter blades. Through these, and other modifications, a stage efficiency of 81% is possible, with an improvement of 7.5 points over the baseline design.

Commentary by Dr. Valentin Fuster
J. Eng. Gas Turbines Power. 2019;141(9):091005-091005-11. doi:10.1115/1.4043700.

Measuring and analyzing combustion is a critical part of the development of high efficiency and low emitting engines. Faced with changes in legislation such as real driving emissions (RDE) and the fundamental change in the role of the combustion engine with the introduction of hybrid-electric powertrains, it is essential that combustion analysis can be conducted accurately across the full range of operating conditions. In this work, the sensitivity of five key combustion metrics is investigated with respect to eight necessary assumptions used for single zone diesel combustion analysis. The sensitivity was evaluated over the complete operating range of the engine using a combination of experimental and modeling techniques. This provides a holistic understanding of combustion measurement accuracy. For several metrics, it was found that the sensitivity at the mid-speed/load condition was not representative of sensitivity across the full operating range, in particular at low speeds and loads. Peak heat release rate and indicated mean effective pressure (IMEP) were found to be most sensitive to the determination of top dead center (TDC) and the assumption of in-cylinder gas properties. An error of 0.5 deg in the location of TDC would cause on average a 4.2% error in peak heat release rate. The ratio of specific heats had a strong impact on peak heat release with an error of 8% for using the assumption of a constant value. A novel method for determining TDC was proposed which combined a filling and emptying simulation with measured data obtained experimentally from an advanced engine test rig with external boosting system. This approach improved the robustness of the prediction of TDC which will allow engineers to measure accurate combustion data in operating conditions representative of in-service applications.

Commentary by Dr. Valentin Fuster
J. Eng. Gas Turbines Power. 2019;141(9):091006-091006-8. doi:10.1115/1.4043643.

Natural gas as an alternative fuel in engine applications substantially reduces both pollutant and greenhouse gas emissions. High pressure dual fuel (HPDF) direct injection of natural gas and diesel pilot has the potential to minimize methane slip from gas engines and increase the fuel flexibility, while retaining the high efficiency of a diesel engine. Speed and load variations as well as various strategies for emission reduction entail a wide range of different operating conditions. The influence of these operating conditions on the ignition and combustion process is investigated on a rapid compression expansion machine (RCEM). By combining simultaneous shadowgraphy (SG) and OH* imaging with heat release rate analysis, an improved understanding of the ignition and combustion process is established. At high temperatures and pressures, the reduced pilot ignition delay and lift-off length minimize the effect of natural gas jet entrainment on pilot mixture formation. A simple geometrical constraint was found to reflect the susceptibility for misfiring. At the same time, natural gas ignition is delayed by the early pilot ignition close to the injector tip. The shape of heat release is only marginally affected by the operating conditions and mainly determined by the degree of premixing at the time of gas jet ignition. Luminescence from the sooting natural gas flame is generally only detected after the flame extends across the whole gas jet at peak heat release rate. Termination of gas injection at this time was confirmed to effectively suppress soot formation, while a strongly sooting pilot seems to intensify soot formation within the natural gas jet.

Commentary by Dr. Valentin Fuster
J. Eng. Gas Turbines Power. 2019;141(9):091007-091007-12. doi:10.1115/1.4043848.

Perforated plates are widely used to attenuate noise emission and as acoustic liners in combustion chambers. In this study, the damping performance of the perforated plate located in the combustor inlet section is experimentally and numerically studied. The primary response of nonpremixed swirl flame under 30–400 Hz acoustic excitation with a 445 mm inlet length occurs at 134 Hz and 210 Hz modes. The perforated plate designed for 210 Hz sound absorption with a 328 mm cavity length and an 8.04% porosity is compared to plates with various cavity lengths and different orifice patterns. The acoustic absorption capability of perforated plates is evaluated by the Luong model and tested in an impedance tube. The acoustic measurements show that the sound absorption performance of each plate is strongly affected by the bias flow velocity and cavity length. The combustion results indicate that the installation of perforated plates at the inlet section has two effects: sound attenuation and redistribution of the pressure mode of the combustor. The acoustic mode analysis further demonstrated that, for damping the nonpremixed flame when the combustion instability is caused by the inlet pressure fluctuation, modification of the inlet acoustic mode shape is more efficient than the sound attenuation.

