While modern gas turbine engines operate at hot gas path velocities approaching the speed of sound, few facilities have studied the effects that the flow’s compressibility can have on the adiabatic effectiveness. A new facility at the University of Texas at Austin has been developed to investigate these high Mach number effects and how to appropriately scale laboratory film cooling experiments to engine conditions. This study investigates two film cooling hole geometries, a baseline 7-7-7 shaped film cooling hole and a recent design which has been numerically optimized for increased effectiveness. Both holes are tested at mainstream Mach numbers of 0.25 and 0.50 in a flat plate test section. The optimized hole outperforms the effectiveness of the baseline geometry at all blowing ratios tested, matching the trend in the results of previous studies on these geometries. However, there is a marked decrease in film cooling hole performance as the Mach number is increased.
more »
« less
Transpiration cooling in hypersonic flow and mutual effect on turbulent transition and cooling performance
This work presents recent advancements in the study of film cooling in hypersonic flows, considering experimental and numerical investigations, with the aim to characterize the wall-cooling performance in different coolant injection and baseflow conditions in a Mach number range 2–7.7. The study explores the mutual interaction between the injected coolant film and the boundary-layer flow, with emphasis on the effects of wall blowing on the boundary-layer characteristics, stability, and transition to turbulence, as well as the effect of transition on wall-cooling performance. Considered flow configurations include cases of effusion cooling in both wall-normal or slightly inclined and wall-parallel blowing, different types of coolant, cases of favorable pressure gradient compared to zero pressure gradient, as well as transpiration cooling cases at different blowing ratios and surface geometries. For the transpiration cooling case, experiments in different hypersonic wind tunnel facilities are presented for flat plate and cone geometries, with coolant injected through C/C porous samples, whereas numerical simulations of modeled porous injection are presented for a flat plate and a blunt cone, showing results for the boundary-layer receptivity with coolant injection and the associated effects on transition and cooling performance. A summary of the main findings is provided along with a critical analysis based on a comparative study to evaluate the effect of each configuration, injection strategy, and key parameters on the boundary-layer flow and the feedback on wall-cooling performance. Conclusions are drawn about potential directions of study for the further development and optimization of the film cooling technique for future hypersonic vehicles.
more »
« less
- Award ID(s):
- 2146100
- PAR ID:
- 10589335
- Publisher / Repository:
- American Institute of Physics
- Date Published:
- Journal Name:
- Physics of Fluids
- Volume:
- 37
- Issue:
- 2
- ISSN:
- 1070-6631
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
More Like this
-
-
A novel, double hole film cooling configuration is investigated as an alternative to traditional cylindrical and fanshaped, laidback holes. This experimental investigation utilizes a Stereo-Particle Image Velocimetry (S-PIV) to quantitatively assess the ability of the proposed, double hole geometry to weaken or mitigate the counter-rotating vortices formed within the jet structure. The three-dimensional flow field measurements are combined with surface film cooling effectiveness measurements obtained using Pressure Sensitive Paint (PSP). The double hole geometry consists of two compound angle holes. The inclination of each hole is = 35°, and the compound angle of the holes is = ± 45° (with the holes angled toward one another). The simple angle cylindrical and shaped holes both have an inclination angle of = 35°. The blowing ratio is varied from M = 0.5 to 1.5 for all three film cooling geometries while the density ratio is maintained at DR = 1.0. Time averaged velocity distributions are obtained for both the mainstream and coolant flows at five streamwise planes across the fluid domain (x/d = -4, 0, 1, 5, and 10). These transverse velocity distributions are combined with the detailed film cooling effectiveness distributions on the surface to evaluate the proposed double hole configuration (compared to the traditional hole designs). The fanshaped, laidback geometry effectively reduces the strength of the kidney-shaped vortices within the structure of the jet (over the entire range of blowing ratios considered). The three-dimensional velocity field measurements indicate the secondary flows formed from the double hole geometry strengthen in the plane perpendicular to the mainstream flow. At the exit of the double hole geometry, the streamwise momentum of the jets is reduced (compared to the single, cylindrical hole), and the geometry offers improved film cooling coverage. However, moving downstream in the steamwise direction, the two jets form a single jet, and the counter-rotating vortices are comparable to those formed within the jet from a single, cylindrical hole. These strong secondary flows lift the coolant off the surface, and the film cooling coverage offered by the double hole geometry is reduced.more » « less
-
