Scaling Roughness Effects on Pressure Loss and Heat Transfer of Additively Manufactured Channels

2016 ◽  
Vol 139 (2) ◽  
Author(s):  
Curtis K. Stimpson ◽  
Jacob C. Snyder ◽  
Karen A. Thole ◽  
Dominic Mongillo
Keyword(s):  
Heat Transfer ◽  
Metal Powder ◽  
Pressure Loss ◽  
Complex Flow ◽  
Roughness Effects ◽  
Flow Paths ◽  
Flow And Heat Transfer ◽  
Flow Through ◽  
High Temperature Components ◽  
Small Channels

Additive manufacturing (AM) with metal powder has made possible the fabrication of gas turbine components with small and complex flow paths that cannot be achieved with any other manufacturing technology presently available. The increased design space of AM allows turbine designers to develop advanced cooling schemes in high-temperature components to increase cooling efficiency. Inherent in AM with metals is the large surface roughness that cannot be removed from small internal geometries. Such roughness has been shown in previous studies to significantly augment pressure loss and heat transfer of small channels. However, the roughness on these channels or other surfaces made from AM with metal powder has not been thoroughly characterized for scaling pressure loss and heat transfer data. This study examines the roughness of the surfaces of channels of various hydraulic length scales made with direct metal laser sintering (DMLS). Statistical roughness parameters are presented along with other parameters that others have found to correlate with flow and heat transfer. The pressure loss and heat transfer previously reported for the DMLS channels studied in this work are compared to the physical roughness measurements. Results show that the relative arithmetic mean roughness correlates well with the relative equivalent sand grain roughness. A correlation is presented to predict the Nusselt number of flow through AM channels, which gives better predictions of heat transfer than correlations currently available.

Scaling Roughness Effects on Pressure Loss and Heat Transfer of Additively Manufactured Channels

2016 ◽  
Author(s):  
Curtis K. Stimpson ◽  
Jacob C. Snyder ◽  
Karen A. Thole ◽  
Dominic Mongillo
Keyword(s):  
Heat Transfer ◽  
Metal Powder ◽  
Pressure Loss ◽  
Complex Flow ◽  
Roughness Effects ◽  
Flow Paths ◽  
Flow And Heat Transfer ◽  
Flow Through ◽  
High Temperature Components ◽  
Small Channels

Additive manufacturing (AM) with metal powder has made possible the fabrication of gas turbine components with small and complex flow paths that cannot be achieved with any other manufacturing technology presently available. The increased design space of AM allows turbine designers to develop advanced cooling schemes in high temperature components to increase cooling efficiency. Inherent in AM with metals is the large surface roughness that cannot be removed from small internal geometries. Such roughness has been shown in previous studies to significantly augment pressure loss and heat transfer of small channels. However, the roughness on these channels or other surfaces made from AM with metal powder has not been thoroughly characterized for scaling pressure loss and heat transfer data. This study examines the roughness of the surfaces of channels of various hydraulic length scales made with direct metal laser sintering (DMLS). Statistical roughness parameters are presented along with other parameters that others have found to correlate with flow and heat transfer. The pressure loss and heat transfer previously reported for the DMLS channels studied in this work are compared to the physical roughness measurements. Results show that the relative arithmetic mean roughness correlates well with the relative equivalent sand grain roughness. A correlation is presented to predict the Nusselt number of flow through AM channels which gives better predictions of heat transfer than correlations currently available.

Roughness Effects on Flow and Heat Transfer for Additively Manufactured Channels

2016 ◽  
Vol 138 (5) ◽  
Author(s):  
Curtis K. Stimpson ◽  
Jacob C. Snyder ◽  
Karen A. Thole ◽  
Dominic Mongillo
Keyword(s):  
Heat Transfer ◽  
Nusselt Number ◽  
Friction Factor ◽  
Flow Conditions ◽  
Roughness Effects ◽  
Flow And Heat Transfer ◽  
Technological Advances ◽  
Rectangular Channels ◽  
Significant Augmentation ◽  
Flow Through

Recent technological advances in the field of additive manufacturing (AM), particularly with direct metal laser sintering (DMLS), have increased the potential for building gas turbine components with AM. Using the DMLS for turbine components broadens the design space and allows for increasingly small and complex geometries to be fabricated with little increase in time or cost. Challenges arise when attempting to evaluate the advantages of the DMLS for specific applications, particularly because of how little is known regarding the effects of surface roughness. This paper presents pressure drop and heat transfer results of flow through small, as produced channels that have been manufactured using the DMLS in an effort to better understand roughness. Ten different coupons made with the DMLS all having multiple rectangular channels were evaluated in this study. Measurements were collected at various flow conditions and reduced to a friction factor and a Nusselt number. Results showed significant augmentation of these parameters compared to smooth channels, particularly with the friction factor for minichannels with small hydraulic diameters. However, augmentation of Nusselt number did not increase proportionally with the augmentation of the friction factor.

