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High efficiency heat exchangers, such as intercoolers and recuperators, are composed of complex and compact structures to enhance heat transfer. This limits the installation of conventional temperature sensors to measure the temperature inside the heat exchanger without flow disturbance. To overcome this limitation, we have developed a direct patterning method in which metal is sputtered onto a curved surface using film photoresist and the fabrication of thin film Au resistance temperature detection (RTD) temperature sensors. A photosensitive film resist has been used to overcome the difficulty of 3-dimensional photolithography on a curved surface. The film resist after 2-dimensional photolithography is laminated over an alumina rod which is deposited with Au as an RTD sensing material. The Au metal is etched chemically, and the film resist is removed to form the thin film Au-RTD temperature sensors. They are calibrated by measuring the resistance change against temperature in a thermally controlled furnace. The second order polynomial fit shows good agreement with the measured temperatures with a standard deviation of 0.02 for the temperature range of 20-450 • C. Finally, the performance of the Au-RTD temperature sensors was evaluated.

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The inclusion of roughness elements on the target surface of a turbine aerofoil impingement cooling system is an attractive means of heat transfer enhancement. In such a system, it is important to minimise additional pressure loss caused by the roughness elements and thus their shape, size and position need to be optimised. The research showed how heat transfer enhancement is normally achieved at the expense of extra pressure loss. A hexagonal roughness element designed by the authors showed up to 10% heat transfer enhancement with minimal extra pressure loss. The present work includes shear pattern visualisation on the target surface, pressure loss measurements and heat transfer coefficient measurements for an impingement cooling system with simply shaped roughness elements-specifically cylindrical & diamond pimples. Flow visualisation results and pressure loss measurements for the above configurations provided criteria for selecting the shape, size and position of the roughness elements. The detailed heat transfer measurements on the target surface and over the roughness elements were used to explain the heat transfer enhancement mechanisms. It was found that the largest contribution to heat transfer is the impingement stagnation point and the developing wall jet regions. However, the research showed that the low heat transfer coefficient region could be made to contribute more by using strategically located roughness elements. A hexagonal rim was designed to cover the complete low heat transfer coefficient region midway between neighbouring jets. The effect of the height, cross sectional shape and wall angle of the hexagonal rim were studied using a series of heat transfer and pressure loss experiments. The transient heat transfer tests were conducted using a triple thermochromic liquid crystal technique and the thermal transient was produced by a fine wire mesh heater. The heat transfer coefficient over the pimples was measured using a hybrid transient method that analysed the thermal transient of the copper pimple. The detailed heat transfer coefficient distributions over the complete area of the target surface provided comprehensive understanding of the performance of the hexagonal rim. Tests were conducted at three different mass flow rates for each configuration. The average and local jet Reynolds numbers varied between 21500 and 31500, and 17000 and 41000 respectively.

A study of a large-scale model of an engine representative impingement cooling system has been performed. A series of tests have been carried out to fully characterise the behaviour of the system. These include cold flow diagnostic tests to determine the pressure loss and the static pressure distribution, and flow visualisation to assess surface shear. The surface shear stress pattern provided by multiple stripes of coloured paint applied to the target surface yielded important information on the near wall flow features far from the jet axis. The row solved flow and pressure distributions are compared to industry standard predictions. Heat transfer tests using the transient liquid crystal technique were also conducted using coatings comprised of a mixture of three thermochromic liquid crystals. Analysis of the thermochromic liquid crystal data was enhanced by recent developments in image processing. In addition, an energy balance approach to analysing signals from fast response thermocouples for air temperature measurement was applied to verify the levels of heat transfer coefficients on surfaces not coated with the temperature sensitive liquid crystal.