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Michael Gritsch t, Stefan Baldauf, Moritz Martiny", Achmed Schulz, and Sigmar Wittig
ABSTRACT where the adiabatic wall temperature Taw is typically presented as the
The present paper reports on the use of the superposition ap- non-dimensionalized film cooling effectiveness (Goldstein 1971)
proach in high density ratio film cooling flows. It arises from the
linearity and homogeneity of the simplified boundary layer differential
~=~w-~ m
equations. However, it is widely assumed that the linearity does not
r, -Tm
hold for variable property flows. Therefore, theoretical considerations Both the film cooling effectiveness ~ and the heat transfer coefficient
and numerical calculations will demonstrate the linearity of the heat h, have to be known to calculate the heat flux to the blade. Most of the
transfer coefficient with the dimensionless coolant temperature eas research with respect to film cooling dealt with the determination of
long as identical flow conditions are applied. This makes it necessary the film cooling effectiveness, while the heat transfer coefficient has
to perform at least two experiments at different e
but with the coolant received much less attention. It was widely assumed that the heat
to main flow temperature ratio kept unchanged. transfer coefficient without film cooling, 110, remains virtually un-
A comprehensive set of experiments is presented to demonstrate changed by the coolant injection and can, therefore, be used in Eq. (I)
the capability of the superposition approach for determining heat resulting in
transfer coefficients for different film cooling geometries. These com- q"=ho (Taw-Tw) (3)
prise coolant injection from two dimensional tangential slots, single However, immediately downstream of the coolant injection loca-
holes, and rows of cylindrical holes. Particularly, two dimensional tion the flow field is altered by the coolant jet penetrating into the
local distributions of the heat transfer coefficient will be addressed. main flow boundary layer (e.g., Crawford et al. 1980). Therefore, the
heat transfer of the flow without coolant injection, ho, cannot be used
INTRODUCTION to predict the heat transfer to the blade. Subsequently, an alternate
Film cooling is widely used to protect gas turbine blades from hot approach was developed where the heat transfer to the blade is now
gases by injecting relatively cold compressor bleed air through discrete based on the temperature difference of main flow and wall
holes in the blade surface. Minimizing blade temperatures and tem- q"= h (Tm-Tw) (4)
perature gradients without spending large amounts of coolant is the All effects of coolant injection are described by the value of the heat
primary goal of efficient cooling design. Therefore, accurate knowl- transfer coefficient h (Choe et al. 1974), which depends on the dimen-
edge of the heat flux from the hot gas to the blade is crucial to predict sionless temperature ratio
the temperature field inside the blade.
(5)
The most common approach of describing the heat transfer to a
film cooled blade is
(I)
THEORETICAL CONSIDERATIONS
Experimental investigations first performed by Metzger et al.
t Present address: ABB Corporate Research Ltd.,
5405 Baden-Dattwil, Switzerland (1968, 1971, 1973) showed that h varies linearly with e for film cool-
t Present address: Porsche AG Entwicklungszentrum, ing applications like slots, holes or multi hole arrangements in incom-
71287 Weissach, Germany
Presented at the International Gas Turbine & Aeroengine Congress & Exhibttion
Indianapolis, Indiana - June 7-June 10, 1999 .
aT
pCp ( uax-+v
aT
ay
J: a ( ar J +Jl
ay kay-
(au
ay
)2 (6)
tion location. There has been some debate whether the superposition
scheme can be transferred to these types of flow. Ligrani and Camci
(1985) presented their efforts to combine data of the heat transfer
with effective k and Jl of the turbulent flow. Equation (6) shows the coefficient h, from iso-energetic measurements at DR:l and adiabatic
equivalence of convective energy transport and thermal conduction effectiveness measurements at high density ratio with their own meas-
and dissipation with respect to a differential volume. In incompressible urements of h(e). They varied the coolant temperature at constant main
flows, the energy and momentum transport equations of the boundary flow temperature (i.e. the density ratio) to realize a variation of the
layer are not coupled. Assuming constant properties, a linear differen- dimensionless temperature ratio 9 and came up with nonlinear rela-
tial equation in T is given which can be solved by superposing two tions of h(9). Subsequently they presented a variable property correc-
particular solutions of the same flow field. Therefore, at least two tion of these nonlinear effects for high density ratio flows, not taking
different sets of data taken at different 9 are needed to describe h as a into account the altered flow field by the different density ratios within
function of 9. The local heat flux can be determined, for instance. as their data sets to produce one line.
q"(x,Z): ql"(x,z) (Tw-Tm) + q2"(X,Z) (Tc-Tw) (7) It was shown by Forth et al. (1985, 1986) and Teekaram et al.