Commentary by Dr. Valentin Fuster
J. Eng. Gas Turbines Power. 2019;141(9):091008-091008-11. doi:10.1115/1.4043694.

Considered is double wall cooling, with full-coverage effusion-cooling on the hot side of the effusion plate, and a combination of impingement cooling and cross flow cooling, employed together on the cold side of the effusion plate. Data are given for a main stream flow passage with a contraction ratio (CR) of 4 for main stream Reynolds numbers Rems and Rems,avg of 157,000–161,000 and 233,000–244,000, respectively. Hot-side measurements (on the main stream flow or hot side of the effusion plate) are presented, which are measured using infrared thermography. Using a transient thermal measurement approach, measured are spatially resolved distributions of surface adiabatic film cooling effectiveness, and surface heat transfer coefficient. For the same Reynolds number, initial blowing ratio (BR), and streamwise location, increased thermal protection is often provided when the effusion coolant is provided by the cross flow/impingement combination configuration, compared to the cross flow only supply arrangement. In general, higher adiabatic effectiveness values are provided by the impingement only arrangement, relative to the impingement/cross flow combination configuration, when compared at the same Reynolds number, initial BR, and x/de location. Data for one streamwise location of x/de = 60 show that the highest net heat flux reduction line-averaged net heat flux reduction (NHFR) values are produced either by the impingement/cross flow combination configuration or by the impingement only arrangement, depending upon the particular magnitude of BR, which is considered.

Commentary by Dr. Valentin Fuster
J. Eng. Gas Turbines Power. 2019;141(9):091009-091009-8. doi:10.1115/1.4043397.

With the engine technology moving toward more challenging (highly dilute and boosted) operation, spark-ignition processes play a key role in determining flame propagation and completeness of the combustion process. On the computational side, there is plenty of spark-ignition models available in literature and validated under conventional, stoichiometric spark ignition (SI) operation. Nevertheless, these models need to be expanded and developed on more physical grounds since at challenging operation they are not truly predictive. This paper reports on the development of a dedicated model for the spark-ignition event at nonquiescent, engine-like conditions, performed in the commercial CFD code converge. The developed methodology leverages previous findings that have expanded the use and improved the accuracy of Eulerian-type energy deposition models. In this work, the Eulerian energy deposition is coupled at every computational time-step with a Lagrangian-type evolution of the spark channel. Typical features such as spark channel elongation, stretch, and attachment to the electrodes are properly described to deliver realistic energy deposition along the channel during the entire ignition process. The numerical results are validated against schlieren images from an optical constant volume chamber and show the improvement in the simulation of the spark channel during the entire ignition event, with respect to the most commonly used energy deposition approach. Further developmental pathways are discussed to provide more physics-based features from the developed ignition model in the future.

Commentary by Dr. Valentin Fuster
J. Eng. Gas Turbines Power. 2019;141(9):091010-091010-13. doi:10.1115/1.4043745.

Interest is growing in converting commercially available, two-stroke spark-ignition engines from motor gasoline to low-anti-knock-index fuel such as diesel and Jet A, where knock-limited operation is a significant consideration. Previous efforts have examined the knock limits for small two-stroke engines and explored the effect of engine controls such as equivalence ratio, combustion phasing, and cooling on engine operation during knock-free operation on high octane number fuel. This work culminates the research begun in those efforts, investigating the degree of knock-mitigation achievable through varying equivalence ratio, combustion phasing, and engine cooling on three small (28, 55, and 85 cm3 displacement) commercially available two-stroke spark-ignition engines operating on a 20 octane number blend of iso-octane and n-heptane. Combustion phasing had the largest effect; a 10 deg retardation in the CA50 mass-fraction burned angle permitted an increase in throttle that yielded a 9–11% increase in power. Leaning the equivalence ratio from 1.05 to 0.8 resulted in a 10% increase in power; enriching the mixture from 1.05 to 1.35 yielded a 6–7% increase in power but at the cost of a 25% decrease in fuel-conversion efficiency. Varying the flow rate of cooling air over the engines had a minimal effect. The results indicate that the addition of aftermarket variable spark timing and electronic fuel-injection systems offer substantial advantages for converting small, commercially available two-stroke engines to run on low-anti-knock-index fuels.

