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Thermal barrier coated surface modifications for gas turbine film cooling: a review

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Abstract

Gas turbines are widely used in the areas of air propulsion, electric power generation, ship propulsion, external driving units, and other industrial applications. Efficient coating and cooling methods are often essential for the gas turbine surfaces to further achieve higher turbine inlet temperature and output efficiency. The thermal barrier coating (TBC) is the type of multilayered coating applied on rotating and stationary surfaces of the gas turbine components to safeguard them against the attack of high stream thermal loads and pressure gradients of the hot mainstream flows. TBC can also assist in surface-modified film cooling of gas turbine components. In this paper, the thermal barrier coated surface-modified film cooling methods for gas turbine components, viz. leading edge, pressure side, suction side, end wall, flat surfaces of stator guide vane and rotor blade, were reviewed and discussed in detail. The surface-modified film cooling methods for gas turbine components are grouped into three broad categories based on their geometric appearance. Each group was reviewed in detail for geometric and flow parameters, measurement techniques, flow characteristics, and performance parameters. Further, this study provides an overview of geometric and flow parameters of the compound angled film hole. Finally, the areas required for future research on the application of surface-modified film cooling methods are recommended in this review.

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Abbreviations

A :

Area of thermal flux surface (mm2)

B :

Distance between bump trailing edge and film hole center (mm)

C :

Distance between step trailing edge and film hole center (mm)

c :

Specific heat capacity (J kg−1 K−1)

D :

Film hole diameter (mm)

D t,m :

Turbulent diffusion coefficient (m2 s−1)

d :

Depth of the trench (mm)

E :

Crater diameter (mm)

\(\vec{E}\) :

Flux vector in the x-direction (–)

F :

Height of blockage within the film hole (mm)

G :

Height of micro-vortex generator (mm)

H :

Height of the barchan dune (mm)

\(\vec{H}\) :

Source vector term (–)

h :

Heat transfer coefficient (W m−2 K−1)

I :

Current (A)

J :

Distance between the trailing edge of vortex generator and film hole (mm)

K :

Thermal conductivity (W m−1 K−1)

L :

Length of film cooling hole (mm)

ℓ :

Width of the trench (mm)

L/D :

Length-to-diameter ratio of film hole (–)

M :

Injection (or) blowing ratio (–)

n :

Depth of crater (mm)

P/D :

Pitch-to-diameter ratio of film hole (–)

Pr:

Prandtl number (–)

Q :

Distance between the obstacle and film hole exit (mm)

q″:

Surface heat flux (W m−2)

R:

Height of the step (mm)

R:

Thermal resistance (m2 K W−1)

S :

Distance between ramp trailing edge and the leading edge of film hole (mm)

Sc:

Schmidt number (–)

TI:

Turbulence intensity (%)

T R :

Reference temperature (K)

t :

Temporal coordinate (s)

t :

Time (s)

\(\vec{U}\) :

Solution vector (–)

u :

Velocity of flow (m s−1)

u 2 :

Finite speed of thermal wave propagation (m s−1)

ū :

Local average absolute velocity (m s−1)

ū m :

Main flow average absolute velocity (m s−1)

ū/ū m :

Average normalized velocity (–)

V :

Voltage (V)

W :

Height of bump or block (mm)

X/D :

Non-dimensional longitudinal length of the test surface (–)

\(x\) :

Spatial coordinate in \(x\)-direction (m)

Y/D :

Non-dimensional span side length of the test surface (–)

Z/D :

Non-dimensional vertical length from the test surface (–)

α :

Ramp angle (°)

α :

Thermal diffusivity (m2 s−1)

β :

Injection angle of film hole (°)

\(\varGamma_{\text{m}}\) :

Mass fraction of species m (–)

\(\nabla\)T:

Temperature gradient (K m−1)

γ :

Film hole compound angle (°)

ε :

Emissivity (–)

\(\eta\) :

Film cooling effectiveness (–)

θ :

Non-dimensional temperature (–)

ρ :

Density (kg m−3)

σ :

Stephen Boltzmann constant (W m−2 K−4)

τ :

Relaxation time (s)

φ :

Overall film cooling effectiveness (–)

\(\chi\) :

Coolant warming factor (–)

ω Z :

Spanwise instantaneous vorticity (s−1)

ave:

Averaged

aw:

Adiabatic wall

c:

Coolant

c,exit:

Coolant at film cooling hole exit

c,in:

Coolant at upstream of impingement plate

e:

External surface

f:

With film cooling

i:

Initial

i:

Internal

o:

Without film cooling

surf:

Surface

t:

Time

w:

Wall

∞:

Mainstream

APS:

Air plasma spraying

BD:

Barchan dune

BDSR:

Barchan-dune-shaped ramp

BL:

Boundary layer

CFD:

Computational fluid dynamics

CL:

Centerline

CR:

Covering ratio

CRV:

Counter-rotating vortex

DC:

Discharge coefficient

DSGT:

Double-sided grooved trench

EB PVD:

Electron beam physical vapor deposition

FC:

Film cooling

FCE:

Film cooling effectiveness

FCH:

Film cooling hole

HT:

Heat transfer

HTC:

Heat transfer coefficient

IR:

Injection ratio

KH:

Kelvin–Helmholtz

LA:

Lateral averaged

LCT:

Liquid crystal thermography

LES:

Large-eddy simulation

LE:

Leading edge

PS:

Pressure side

RANS:

Reynolds averaged Navier strokes

RFC:

Ramp film cooling

SA:

Spatial averaged

SH:

Showerhead

SST:

Shear stress transport

ST:

Segregated trench

TBC:

Thermal barrier coating

TE:

Trailing edge

TFC:

Trench film cooling

TGO:

Thermal grown oxide

TT:

Transverse trench

VG:

Vortex generator

YSZ:

Yttria-stabilized zirconia

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Acknowledgements

The first author gratefully acknowledges the Department of Science and Technology, Government of India, for the award of DST INSPIRE fellowship.

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  1. Department of Aerospace Engineering, Anna University, MIT Campus, Chennai, India

    V. G. Krishna Anand & K. M. Parammasivam

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  1. V. G. Krishna Anand
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Krishna Anand, V.G., Parammasivam, K.M. Thermal barrier coated surface modifications for gas turbine film cooling: a review. J Therm Anal Calorim 146, 545–580 (2021). https://doi.org/10.1007/s10973-020-10032-2

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