(1989) that the linearity of h with 9 holds for compressible
where q," is the local heat flux resulting for a unit temperature differ-
(Mam=0.55) and variable property (DR=0.8 ...2) flows if the flow field
ence between wall and main flow and Tc=Tw, and q," is the local heat
is not altered. This is due to the fact that a variation of the wall tem-
flux resulting for a unit temperature difference between wall and cool-
perature within the limits of coolant and main flow temperatures does
ant flow and Tm=Tw(Loftus and Jones 1983).
not have a first order effect on the flow field (Jones 1991).
NOMENCLATURE T Temperature, K
Symbols Tu Turbulence intensity
cp Thermal capacity, W/kgK St Stanton number
Ec Eckert number u Streamwise velocity component, rnIs
D Film cooling hole diameter, m v Vertical velocity component, rnIs
DR Coolant to main flow density ratio VR Coolant to main flow velocity ratio
h Heat transfer coefficient, W/m2K, Eq. (4) x Streamwise coordinate, m
h, Heat transfer coefficient at 9: 0, W/m2K, Eq. (I) Z Span wise coordinate, m
I Coolant to main flow momentum ratio
k Thermal conductivity, W/mK a Partial differential
M Blowing ratio 11 Adiabatic film cooling effectiveness, Eq. (2)
Ma Mach number Jl Dynamic viscosity, N/sm2
q" Local heat flux, W/m2 p Density, kg/rrr'
q' Laterally averaged heat flux, W/m2 9 Dimensionless temperature ratio, Eq. (5)
s Film cooling slot height, m Subscripts
Re Reynolds number aw Adiabatic wall conditions (q"= 0)
T Temperature, K c Coolant conditions
Tu Turbulence intensity d Based on cooling hole diameter
St Stanton number m Main flow conditions
u Streamwise velocity component, rnIs w Diabatic wall conditions (q":;>,;0)
v Vertical velocity component, rnIs o No injection case (M = 0)
NUMERICAL RESULTS
Numerical calculations have been performed to obtain informa-
tion on whether variable properties resulting from high temperature
ratio flows do influence the linearity of h(6) significantly. The inten-
tion was to conduct the numerical experiment to create data sets with a
granted reproducibility of flow and boundary conditions that are well
defined and easy to control. The computational prediction of the heat symmetry --t--+--
transfer is very sensitive to the numerical models used, i.e. turbulence
modeling. Various authors, e.g. Leylek and Zerkle (1994) and Walters main flow
and Leylek (1997), showed that a very careful computational method-
coolant ---.b:::::t:::=:::-
ology is necessary to predict the flow field and resulting surface effects
solid
of the actual discrete hole film cooling flow situation. Therefore, it
was decided to examine a simplified flow situation that still features canst T b.da';d. -t:;;;::::t::::::==--
the effects of a pronounced local heat transfer distribution. In this way Fig. 2: Boundary conditions for numerical calculation and temperature field
a typical situation of high density gradient flows could be examined in results within the flow and solid volumes
EXPERIMENTAL RESULTS
·1
Validation of the supemosition scheme
In the following, experimental results of different film cooling
·2
studies conducted at Karlsruhe University are used to reveal the valid-
ity of the superposition scheme. These studies include investigations
of local heat transfer coefficients associated with film cooling from
2 4 6 tangential slots and discrete holes. The average uncertainty of all
8
experimental heat transfer data presented is in the range of 3% to 7%.
3r-----~----------------------_,
xlO=14.8
Depending on the extrapolation procedure, the error of the determined
heat transfer data
(single computation) hf is within 4% to 9%. Further particulars of the experimental condi-
2 ____ adiabatic wall data tions can be found in the referenced publications.
Two studies were conducted to confirm the superposition ap-
proach at low density ratio levels. Bittlinger et al. (1994) performed
heat transfer coefficient measurements for tangential slot injection at
J:;'
0
:2 high blowing ratios at a density ratio DR=1.2. In this investigation 9
was varied by altering the temperature levels of coolant and main flow
·1
at constant flow conditions and virtually constant wall temperature. In
Fig. 4 a series of heat transfer coefficient measurements at different
·2 blowing rates is shown. Laterally constant heat transfer coefficients are
given at several downstream locations. Unfortunately, 9 of the two
·3
·2 0 8 upper temperature levels became very close. Hence, the almost identi-
8 cal values of the heat transfer coefficient document quality and repro-
Fig. 3: Local heat transfer coefficients for a set of seven computations with a ducibility of the measurements. Beside a slight statistical data scatter a
variation of the wall temperature condition good linearity of the local h(9) at this density ratio is given.
~.
0.6
<,
-,•
, -,
<,
<,
<,
-, ~.
