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Experimental simulations of effects of surface roughness level of TBC on overall effectiveness of film cooling under typical vane environment

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Abstract

The principle of selection of surface roughness level of thermal barrier coatings (TBCs) at turbine film-cooled vanes is unclear. In this work, the universal turbine vane flow environment was characterized by the proper combinations of different wall curvatures and streamwise pressure gradients. To achieve the direct measurements of overall effectiveness, a conjugate film cooling model with simulated TBCs was established by matching the hot-side Biot numbers of actual materials. The surface roughness levels were set in a range for TBC design stage. The measurements displayed the detailed trends in overall effectiveness of metal and TBC with the surface roughness level, wall curvature, streamwise pressure gradient, and cooling air flowrate. The roughness effect on overall effectiveness was complicated by the wall curvature, due to generating different jet mechanisms. When the engine Ra changes from 0.2 to 14 μm, the variations of metal overall effectiveness can be controlled below 15% at different walls. Overall, to improve the protection ability to metal, the smoother TBC is suggested to spray at the flat wall, while, at the convex and concave walls, the proper roughness of TBC can be considered in the near-hole region under the acceptable stress level.

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Abbreviations

Bi:

Biot number (−)

D :

Inlet diameter of film-hole (mm)

H :

Wall thickness (mm)

h :

Heat transfer coefficient (W m−2 K−1)

K :

Acceleration parameter (−)

k :

Thermal conductivity (W m−1 K−1)

k s :

Sand roughness (μm)

P :

Pitch of film-holes (mm)

R :

Radium of wall curvature (mm)

Ra:

Centerline average roughness (μm)

Re:

Reynolds number (−)

S :

Curvature coordinate (−)

T :

Temperature (K)

U :

Mean velocity (m s−1)

u :

Component of velocity (m s−1)

Y :

Spanwise coordinate (−)

Z :

Vertical coordinate

α :

Inclination angle (°)

∆ :

Relative deviation (%)

ρ :

Fluid density (kg m−3)

τ :

TBC effectiveness (−)

ϕ :

Metal overall effectiveness

av:

Area-averaged

c :

Cooling air

m :

Metal

∞:

Mainstream

APG:

Adverse pressure gradient

BR:

Blowing ratio

CVP:

Counter-rotating vortex pair

DR:

Density ratio

FC:

Film cooling

FPG:

Favorable pressure gradient

SPG:

Streamwise pressure gradient

TBC:

Thermal barrier coating

ZPG:

Zero pressure gradient

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Acknowledgements

The project is supported by Anhui Provincial Natural Science Foundation of China (Contract No. 2108085ME176) and Shenyang Aero-engine Institute of Aero Engine Corporation of China. The authors are grateful to Dr. Yi Jin and Dr. An-feng Shi at Experimental Center of Engineering and Material Sciences, USTC for their guidance with infrared thermal imaging technique.

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Authors and Affiliations

  1. CAS Key Laboratory of Mechanical Behavior and Design of Materials, Department of Thermal Science and Energy Engineering, University of Science and Technology of China, No. 96 Jinzhai Road, Hefei, 230027, Anhui, People’s Republic of China

    Jian Pu, Tiao Zhang, Xu Shuai & Jian-hua Wang

  2. Shenyang Aero-Engine Institute of Aero Engine Corporation of China, No. 1 Wanlian Road, Shenyang, 110015, Liaoning, People’s Republic of China

    Yun Chen & Wei-long Wu

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  1. Jian Pu
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Pu, J., Zhang, T., Shuai, X. et al. Experimental simulations of effects of surface roughness level of TBC on overall effectiveness of film cooling under typical vane environment. J Therm Anal Calorim 148, 10251–10267 (2023). https://doi.org/10.1007/s10973-023-12409-5

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