Roughness Effects on Flow and Heat Transfer for Additively Manufactured Channels

2015 ◽  
Author(s):  
Curtis K. Stimpson ◽  
Jacob C. Snyder ◽  
Karen A. Thole ◽  
Dominic Mongillo
Keyword(s):  
Heat Transfer ◽  
Nusselt Number ◽  
Friction Factor ◽  
Roughness Effects ◽  
Flow And Heat Transfer ◽  
Technological Advances ◽  
Rectangular Channels ◽  
Mini Channels ◽  
Significant Augmentation ◽  
Flow Through

Recent technological advances in the field of additive manufacturing (AM), particularly with direct metal laser sintering (DMLS), have increased the potential for building gas turbine components with AM. Using DMLS for turbine components broadens the design space and allows for increasingly small and complex geometries to be fabricated with little increase in time or cost. Challenges arise when attempting to evaluate the advantages of DMLS for specific applications, particularly because of how little is known regarding the effects of surface roughness. This paper presents pressure drop and heat transfer results of flow through small, as produced channels that have been manufactured using DMLS in an effort to better understand roughness. Ten different coupons made with DMLS all having multiple rectangular channels were evaluated in this study. Measurements were collected at various flow conditions and reduced to a friction factor and a Nusselt number. Results showed significant augmentation of these parameters compared to smooth channels, particularly with the friction factor for mini-channels with small hydraulic diameters. However, augmentation of Nusselt number did not increase proportionally with the augmentation of the friction factor.

scholarly journals Large-Eddy Simulation Study of Flow and Heat Transfer in Swirling and Non-Swirling Impinging Jets on a Semi-Cylinder Concave Target

2021 ◽  
Vol 11 (15) ◽  
pp. 7167
Author(s):  
Liang Xu ◽  
Xu Zhao ◽  
Lei Xi ◽  
Yonghao Ma ◽  
Jianmin Gao ◽  
...  
Keyword(s):  
Heat Transfer ◽  
Large Eddy Simulation ◽  
Wall Temperature ◽  
Target Surface ◽  
Impinging Jets ◽  
Small Scale ◽  
Complex Flow ◽  
Eddy Simulation ◽  
Flow And Heat Transfer ◽  
Large Eddy

Swirling impinging jet (SIJ) is considered as an effective means to achieve uniform cooling at high heat transfer rates, and the complex flow structure and its mechanism of enhancing heat transfer have attracted much attention in recent years. The large eddy simulation (LES) technique is employed to analyze the flow fields of swirling and non-swirling impinging jet emanating from a hole with four spiral and straight grooves, respectively, at a relatively high Reynolds number (Re) of 16,000 and a small jet spacing of H/D = 2 on a concave surface with uniform heat flux. Firstly, this work analyzes two different sub-grid stress models, and LES with the wall-adapting local eddy-viscosity model (WALEM) is established for accurately predicting flow and heat transfer performance of SIJ on a flat surface. The complex flow field structures, spectral characteristics, time-averaged flow characteristics and heat transfer on the target surface for the swirling and non-swirling impinging jets are compared in detail using the established method. The results show that small-scale recirculation vortices near the wall change the nearby flow into an unstable microwave state, resulting in small-scale fluctuation of the local Nusselt number (Nu) of the wall. There is a stable recirculation vortex at the stagnation point of the target surface, and the axial and radial fluctuating speeds are consistent with the fluctuating wall temperature. With the increase in the radial radius away from the stagnation point, the main frequency of the fluctuation of wall temperature coincides with the main frequency of the fluctuation of radial fluctuating velocity at x/D = 0.5. Compared with 0° straight hole, 45° spiral hole has a larger fluctuating speed because of speed deflection, resulting in a larger turbulence intensity and a stronger air transport capacity. The heat transfer intensity of the 45° spiral hole on the target surface is slightly improved within 5–10%.