Commentary by Dr. Valentin Fuster
J. Eng. Gas Turbines Power. 2019;141(9):091011-091011-9. doi:10.1115/1.4043964.

This work evaluates different optimization algorithms for computational fluid dynamics (CFD) simulations of engine combustion. Due to the computational expense of CFD simulations, emulators built with machine learning algorithms were used as surrogates for the optimizers. Two types of emulators were used: a Gaussian process (GP) and a weighted variety of machine learning methods called SuperLearner (SL). The emulators were trained using a dataset of 2048 CFD simulations that were run concurrently on a supercomputer. The design of experiments (DOE) for the CFD runs was obtained by perturbing nine input parameters using a Monte-Carlo method. The CFD simulations were of a heavy duty engine running with a low octane gasoline-like fuel at a partially premixed compression ignition mode. Ten optimization algorithms were tested, including types typically used in research applications. Each optimizer was allowed 800 function evaluations and was randomly tested 100 times. The optimizers were evaluated for the median, minimum, and maximum merits obtained in the 100 attempts. Some optimizers required more sequential evaluations, thereby resulting in longer wall clock times to reach an optimum. The best performing optimization methods were particle swarm optimization (PSO), differential evolution (DE), GENOUD (an evolutionary algorithm), and micro-genetic algorithm (GA). These methods found a high median optimum as well as a reasonable minimum optimum of the 100 trials. Moreover, all of these methods were able to operate with less than 100 successive iterations, which reduced the wall clock time required in practice. Two methods were found to be effective but required a much larger number of successive iterations: the DIRECT and MALSCHAINS algorithms. A random search method that completed in a single iteration performed poorly in finding optimum designs but was included to illustrate the limitation of highly concurrent search methods. The last three methods, Nelder–Mead, bound optimization by quadratic approximation (BOBYQA), and constrained optimization by linear approximation (COBYLA), did not perform as well.

Commentary by Dr. Valentin Fuster
J. Eng. Gas Turbines Power. 2019;141(9):091012-091012-10. doi:10.1115/1.4043966.

The analysis of intake silencer insertion loss (IL) was conducted using a hybrid numerical method, which combined computational fluid dynamics (CFD) and acoustic finite element method (FEM). First, an experimental test was conducted to obtain the compressor intake noise spectrum under two different conditions: the turbocharger directly connected to the substitution duct and to the intake silencer, respectively. Then, the hybrid numerical method was introduced to predict the intake noise propagation. The compressor unsteady flow was calculated under the two different conditions, the pressure fluctuation on the impeller inlet plane was then extracted as noise source. The noise propagation under two different conditions were obtained. The comparison of numerical and experimental results indicates that the hybrid method used in this paper can predict the IL in different conditions as the IL under three different compressor working conditions was consistent with the experimental values. Furthermore, the noise spectral characteristics and acoustic directivity of compressor intake noise were also discussed.

Commentary by Dr. Valentin Fuster
J. Eng. Gas Turbines Power. 2019;141(9):091013-091013-16. doi:10.1115/1.4043993.