Abstract Due to the increasing computational demand driven by artificial intelligence, machine learning, and the Internet of Things (IoT), there has been an unprecedented growth in transistor density for high-end CPUs and GPUs. This growth has resulted in high thermal dissipation power (TDP) and high heat flux, necessitating the adoption of advanced cooling technologies to minimize thermal resistance and optimize cooling efficiency. Among these technologies, direct-to-chip cold plate-based liquid cooling has emerged as a preferred choice in electronics cooling due to its efficiency and cost-effectiveness. In this context, different types of single-phase liquid coolants, such as propylene glycol (PG), ethylene glycol (EG), DI water, treated water, and nanofluids, have been utilized in the market. These coolants, manufactured by different companies, incorporate various inhibitors and chemicals to enhance long-term performance, prevent biogrowth, and provide corrosion resistance. However, the additives used in these coolants can impact their thermal performance, even when the base coolant is the same. This paper aims to compare these coolant types and evaluate the performance of the same coolant from different vendors. The selection of coolants in this study is based on their performance, compatibility with wetted materials, reliability during extended operation, and environmental impact, following the guidelines set by ASHRAE. To conduct the experiments, a single cold plate-based benchtop setup was constructed, utilizing a thermal test vehicle (TTV), pump, reservoir, flow sensor, pressure sensors, thermocouple, data acquisition units, and heat exchanger. Each coolant was tested using a dedicated cold plate, and thorough cleaning procedures were carried out before each experiment. The experiments were conducted under consistent boundary conditions, with a TTV power of 1000 watts and varying coolant flow rates (ranging from 0.5 lpm to 2 lpm) and supply coolant temperatures (17°C, 25°C, 35°C, and 45°C), simulating warm water cooling. The thermal resistance (Rth) versus flow rate and pressure drop (ΔP) versus flow rate graphs were obtained for each coolant, and the impact of different supply coolant temperatures on pressure drop was characterized. The data collected from this study will be utilized to calculate the Total Cost of Ownership (TCO) in future research, providing insights into the impact of coolant selection at the data center level. There is limited research available on the reliability used in direct-to-chip liquid cooling, and there is currently no standardized methodology for testing their reliability. This study aims to fill this gap by focusing on the reliability of coolants, specifically propylene glycols at concentrations of 25%. To analyze the effectiveness of corrosion inhibitors in these coolants, ASTM standard D1384 apparatus, typically used for testing engine coolant corrosion inhibitors on metal samples in controlled laboratory settings, was employed. The setup involved immersing samples of wetted materials (copper, solder coated brass, brass, steel, cast iron, and cast aluminum) in separate jars containing inhibited propylene glycol solutions from different vendors. This test will determine the reliability difference between the same inhibited solutions from different vendors.more » « less
-
Recent evidence suggests that film cooling flows with engine realistic mainstream Mach number have declined performance in comparison to those with conventional low-speed laboratory conditions. Consideration and understanding of these effects are fundamental to improving film cooling research. The proposed computational study investigates the film cooling performance of a 7-7-7 shaped film cooling hole with respect to varying mainstream Mach number, with constant Reynolds number. The cases studied include mainstream Mach numbers from 0.15–0.75, with a fixed, engine realistic, hole Reynolds number of Red = 10, 100. Significant results are then evaluated against varying stagnation temperature ratio and blowing ratio. The results showed that at a blowing ratio of 1.75, the adiabatic effectiveness declines significantly with high mainstream Mach number. The decreased performance is due to supersonic flows and shocks in the film cooling hole that disrupt flow in the diffuser section of the hole. These characteristics are observed across all stagnation temperature ratios considered. In addition to these insights, the study discusses the importance of proper thermal scaling and definition of adiabatic effectiveness when operating at high mainstream Mach number. It is demonstrated that the effects of high-speed flow challenge the efficacy of the conventional parameters used to characterize film cooling performance.more » « less
-
Direct numerical simulations (DNS) are performed to investigate the spatial evolution of flat-plate zero-pressure-gradient turbulent boundary layers over long streamwise domains ( $${>}300\delta _i$$ , with $$\delta _i$$ the inflow boundary-layer thickness) at three different Mach numbers, $2.5$ , $4.9$ and $10.9$ , with the surface temperatures ranging from quasiadiabatic to highly cooled conditions. The settlement of turbulence statistics into a fully developed equilibrium state of the turbulent boundary layer has been carefully monitored, either based on the satisfaction of the von Kármán integral equation or by comparing runs with different inflow turbulence generation techniques. The generated DNS database is used to characterize the streamwise evolution of multiple important variables in the high-Mach-number, cold-wall regime, including the skin friction, the Reynolds analogy factor, the shape factor, the Reynolds stresses, and the fluctuating wall quantities. The data confirm the validity of many classic and newer compressibility transformations at moderately high Reynolds numbers (up to friction Reynolds number $$Re_\tau \approx 1200$$ ) and show that, with proper scaling, the sizes of the near-wall streaks and superstructures are insensitive to the Mach number and wall cooling conditions. The strong wall cooling in the hypersonic cold-wall case is found to cause a significant increase in the size of the near-wall turbulence eddies (relative to the boundary-layer thickness), which leads to a reduced-scale separation between the large and small turbulence scales, and in turn to a lack of an outer peak in the spanwise spectra of the streamwise velocity in the logarithmic region.more » « less
An official website of the United States government