-, -, <,
"-
:c 0
~
0.4
'" -,
".t. -, ~
<,
<,
<,
-, ~ <,
<,
<, <,
0.2 -, <, -, -2
<,
-, -, <,
M=O.56 -,
DO 0.5 1 1.5 2
-3
-2 -, 0 2 3 4 5
e e
1.4...-...----.-------------....., Fig. 5: Heat transfer coefficients associated with the interaction of cooling film
ejected from a tangential slot and a mixing jet
1 \::: ••
•
~JI--. ...•..
- ..- ..- ..- ..- ..- .._..
______ zlO=4.5
\ •.....
, -..-. -
-
.•... -"'0=9
• 'P"" • - xID=18
~ <, 0.25
·0.25
\
\
.0.5
0 4 6 8 10 12
e
1.25 Fig. 7: Laterally averaged heat transfer coefficients for a set of six measure-
xlD=9 ments with a variation of the wall temperature condition
-.....•
-,
'\ ...",. backside by water or oil. The wall temperature level, and thus e, could
\ '" . be controlled by the temperature level of the coolant fluid. The wall
\ ~ temperature on the test surface was measured by an infrared camera
~ -,
=0
:2 '-'" .•. -,
system providing a two-dimensional distribution of the temperature on
0.25 -, <,
the plate surface. Thermocouples on the test plate surface were used
for an in situ calibration of the camera system. Details of the calibra-
0 "t \
"'. -,
-,
tion procedure are given by Martiny et al. (1996).
The three-dimensional temperature distribution inside the test
-0.25 -, plate was calculated by a finite element analysis to determine the heat
\
\
-, flux distribution perpendicular to the test plate surface, q"(x,z). The
.0.5
0 4 6 8 10 12 surface temperature distribution measured by the infrared camera
e
system and the temperature on the coolant side of the test plate served
1.25
as thermal boundary conditions for the finite element analysis. The
xID=18 ______ zlD=O
heat transfer coefficient distribution h(x,z) was then calculated as the
1
- .•... - zlD=0.5
0.75
"-\''f.~... _.
_ ..•..
'P""' - zlD=1
- zlD=1.5
ratio of surface heat flux q"(x,z) and main flow to wall temperature
difference, T m" Tw(x,z).This calculation procedure has to be performed
\o. •••~ -,
for at least two different e values at every surface location to receive a
=0
:2
0.5
"
-,.• ..•..•.•...•<,
•••....... ",
-, <,
linear regression curve from which ht(x,z) is determined.
Gritsch et al. (1998) measured highly resolved distributions of lo-
0.25
\
-, <,
cal heat transfer coefficient in the near field of single film cooling
" \
<,
<,
<,
holes with various hole geometries at high main flow Mach numbers,
-, <, Mam=O.6, and high density ratios, DR=1.85. The experiments were
\ -, <,
-0.25 -, <, performed with an adiabatic surface test plate and a water cooled test
\
\
-, <,
<,
plate to gain two points, i.e. particular solutions of the heat transfer
.0.5
0
.
2 4 6 10 12 problem, for every location on the surface. As can be seen from Fig. 8,
e the characteristic patterns of heat transfer augmentation in the vicinity
of the ejection from a single inclined cylindrical film cooling hole
Fig. 6: Local heat transfer coefficients for a set of six measurements with a could be detected.
variation of the wall temperature condition
zlD
assured for the design relevant lateral averaged data derived from the 1
surface distributions. 1.7
Local heat transfer coefficient distributions o 1.5
In most cases documented in the literature, the superposition ap- ejection 1.3
hole
proach is used to derive laterally or spatially averaged heat transfer -1 1.1
coefficients. As shown before, the superposition approach is an excel- 0.9
lent means to receive accurate local heat transfer coefficient distribu- 0.7
2 3 4 5 6 7 xlD
tions. In the experimental studies presented in the following, the test-
plate used for acquiring heat transfer coefficients was cooled from the Fig.S: Local heat transfer coefficient distribution in the near field downstream
of a cylindrical film cooling hole
1
zlD 1.2
1.15
o 1.1
-1
t(JW ~ .05
o 5 10 15 20 25 30 WUW 0.95
xlD 0.9
Fig. 9: Local heat transfer coefficient distribution downstream a row of cylindrical film cooling holes
Baldauf et al. (1999) investigated the local heat transfer distribu- Baldauf S., Schulz A., and Wittig S. (1999). High Resolution
tions downstream of a row of cylindrical holes at high density ratios. Measurements of Local Heat Transfer Coefficients by Discrete Hole
They used thermostatic oil as wall backside coolant enabling a wall Film Cooling. To be presented at The International Gas Turbine and
temperature variation in a very wide range. Beside the confirmation of Aeroengine Congress and Exhibition, June 7-10, Indianapolis, IN.