To reduce power losses due to oil flows in aeroengine gearboxes, the oil flows should be visualized and measured. In this study, we develop a flow visualization borescope that qualitatively visualizes oil flows along with a two-phase flow probe that quantitatively measures the oil/air ratio and flow velocity. The flow visualization borescope comprises a 16-mm-diameter pipe. Within the pipe, an air purge passage for removing oil mist and a borescope are integrated with an illumination laser and optical lenses, enabling clear, high-speed photography. The two-phase probe consists of a 5-mm-diameter pipe with a 1-mm-diameter measurement hole and an internal pressure adjustment pipe. The borescope and flow probe were demonstrated using a shrouded spur gear with a peripheral speed of 100 m/s and oil supply of 20 l/min. Flow visualization at 30,000 fps revealed that oil outflow from the shroud opening spreads turbulently over the entire width of the opening. Measurements of the oil/air ratio and flow velocity using the two-phase flow probe revealed a thin oil-rich layer on the shroud wall and showed that the flow speed is lower than the gear peripheral speed. The measurement equipment used herein would be easy to install in a gearbox and is therefore expected to be applied in actual aeroengine gearboxes.

Commentary by Dr. Valentin Fuster
J. Eng. Gas Turbines Power. 2019;141(9):091014-091014-9. doi:10.1115/1.4044062.

In this study, the performance characteristics of a regenerative flow turbine (RFT) prototype have been investigated by means of a computational fluid dynamics (CFD) study. The prototype has been initially designed to be used in gas pipelines replacing expansion valves but, because of the intrinsic characteristics of this kind of expander, its use can be extended to other applications like the expansion process in small-scale organic Rankine cycle (ORC) plants. In the first part of this work, the numerical results of the CFD analysis have been validated with the experimental data reported in literature for the same turbine prototype. After the validation of the model, a detailed study has been carried out in order to evaluate specific features of the turbine, focusing the attention on the typical operating conditions of small-scale low-temperature ORC systems. Results have shown that the considered RFT prototype operates with higher isentropic efficiencies (about 32% at 6000 rpm) at lower mass flow rates, while the power output is penalized compared to other operating points. The numerical analysis has also pointed out the high impact of the losses in the leakage flow in the gap between the blade tips and the stripper walls. Therefore, the CFD analysis carried out has provided a thoughtful understanding of the performance of the expander at varying operating conditions and useful insights for the future redesign of this kind of machine for the application in small-scale ORCs.

Commentary by Dr. Valentin Fuster
J. Eng. Gas Turbines Power. 2019;141(9):091015-091015-12. doi:10.1115/1.4044060.

This paper presents detailed analysis of an experimental investigation of the impact of swirl number of subsonic cross-flowing air stream on liquid jet breakup at an airflow Mach number of 0.12, which is typical in gas turbine conditions. Experiments are performed for four different swirl numbers (0, 0.2, 0.42, and 0.73) using swirl vanes at air inlet having angles of 0 deg, 15 deg, 30 deg, and 45 deg, respectively. Liquid to air momentum flux ratios (q) have been varied from 1 to 25. High-speed images of the interaction of liquid and air streams are captured and processed to estimate the jet penetration height as well as the breakup location for various flow conditions. The results show unique behavior for each swirl number, which departs from the straight flow correlations available in the literature. Based on the results, an attempt has been made to understand the physics of the phenomena and come up with a simplified physical model for prediction of jet penetration. Furthermore, the high-speed images show a dominant influence of liquid column fluttering on fracture mechanism (column or shear breakup mechanism).

Commentary by Dr. Valentin Fuster
J. Eng. Gas Turbines Power. 2019;141(9):091016-091016-9. doi:10.1115/1.4044121.

The identification method using infinitesimal theory is proposed to predict rotordynamic coefficients of annular gas seals. The transient solution combined with moving grid method was unitized to obtain the fluid reaction force at a specific position under different whirling frequencies. The infinitesimal method is then applied to obtain the rotordynamic coefficients, which agrees well with published experimental results for both labyrinth seals and eccentric smooth annular seals. Particularly, the stability parameter of the effective damping coefficient can be solved precisely. Results show that the whirling frequency has little influence on direct damping coefficient, effective damping coefficient, and cross-coupled stiffness coefficient for the labyrinth seal. And the effective damping coefficients decrease as the eccentricity ratio increases. A higher eccentricity ratio tends to destabilize the seal system, especially at a low whirling frequency. Results also show that the fluid velocity in the maximum clearance in the seal leakage path is less than that in the minimum clearance. The inertial effect dominates the flow field. Then it results in higher pressure appearing in maximum clearances. The pressure difference aggravates the eccentricity of rotor and results in static instabilities of the seal system.

