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In fluid mechanics, topology optimization is used for designing flow passages, connecting predefined inlets and outlets, with optimal performance based on selected criteria. In this article, the continuous adjoint approach to topology optimization in incompressible ducted flows with heat transfer is presented. A variable porosity field, to be determined during the optimization, is the means to define the optimal topology. The objective functions take into account viscous losses and the amount of heat transfer. Turbulent flows are handled using the Spalart-Allmaras model and the proposed adjoint is exact, i.e. the adjoint to the turbulence model equation is formulated and solved, too. This is an important novelty in this article which extends the porosity-based method to account for heat transfer flow problems in turbulent flows. In problems such as the design of manifolds, constraints on the outlet flow direction, rates and mean outlet temperatures are imposed.

This paper focuses on discrete and continuous adjoint approaches and direct differentiation methods that can efficiently be used in aerodynamic shape optimization problems. The advantage of the adjoint approach is the computation of the gradient of the objective function at cost which does not depend upon the number of design variables. An extra advantage of the formulation presented below, for the computation of either first or second order sensitivities, is that the resulting sensitivity expressions are free of field integrals even if the objective function is a field integral. This is demonstrated using three possible objective functions for use in internal aerodynamic problems; the first objective is for inverse design problems where a target pressure distribution along the solid walls must be reproduced; the other two quantify viscous losses in duct or cascade flows, cast as either the reduction in total pressure between the inlet and outlet or the field integral of entropy generation. From the mathematical point of view, the three functions are defined over different parts of the domain or its boundaries, and this strongly affects the adjoint formulation. In the second part of this paper, the same discrete and continuous adjoint formulations are combined with direct differentiation methods to compute the Hessian matrix of the objective function. Although the direct differentiation for the computation of the gradient is time consuming, it may support the adjoint method to calculate the exact Hessian matrix components with the minimum CPU cost. Since, however, the CPU cost is proportional to the number of design variables, a well performing optimization scheme, based on the exactly computed Hessian during the starting cycle and a quasi Newton (BFGS) scheme during the next cycles, is proposed.

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