the linearity of h(9) in high density ratio film cooling (see above), Bittlinger G., Schulz A., and Wittig S. (1994). Film Cooling Ef-
multiple data points of h(9) enabled a very precise determination of hf. fectiveness and Heat Transfer Coefficients for Slot Injections at High
Figure 9 displays the typical heat transfer variation patterns following Blowing Ratios. ASME Paper 94-GT-182.
the ejection from a row of holes at a moderate blowing ratio. The CFX-TASCflow (1998). Theory Documentation. AEA Technol-
ejected coolant and induced vortex patterns are fully attached to the ogy Engineering Software Ltd. Waterloo, Ontario, Canada.
surface. Since the turbulence level of the flow was low, the vortices Choe H., Kays W.M., and Moffat R.J. (1974). The Superposition
from the ejection are very stable and significant traces indicate their Approach to Film-Cooling. ASME Paper 74-W A/HT-27.
positions as contours of h, Crawford M.E., Kays W.M., and Moffat Rol. (1980). Full-
Coverage Film Cooling. ASME Journal of Engineering for Power,
CONCLUSIONS Vol. 102, pp. 1000-1005.
Detailed numerical as well as experimental studies were per- Eckert E.R.G. (1984). Analysis of Film Cooling and Full-
formed to demonstrate the applicability of the superposition scheme Coverage Film Cooling of Gas Turbine Blades. AS ME Journal of
for variable property flows, in particular flows with high coolant to Engineering for Gas Turbines and Power, Vol. 106, pp. 207-213.
main flow density ratios. Theoretical and numerical considerations Forth C.J.P., Loftus Pol., and Jones T.V. (1985). The effect of
confirmed that linearity is given for idealized boundary conditions. Density Ratio on the Film-Cooling of a Flat Plate. Heat Transfer and
The experimental evidence revealed that the linear superposition ap- Cooling in Gas Turbines, AGARD-CP-390, Paper 10.
proach can be applied without any restrictions to any film cooling flow Forth C.J.P., and Jones T.V. (1986). Scaling Parameters in Film-
situation of engine typical conditions. The linearity of h with 9 holds Cooling. Proceedings of the 8th International Heat Transfer Confer-
as long as identical flow conditions were applied to the measurements ence, Vol.3, pp. 1271-1276.
of one data set to derive h(9). This means a variation of 9 has to be Goldstein R.G. (1971). Film Cooling. Advances in Heat Transfer,
performed without changing any flow describing parameter, e.g. tem- Vol. 7, pp. 312-379.
perature ratio T/T m- Gritsch M., Schulz A., and Wittig S. (1998). Heat Transfer Coef-
Furthermore, the superposition scheme was found to be an ex- ficient Measurements of Film-Cooling Holes with Expanded Exits.
cellent means to determine global heat transfer coefficients as well as ASME Paper 98-GT-28.
highly resolved local heat transfer coefficient distributions in film Jones T.V. (1991). Definition of heat transfer coefficients in the
cooling applications. It enables the examination of the heat transfer turbine situation. Turbomachinery: Latest Developments in a Chang-
patterns of specific configurations and to trace the according flow ing Scene, Paper C423/046, Proc. of the IMechE, pp. 201- 206.
behavior. In high temperature ratio flows typical for technical applica- Kays W.M., and Crawford M.E. (1980). Convective Heat and
tions, the superposition approach is the only possibility to determine Mass Transfer, McGraw Hill, New York.
the 9 independent heat transfer coefficient hf. In experimental set-ups Leylek J.H., and Zerkle R.D. (1994). Discrete-Jet Film Cooling: •
where adiabatic wall conditions are difficult to establish, it allows for A Comparison of Computational Results With Experiments. AS ME
determining adiabatic film cooling effectiveness. The superposition Journal of Turbomachinery, Vol. 116, pp. 358-368.
approach is the interconnection of the film cooling quantifying entities Ligrani P.M., and Camci C. (1985). Adiabatic Film Cooling Ef-
1), hf, and h(9). fectiveness from Heat Transfer Measurements in Compressible, Vari-
able-Property Flow. ASME Journal of Heat Transfer, Vol. 107, pp.
REFERENCES 313-320.
Baldauf S., and Scheurlen M. (1996). CFD Based Sensitivity Loftus P'L, and T.V. Jones (1983). The Effect of Temperature
Study of Flow Parameters for Engine Like Film Cooling Conditions. Ratios on the Film Cooling Process. ASME Journal of Engineering for
ASME Paper 96-GT-310. Power, Vol. 105, pp. 615-620.