Commentary by Dr. Valentin Fuster
J. Eng. Gas Turbines Power. 2019;141(9):091017-091017-9. doi:10.1115/1.4044133.

In this study, the application of ultra-high fuel injection pressure (up to 300 MPa) is compared with that of a post injection strategy for the reduction of soot at medium load conditions with exhaust gas recirculation (EGR) rates greater than 40%. Emissions were predominantly studied at the engine's maximum brake torque speed of 1600 rpm. A 4.5-L, four-cylinder diesel engine with series turbochargers and a high-pressure EGR loop was used for all tests. Results indicate that, ultra-high injection pressures may not have large effects on hydrocarbons (HC) or CO emissions. Small soot reductions were achieved at the expense of increased NOx emissions. Post injections resulted in larger soot reductions for a small increase in NOx while allowing lower fuel pressures to be utilized. The increase in NOx emissions with a post injection was observed to be comparatively less at increased engine speeds. For operation at high EGR, post injections were observed to be more effective at reducing soot than ultra-high injection pressures. Both injection pressure and post injections were observed to have small to negligible effects on engine fuel consumption, leaving EGR and injection timing as the primary efficiency drivers at the conditions studied.

Commentary by Dr. Valentin Fuster
J. Eng. Gas Turbines Power. 2019;141(9):091018-091018-9. doi:10.1115/1.4044202.

A modified experimental method using digital image correlation (DIC), a noncontact optical method for measuring full-field displacements and strains, is used to interrogate accumulated fatigue damage for low and high cycle fatigue at continuum scales. Previous energy-based fatigue life prediction methods have shown that cyclic strain energy dissipated during fatigue acts as a key damage parameter for accurate determination of total and remaining fatigue life. DIC enables the collection of accurate strain energy measurements or damaging energy of complex geometries that would otherwise be exceedingly difficult and time consuming using traditional strain measurement techniques. Thus, the use of DIC to obtain strain energy measurements of gas turbine engine (GTE) components is highly advantageous for energy-based fatigue life prediction methods. Presented in this study is the experimental characterization of the cyclic strain energy dissipation as a means of predicting fatigue performance and assessment of damage progression of Aluminum 6061 subjected to fully reversed axial fatigue loading utilizing DIC. Validation of total and cyclic strain energy dissipation DIC measurements is accomplished with the simultaneous use of axial extensometery for direct comparison and implementation to strain energy-based life prediction methods.

Commentary by Dr. Valentin Fuster
J. Eng. Gas Turbines Power. 2019;141(9):091019-091019-9. doi:10.1115/1.4044196.

This paper presents a model predictive controller (MPC) operating a solid oxide fuel cell (SOFC) gas turbine hybrid plant at end-of-life performance condition. Its performance was assessed with experimental tests showing a comparison with a proportional integral derivative (PID) control system. The hybrid system (HS) operates in grid-connected mode, i.e., at variable speed condition of the turbine. The control system faces a multivariable constrained problem, as it must operate the plant into safety conditions while pursuing its objectives. The goal is to test whether a linearized controller design for normal operating condition is able to govern a system which is affected by strong performance degradation. The control performance was demonstrated in a cyber-physical emulator test rig designed for experimental analyses on such HSs. This laboratory facility is based on the coupling of a 100 kW recuperated microturbine with a fuel cell emulation system based on vessels for both anodic and cathodic sides. The components not physically present in the rig were studied with a real-time model running in parallel with the plant. Model output values were used as set-point data for obtaining in the rig (in real-time mode) the effect of the fuel cell system. The result comparison of the MPC tool against a PID control system was carried out considering several plant properties and the related constraints. Both systems succeeded in managing the plant, still the MPC performed better in terms of smoothing temperature gradient and peaks.