Effects of Guide Vanes on the Tip Heat Transfer Enhancement of a Turbine Blade

2011 ◽  
Author(s):  
Gongnan Xie ◽  
Bengt Sunde´n
Keyword(s):  
Heat Transfer ◽  
Fluid Flow ◽  
Heat Transfer Enhancement ◽  
Turbine Blade ◽  
Pressure Loss ◽  
Transfer Enhancement ◽  
Guide Vanes ◽  
Flow And Heat Transfer ◽  
Numerical Predictions ◽  
Blade Tip

Gas turbine blade tips encounter large heat load as they are exposed to the high temperature gas. A common way to cool the blade and its tip is to design serpentine passages with 180-deg turns under the blade tip-cap inside the turbine blade. Improved internal convective cooling is therefore required to increase the blade tip life time. This paper presents numerical predictions of turbulent fluid flow and heat transfer through two-pass channels with and without guide vanes placed in the turn regions using RANS turbulence modeling. The effects of adding guide vanes on the tip-wall heat transfer enhancement and the channel pressure loss were analyzed. The guide vanes have a height identical to that of the channel. The inlet Reynolds numbers are ranging from 100,000 to 600,000. The detailed three-dimensional fluid flow and heat transfer over the tip-walls are presented. The overall performances of several two-pass channels are also evaluated and compared. It is found that the tip heat transfer coefficients of the channels with guide vanes are 10∼60% higher than that of a channel without guide vanes, while the pressure loss might be reduced when the guide vanes are properly designed and located, otherwise the pressure loss is expected to be increased severely. It is suggested that the usage of proper guide vanes is a suitable way to augment the blade tip heat transfer and improve the flow structure, but is not the most effective way compared to the augmentation by surface modifications imposed on the tip-wall directly.

Flow and Heat Transfer Characteristics in Models of Turbine Blade Tip-Walls With Three Kinds of Turning Vanes

2018 ◽  
Author(s):  
Bin Wu ◽  
Xing Yang ◽  
Lv Ye ◽  
Zhao Liu ◽  
Yu Jiang ◽  
...  
Keyword(s):  
Heat Transfer ◽  
Turbine Blade ◽  
Double Layer ◽  
Pressure Loss ◽  
Stokes Equations ◽  
Wall Heat Transfer ◽  
Heat Transfer Characteristics ◽  
Transfer Characteristics ◽  
Flow And Heat Transfer ◽  
Blade Tip

In this paper, effects of three kinds of turning vanes on flow and heat transfer of turbine blade tip-walls with a U-shaped channel have been numerically studied. Numerical simulations are performed to solve three-dimensional, steady, Reynolds-averaged Navier-Stokes equations with the standard k-ω turbulence model. The aspect ratio (AR) and the hydraulic diameter of the channel are 2 and 93.13 mm, respectively. The effects of single-layer, double-layer and double-layer dome-shaped turning vanes in the turn region on the tip-wall heat transfer and overall pressure loss of rectangular U-shaped channels are analyzed. Detailed flow and heat transfer characteristics over the tip-walls, as well as the overall performance, are presented and compared with each other. Results show that the tip-wall heat transfer coefficients with double-layer dome-shaped turning vanes are the highest among the three cases. Double-layer dome-shaped turning vanes can promote the lateral spreading of secondary flow and effectively increase the uniformity of heat transfer on the tip-wall. More importantly, this structure can make the cooling air expand and accelerate at the center region of the top of the U-shaped channel, resulting in more heat to be removed from the tip-wall. Additionally, double-layer dome-shaped turning vanes can effectively reduce the pressure loss of the channel.

Numerical Optimization, Characterization, and Experimental Investigation of Additively Manufactured Communicating Microchannels

2018 ◽  
Vol 140 (11) ◽  
Author(s):  
Kathryn L. Kirsch ◽  
Karen A. Thole
Keyword(s):  
Heat Transfer ◽  
Experimental Investigation ◽  
Pressure Loss ◽  
Reynolds Numbers ◽  
Transport Systems ◽  
Optimized Design ◽  
Internal Cooling ◽  
Natural Systems ◽  
Flow And Heat Transfer ◽  
Successful Replication

The degree of complexity in internal cooling designs is tied to the capabilities of the manufacturing process. Additive manufacturing (AM) grants designers increased freedom while offering adequate reproducibility of microsized, unconventional features that can be used to cool the skin of gas turbine components. One such desirable feature can be sourced from nature; a common characteristic of natural transport systems is a network of communicating channels. In an effort to create an engineered design that utilizes the benefits of those natural systems, the current study presents wavy microchannels that were connected using branches. Two different wavelength baseline configurations were designed; then each was numerically optimized using a commercial adjoint-based method. Three objective functions were posed to (1) minimize pressure loss, (2) maximize heat transfer, and (3) maximize the ratio of heat transfer to pressure loss. All baseline and optimized microchannels were manufactured using laser powder bed fusion (L-PBF) for experimental investigation; pressure loss and heat transfer data were collected over a range of Reynolds numbers. The AM process reproduced the desired optimized geometries faithfully. Surface roughness, however, strongly influenced the experimental results; successful replication of the intended flow and heat transfer performance was tied to the optimized design intent. Even still, certain test coupons yielded performances that correlated well with the simulation results.

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