Boundary Layer Ingesting (BLI) turbofan engines could offer reduced fuel burn compared with podded engines, but the fan stage must be designed to run continuously with severe inlet distortion. This paper aims to explain the fluid dynamics and loss sources in BLI fans running at a cruise condition. High-resolution experimental measurements and full-annulus unsteady CFD have been performed on a low-speed fan rig running with a representative BLI inlet velocity profile. A three-dimensional flow redistribution is observed, leading to an attenuation of the axial velocity non-uniformity upstream of the rotor and to non-uniform swirl and radial angle distributions at rotor inlet. The distorted flow field is shown to create circumferential and radial variations in diffusion factor with a corresponding loss variation around the annulus. Additional loss is generated by an unsteady separation of the casing boundary layer, caused by a localised peak in loading at the rotor tip. Non-uniform swirl and radial angles at rotor exit lead to increased loss in the stator due to the variations in profile loss and corner separation size. An additional CFD calculation of a transonic fan running with the same inlet profile is used to show that BLI leads to wide variations in rotor shock structure, strength and position and hence to loss generation through shock-boundary layer interaction, but otherwise contained the same flow features as the low-speed case. For both fan geometries, BLI was found to reduce the stage efficiency by around 1–2% relative to operation with uniform inlet flow.

Jet engines with boundary layer ingestion (BLI) could offer significant reductions in aircraft fuel burn compared with podded turbofans. However, the engine fans must run continuously with severe inlet distortion, which is known to reduce stability. In this paper, an experimental study has been completed on a low-speed rig fan operating with a BLI-type inlet distortion. Unsteady casing static pressure measurements have been made at multiple locations during stall events. Steady-state, full-annulus area traverses have also been performed at rotor inlet and exit at a near-stall operating point. The reduction in stability caused by BLI is found to be small. It is found that with BLI the fan can operate stably despite the presence of localized regions where the rotor operating point lies beyond the stability boundary measured in clean flow. With the BLI-type distortion applied, the measured rotor incidence varies around the annulus due to nonuniform upstream velocity and swirl. The measured amplitude of unsteady casing pressure fluctuations just prior to stall is found to correlate with the circumferential variation of rotor incidence, suggesting that rotor incidence is a key variable affecting the creation and growth of flow disturbances. In regions of high incidence, disturbances resembling local flow separations are initiated. However, in regions of low or negative incidence, any disturbances decay rapidly. Full rotating stall with BLI occurs when high incidence regions are widespread enough to sustain disturbances which can propagate around the entire annulus.

The viability of boundary layer ingesting (BLI) engines for future aircraft propulsion is dependent on the ability to design robust, efficient engine fan systems for operation with continuously distorted inlet flow. A key step in this process is to develop an understanding of the specific mechanisms by which an inlet distortion affects the performance of a fan stage. In this paper, detailed full-annulus experimental measurements of the flow field within a low-speed fan stage operating with a continuous 60 deg inlet stagnation pressure distortion are presented. These results are used to describe the three-dimensional fluid mechanics governing the interaction between the fan and the distortion and to make a quantitative assessment of the impact on loss generation within the fan. A 5.3 percentage point reduction in stage total-to-total efficiency is observed as a result of the inlet distortion. The reduction in performance is shown to be dominated by increased loss generation in the rotor due to off-design incidence values at its leading edge, an effect that occurs throughout the annulus despite the localized nature of the inlet distortion. Increased loss in the stator row is also observed due to flow separations that are shown to be caused by whirl angle distortion at rotor exit. By addressing these losses, it should be possible to achieve improved efficiency in BLI fan systems.

For an unpowered turbofan in flight, the airflow through the engine causes the fan to freewheel. This paper considers the flow field through a fan operating in this mode, with emphasis on the effects of blade row losses and deviation. A control volume analysis is used to show that windmilling fans operate at a fixed flow coefficient which depends on the blade metal and deviation angles, while the blade row losses are shown to determine the fan mass flow rate. Experimental and numerical results are used to understand how the loss and deviation differ from the design condition due to the flow physics encountered at windmill. Results are presented from an experimental study of a windmilling low-speed rig fan, including detailed area traverses downstream of the rotor and stator. Three-dimensional computational fluid dynamics (CFD) calculations of the fan rig and a representative transonic fan windmilling at a cruise flight condition have also been completed. The rig test results confirm that in the windmilling condition, the flow through the fan stator separates from the pressure surface over most of the span. This generates high loss, and the resulting blockage changes the rotor work profile leading to modified rotational speed. In the engine fan rotor, a vortex forms at the pressure surface near the tip and further loss results from a hub separation caused by blockage from the downstream core and splitter.

A combined experimental and computational test programme, with two low pressure ratio aero-engine fans, has been used to identify the flow mechanisms at stall inception and the subsequent stall cell growth. The two fans have the same rotor tip clearance, annulus design and downstream stators, but different levels of tip loading. The measurement data show that both fans stall via spike-type inception, but that the growth of the stall cell, and the final cell size, is different in each fan. The computations, reproducing both the qualitative and quantitative behaviour of the steady-state and transient measurements, are used to identify the flow mechanisms at the origin of stall inception. In one fan, spillage of tip leakage flow upstream of the leading edge plane is responsible. In the other, sudden growth of casing corner separation blockage leads to stall. These two mechanisms are in accord with the findings from core compressors. However, the transonic aerodynamics and low hub-to-tip radius ratio of the fans leads to the following two findings: first, the casing corner separation is driven by shock-boundary layer interaction; second, the spanwise loading distribution of the fan determines whether the spike develops into full-span or part-span stall and both types of behaviour are represented in the present work. Finally, the axial momentum flux of the tip clearance flow is shown to be a useful indicator of the leakage jet spillage mechanism. A simple model is provided that links the tip loading, stagger and solidity with the tip clearance axial momentum flux, thereby allowing the aerodynamicist to connect, qualitatively, design parameters with the stall behaviour of the fan.