Commentary by Dr. Valentin Fuster
J. Eng. Gas Turbines Power. 2019;141(9):091020-091020-14. doi:10.1115/1.4043718.

Stability of the nuclear turbine blades is difficult to be accurately predicted because the wet steam load (WSL) as well as its induced equivalent damping and stiffness during nonequilibrium condensation process (NECP) is hard to be directly calculated. Generally, in design, NECP is assumed as equilibrium condensation process (ECP), of which the two-phase temperature difference (PTD) between gaseous and liquid is ignored. In this paper, a novel method to calculate the WSL-induced equivalent damping and equivalent stiffness during NECP based on the combined microperturbation method (MPM) and computational fluid dynamics method (CFDM) was proposed. Once the WSL-induced equivalent damping and equivalent stiffness are determined, the stability of the blade-WSL system, of which the blade was modeled by a pretwisted airfoil cantilever beam, can then be predicted based on the Lyapunov's first method. Besides, to estimate the effects of PTD, comparisons between the WSL-induced equivalent damping and equivalent stiffness as well as the unstable area during NECP and ECP were presented. Results show that the WSL-induced equivalent damping and equivalent stiffness during NECP are more sensitive to the inlet boundary due to the irreversible heat transfer caused by PTD during NECP. Accordingly, the unstable area during NECP is about three times larger than during ECP.

Commentary by Dr. Valentin Fuster
J. Eng. Gas Turbines Power. 2019;141(9):091021-091021-12. doi:10.1115/1.4043973.

The realization of commercial mini organic Rankine cycle (ORC) power systems (tens of kW of power output) is currently pursued by means of various research and development activities. The application driving most of the efforts is the waste heat recovery from long-haul truck engines. Obtaining an efficient mini radial inflow turbine, arguably the most suitable type of expander for this application, is particularly challenging, given the small mass flow rate, and the occurrence of nonideal compressible fluid dynamic effects in the stator. Available design methods are currently based on guidelines and loss models developed mainly for turbochargers. The preliminary geometry is subsequently adapted by means of computational fluid-dynamic calculations with codes that are not validated in case of nonideal compressible flows of organic fluids. An experimental 10 kW mini-ORC radial inflow turbine will be realized and tested in the Propulsion and Power Laboratory of the Delft University of Technology, with the aim of providing measurement datasets for the validation of computational fluid dynamics (CFD) tools and the calibration of empirical loss models. The fluid dynamic design and characterization of this machine is reported here. Notably, the turbine is designed using a meanline model in which fluid-dynamic losses are estimated using semi-empirical correlations for conventional radial turbines. The resulting impeller geometry is then optimized using steady-state three-dimensional computational fluid dynamic models and surrogate-based optimization. Finally, a loss breakdown is performed and the results are compared against those obtained by three-dimensional unsteady fluid-dynamic calculations. The outcomes of the study indicate that the optimal layout of mini-ORC turbines significantly differs from that of radial-inflow turbines (RIT) utilized in more traditional applications, confirming the need for experimental campaigns to support the conception of new design practices.

Commentary by Dr. Valentin Fuster
J. Eng. Gas Turbines Power. 2019;141(9):091022-091022-8. doi:10.1115/1.4044061.

The objective of this study is to numerically investigate the effect of cryogenic intake air temperature on the in-cylinder temperature and formation of exhaust emissions in a CI engine. The experimental setup was consisted of a single-cylinder diesel engine. The intake air temperature was varied from 18 °C to 40 °C, which was controlled by cooler and heater. Submodels were applied for the simulations of physical/chemical phenomenon of spray and combustion behaviors. The intake air temperature in numerical condition was varied from −18 °C to 18 °C. The numerical results were validated with experimental results for the reliability of this work. The results of this work were compared in terms of cylinder pressure, rate of heat release (ROHR), indicated specific nitrogen oxide (ISNO), indicated specific carbon monoxide (ISCO), ignition delay, in-cylinder temperature distributions, equivalence ratio distributions, NO mass fraction, and CO mass fraction. When the intake air temperature was decreased in steps of 9 °C, the cylinder temperature and cylinder pressure were decreased in steps of about 14.5 °C and 0.05 MPa, respectively. In all cases, the area where the NO formed in the cylinder was identified with the area of the high equivalence ratio and temperature in the cylinder. The amount of CO generation shows the similar distributions in the cylinder according to the intake air temperature conditions. However, the oxidation rate of formed CO under the low intake air temperature was lower than those of the high intake air temperature.

