The essential ingredient missing in existing prediction methods for the performance of multistage axial compressors is that which would account for the effect of end-wall boundary layers. It is, in fact, believed that end-wall boundary layers play a major role in compressor performance and the absence of an adequate theory represents a handicap to turbomachinery designers that might be likened to the handicap that designers of wings, for example, would face if Prandtl had not introduced the idea of a boundary layer. In this paper a new theory is developed which retains all elements of classical boundary layer theory; for example, we discuss variables such as momentum thickness and wall shear stress. However, the present theory introduces new concepts such as axial and tangential defect force thickness, a rotor exit-stator inlet “jump condition” and the importance of these concepts is demonstrated. Inherent in the derivation is an identification of the role of secondary flow and tip clearance flow. A proper means of matching the boundary layer calculations to conventional main stream calculations is suggested. Independent of empirical parametization it appears that the theory is capable of correctly modeling boundary layer blockage, losses, and end-wall stall. Near stall, the main stream-boundary layer interaction is very strong.
Several design models of centrifugal pump impellers were tested in water to determine tip-clearance effects on noncavitating and cavitating performance. Although most of these impellers were designed without tip shrouds, three direct comparisons for shrouded versus unshrouded models are included. Within the scope of this investigation, varying degrees of tip clearance produced dissimilar trends in the hydraulic performance for the different design models tested. Fully shrouded impellers consistently yielded inferior cavitation performance as compared to unshrouded versions.
A centrifugal compressor stage with an unusually high inlet hub/tip ratio of 0.87 was designed for a pressure ratio of 2.0 at a corrected mass flow of 2.45 lb per sec. The geometry was selected so that the centrifugal stage could replace several of the last stages of a multistage axial compressor. The stage was tested with two diffuser schemes. One diffuser consisted of a series of drilled conical pipes, whereas the other employed multirow vaned cascades. Sea level aerodynamic tests of the compressor stage with each diffuser showed a peak total-to-total efficiency at design speed of 83.8 percent for the pipe diffuser and 82.9 percent for the vaned cascade diffuser. Additional tests were conducted with a vaneless diffuser to determine effects of impeller discharge tip clearance and inlet prewhirl on impeller performance.
The cavitation damage resistance of alloys of aluminum, columbium (niobium), tantalum, molybdenum, and stainless steel was evaluated in water using a rotating disk apparatus that simulated the cavitation vortex patterns encountered in pumps operating at high suction specific speed. The alloys in decreasing order of cavitation resistance were Ta-8W-2Hf, Cb-18W-8Hf, Ta-10W, 316SS, Mo-.5Ti, Cb-1Zr, Al-4Cu-.7Mn-.5Mg, and Al-2.5Mg-.25Cr. The damage resistance order does not follow the variation of any single property such as strain energy to failure, yield strength, or hardness, but appears to be a combination of mechanical properties and phase structure. Photomicrographs show predominant intergranular cracking for the molybdenum alloy and transgranular erosion and cracking for the remaining alloys tested. The second phase precipitate in the aluminum alloy appears to hinder the erosion of material. Investigation of small variations in the grain size of the heat-treated Cb-1Zr alloys resulted in some variation in damage resistance, with the largest grain structure exhibiting the highest resistance. Correlation curves of volume loss as a function of the peripheral velocity are presented for all materials tested. In addition, the operation of the rotating disk apparatus itself was examined in considerable detail and the effects of various design changes were evaluated.
A mixed flow impeller design was tested with six, five, and four vanes in a closed water loop to study the effects of cavitation on hydraulic performance and the results were compared with the work of other investigators. Two idealized flow models for incipient cavitation were derived to illustrate limits of cavitation design. It was found that both vane blockage and solidity effects are important when designing for optimum cavitation performance. Data showing incidence and speed effects plus the tip static pressure profiles in cavitating and noncavitating flow are also presented.
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