Enhanced Film Cooling Effectiveness With New Shaped Holes

Abstract

Gas Turbine Engines operate at temperatures higher than current material temperature limits. This necessitates cooling the metal through internal or external means and/ or protecting the metal with coatings that have higher material limits. Film cooling is one of the major technologies allowing today’s gas turbines to operate at extremely high turbine inlet temperatures, consequently higher power density, and extend the cooled components life. Film cooling is a technique where a coolant is blown over the surface exposed to hot gas and a film of low temperature gas is maintained that protects the metal surface from the hot gas. The application of effective film-cooling techniques provides the first and best line of defense for hot gas path surfaces against the onslaught of extreme heat fluxes, serving to directly reduce the incident convective heat flux on the surface. The effectiveness of film cooling methods depends on the blowing ratio, shape of the cooling holes, and geometrical parameters such as the area ratio and diffusion angle. Film cooling is performed almost exclusively through the use of discrete holes. The holes can be of round or other shaped. A detailed study of the literature shows that the fan shaped has higher effectiveness when compared to other shapes. In this study a number of cooling hole shapes are evaluated numerically using the Computational Fluid Dynamics (CFD) tool ANSYS-CFX-11.0 with the objective of improving cooling effectiveness under a favorable pressure gradient main flow. In order to delineate the effects of shape from that of diffusion, a constant area ratio is assumed first. In the next set of analyses the effect of hole exit diffusion is considered. Results are presented in terms of surface temperatures and adiabatic effectiveness at three different blowing ratios for the different film cooling hole shapes analyzed. Comparison is made with reference to the fan shaped film cooling hole with forward and lateral angles of 10/10/10 degree respectively. Hole shapes that show improvement over the fan shaped hole are identified and optimized.

Adiabatic Effectiveness Measurements for a Baseline Shaped Film Cooling Hole

“…A review of shaped hole geometries found in the literature identified 130 different hole designs. Geometries included conical, laidback, and fanshaped holes [2][3][4][5][6], and many novel designs: bean-shaped [7], cusp-shaped [8], crescent-shaped [9], cratered [10], "Console" [11], double-jet [12], Nekomimi [13], transonic wall jet [14], waist-shaped [15], arrowhead-shaped [16], and anti-vortex holes [17]. The review included not only flat-plate studies, but also endwall, airfoil, and test coupon studies that featured shaped holes [18][19][20].…”

Film cooling sensitivity of laidback fanshape holes to variations in exit configuration and mainstream turbulence intensity

“…They found that high mainstream turbulence intensity only decreased the film cooling effectiveness under small blowing ratios. In recent years, some new shaped film hole configurations have been introduced, such as converging slot hole [23], waist-shape slot hole [24], dumbbell and bean shaped holes [25], NEKOMIMI film hole [26], and novel sister shaped hole [27]. But the majority of these ideas prove to be difficult to manufacture to make their way into production.…”

An Experimental Investigation of Showerhead Film Cooling Performance on a Turbine Blade

“…Results from Yao et al [13,14] demonstrate that the CONSOLE produces better effectiveness and cuts down the aerodynamic loss compared with the cylindrical hole. Other investigators [15][16][17] also came up with some innovative cooling geometries which were verified to produce better cooling performance than fan-shaped holes.…”