Commentary by Dr. Valentin Fuster

Research Papers: Research Papers

J. Eng. Gas Turbines Power. 2019;141(9):091004-091004-16. doi:10.1115/1.4043611.

Shock vector control (SVC) based on transverse jet injection is one of the fluidic thrust vectoring (FTV) technologies, and is considered as a promising candidate for the future exhaust system working at high nozzle pressure ratio (NPR). However, the low vector efficiency (η) of the SVC nozzle remains an important problem. In the paper, a new method, named as the improved SVC, was proposed to improve the vector efficiency (η) of a SVC nozzle, which enhances the vector control of primary supersonic flow by adopting a bypass injection. It needs less secondary flow from high pressure component of an aero-engine and has smaller influence on the working character of an aero-engine. The flow mechanism of the improved SVC nozzle was investigated by solving three-dimensional Reynolds-averaged Navier--Stokes with shear stress transport (SST) κ–ω turbulence model. The shock waves, jets-primary flow interactions, flow separation, and vector performance were analyzed. The influences of aerodynamic and geometric parameters, namely, NPR, secondary pressure ratio (SPR), and bypass injection position (Xj.ad.) on flow characteristics and vector performance were investigated. Based on the design of experiment (DOE), the response surface methodology (RSM) and the simulation model of an aero-engine, a method to estimate the coupling performance of the improved SVC nozzle and an aero-engine was studied, and a new balance relationship between the improved SVC nozzle and an aero-engine was established. Results shows that (1) with the assistance of bypass injection, the jet penetration and the capability of vector control are largely improved, resulting in a vector efficiency (η) of 1.98 deg/%-ω at the designed NPRD = 13.88; (2) in a wide range of operating conditions, larger vector angle (δp), higher thrust coefficient (Cfg), and higher vector efficiency (η) of the improved SVC nozzle were obtained, (3) in the coupling process of the improved SVC nozzle and an aero-engine, a δp of 18.1 deg was achieved at corrected secondary flow ratio of 10% and corrected bypass ratio of 6.98%, and the change of the thrust and the specific fuel consumption (SFC) were within 12%, which is better than the coupling performance of a SVC nozzle and an aero-engine.

Commentary by Dr. Valentin Fuster

Research Papers: Gas Turbines: Turbomachinery

J. Eng. Gas Turbines Power. 2019;141(9):092601-092601-10. doi:10.1115/1.4043690.

In recent years, overspray fogging has become a powerful means for power augmentation of industrial gas turbines. Despite the positive thermodynamic effect on the cycle, droplets entering the compressor increase the risk of water droplet erosion and deposition of water on the blades leading to an increase of required torque and profile loss. Due to this, detailed information about the structure and the amount of water on the surface is key for compressor performance. Experiments were conducted with a droplet laden flow in a transonic compressor cascade focusing on the film formed by the deposited water. Two approaches were taken. In the first approach, the film thickness on the blade was directly measured using white light interferometry. Due to significant distortion of the flow caused by the measurement system, a transfer of the measured film thickness to the undisturbed case is not possible. Therefore, a film model is adapted to describe the film flow in terms of height averaged film parameters. In the second approach, experiments were conducted in an undisturbed cascade setup and the water film pattern was measured using a nonintrusive quantitative image processing tool. Utilizing the measured flow pattern in combination with findings from the literature, the rivulet flow structure is resolved. From continuity of the water flow, a film thickness is derived showing good agreement with the previously calculated results. Using both approaches, a three-dimensional (3D) reconstruction of the water film pattern is created giving first experimental results of the film forming on stationary compressor blades under overspray fogging conditions.

Commentary by Dr. Valentin Fuster

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