Current Research at Turbomachinery Aero-Heat Transfer Laboratory ...

Current Research
at Turbomachinery Aero-Heat Transfer Laboratory
at Penn State
AERONAUTICAL PROPULSION & ENERGY PRODUCTION
Dr. Cengiz Camci
1

TURBOMACHINERY AERO-HEAT TRANSFER LABORATORY
Department of Aerospace Engineering
THE PENNSYLVANIA STATE UNIVERSITY
TEACHING & RESEARCH
Prepared by : Dr. Cengiz Camci
Professor of Aerospace Engineering
223 Hammond Building cxc11@psu.edu
28-KASIM-2007 ODTU
2

FLIGHT
VEHICLE DESIGN
AERONAUTICS
AIR
BREATHING
PROPULSION
&
TURBOMACHINERY
EXPERIMENTAL
COMPUTATIONAL
ANALYTICAL
FLUID MECHANICS
AEROACOUSTICS
RESEARCH ACTIVITIES
AEROSPACE ENGINEERING DEPARTMENT
ROTORCRAFT
ENGINEERING
STRUCTURAL
DYNAMICS
DYNAMICS
&
CONTROLS
STRUCTURES
&
MATERIALS
COMPUTING,INFORMATION
&
COMMUNICATIONS
ASTRODYNAMICS
ASTRONAUTICS
SPACECRAFT
&
SATELLITE DESIGN
SPACE
PROPULSION
COMPUTATIONAL
FLUIDS
&
RAREFIED GAS
DYNAMICS
SPACE
ENVIRONMENT
&
RE-ENTRY
3

TURBOMACHINERY RELATED TEACHING EFFORTS
Theory and Design of Turbomachinery AERSP 507
Aero-thermo-mechanical Design of Small Gas Turbines
for UAV Applications AERSP 597-K
Propulsion System Design and Analysis for
Unmanned Air Vehicles AERSP 597-E
Finite Element Method in Fluid Mechanics and Heat Transfer
AERSP 560
Foundations of Fluid Mechanics AERSP 508
Aerospace Propulsion AERSP 410
Turbulent Flow AERSP 412
4

TEACHING OBJECTIVES
The objectives of a course and lifelong learning:
The objective of a course is
not to cover a certain set of topics,
but rather
to facilitate student
learning.
5

Good teachers are not only concerned with
the learning of a set of facts,
but rather with
learning that can be applied and used
in situations outside the course examinations.
6

TEACHING OBJECTIVES
The students need to develop skills that will help them
in a lifelong learning process.
The teachers need to stimulate interest in further learning.
Offering a base of concepts and skills that will facilitate
further learning and thinking
is an important part of college teaching.
7

MAJOR TURBOMACHINERY RESEARCH FACILITIES
HEAT TRANSFER WIND TUNNEL
LOW SPEED LINEAR CASCADE
HIGH SPEED FLOW facility 600 HP blower, dP=225 ” of H2O
Mach 0.8 flow at cascade exit
A 36 INCH DIAM. TURBINE RESEARCH FACILITY
(a large scale, rotating, cold flow turbine rig)
AXIAL FLOW FAN RESEARCH FACILITY
PLANAR AND STEREOSCOPIC PIV SYSTEMS
VARIOUS PROBE CALIBRATION SYSTEMS
LIQUID CRYSTAL AND PSP CALIBRATION SYSTEMS
8

FLUID DYNAMICS & HEAT TRANSFER STUDIES
APPLIED TO TURBOMACHINERY SYSTEMS
Aero-heat transfer studies of turbine casing treatments
Turbine blade tip aero-heat transfer studies including
novel squealer tips and tip leakage de-sensitization devices
Turbine disk cavity flows and intra-stage leakage aerodynamics
Turbine blade tip injection studies
Secondary flow minimization
(NGV and blade) Endwall contouring including non-axisymmetric contouring
Non-intrusive turbine aero-heat transfer measurements
LDA, PIV, thermographic liquid crystals
pressure sensitive paints and infrared thermography
Numerical prediction of turbomachinery flow and heat transfer in a
high performance computer cluster
9

Two new projects
funded by :
VERTICAL LIFT ROTORCRAFT CENTER OF EXCELLENCE
VLRCOE (2007)
1. DUCTED FAN AEROYNAMICS
2. HELICOPTER BLADE TIP AERODYNAMICS
10

Another new project
funded by :
SIEMENS POWER SYSTEMS (2007)
NON-AXISYMMETRIC
TURBINE ENDWALL
CONTOURING
Secondary flow minimization in
turbine passages (NGV)
11

TURBOMACHINERY AERO-HEAT TRANSFER
LABORATORY
Dept.of Aerospace Engineering
For further details contact to Dr.Cengiz Camci
Dept. of Aerospace Engineering
cxc11@psu.edu
814 865 9871
http://www.personal.psu.edu/cxc11/AFTRF
12

BURSA ERKEK LISESI 1972
CENGIZ CAMCI
ISTANBUL TEKNIK UNIVERSITESI 1976
BOGAZICI UNIVERSITESI 1979
Von Karman Institute for Fluid Dynamics 1980
VKI/Katholieke Universitat Leuven 1985
1986 dan bu yana
Professor of Aerospace Engineering
Pennsylvania State University
Dept. of Aerospace Engineering
TURBOMACHINERY AERO-HEAT TRANSFER LABORATORY
ABD
14

AERO-THERMAL STUDIES AT
PSU TURBOMACHINERY AERO-HEAT TRANSFER
LABORATORY
Sponsor: DOE/DOD GT companies
Dr. Cengiz Camci Prof. of Aerospace Eng.
Objective :
Improving energy efficiency of
turbomachinery systems through
aerodynamic and heat transfer related
performance gains.
16

AERO-THERMAL STUDIES AT
PSU TURBOMACHINERY AERO-HEAT TRANSFER LABORATORY
Potential Impact :
Significant stage efficiency gains in turbomachinery are possible
by minimizing the tip leakage flow mass flow rate,
reducing the secondary kinetic energy of passage vorticity at the stage exit and
using effective turbine cooling schemes.
Approach :
Current studies focus on turbine aero-thermal experiments in a modern large scale rotating turbine rig.
A high performance cluster of computers is also utilized in support of current turbomachinery research
studies.
Recent emphasis areas are: turbine casing treatments
Turbine blade tip aerodynamics including novel squealer tips and
leakage de-sensitization devices
Turbine disk cavity flows and intra-stage leakage aerodynamics
Turbine blade tip injection studies and secondary flow minimization
Endwall contouring including non-axisymmetric contouring
17

EMERGING AREAS
2007
DUCTED FAN RESEARCH FOR MAV/OAV
SAND EROSION OF HELICOPTER BLADES
NON-AXISYMMETRIC TURBINE ENDWALL
PROFILING
18

Axial Flow Turbine Research Facility AFTRF
36 inch diameter axial flow turbine is a
rotating cold flow research facility allowing
us to perform well-simulated
aero-heat transfer experiments
The AFTRF is extensively
instrumented for aerothermal
research and fully
operational.
Turbine stage
characteristics and other
research details can be
obtained from
http://www.personal.psu.edu/cxc11/AFTRF
19
BARIS GUMUSEL Ph.D. Student

AFTRF
Detailed aero-thermal stage flow physics
Fully instrumented and equipped with non-intrusive
measurement systems
Phase-locked LDA
measurements showing the tip
vortices and passage vortex system
in the AFTRF © ASME.
20

INSTANTANEOUS STAGE EXIT FLOW MAPPING
A phase-locked 150 Khz total pressure mapping system
Distinct effect of tip clearance on total pressure drop across blade row
Higher values of Cp (less negative)
Less pressure loss, i.e., goodness
PSU’s AFTRF rig
simulates both tip
and passage loss
producing vortices
-
Rig simulates
expected
blade tip
region flow
physics
UNSTEADY ENTROPY DOWNSTREAM OF
THE ROTOR BLADE OF AN HP TURBINE
, Payne (2003) ASME ©
Engine levels of Mach numbers and Re) Dual
aspirating probe, tip gap 2.25 % of blade height
OTL has formed into a large vortex occupying
more than 50 % of the pitch near the tip. The
upper passage vortex is relatively small, but
visible below the OTL vortex
Oxford rotating rig with
simulated Mach and
Reynolds numbers has
flow patterns similar to
PSU rotating rig AFTRF
21

Intra-stage coolant
injection system in
AFTRF
Disk impingement
Radial injection
Root injection
© ASME
22

Air-transfer system used in tip cooling/de-sensitization studies
in AFTRF © ASME
Stationary to rotating air-transfer system allows
cooling air to pass to
the rotating blade plenum chambers
Tip cooled blades
23

AFTRF Air-transfer system details © ASME
24

AFTRF blade tip injection system
LEAKAGE FLOW
IMPINGEMENT ON THE
SUCTION SIDE
TIP LEAKAGE
TIP INJECTION IS AN EFFECTIVE BLADE COOLING SCHEME.
TIP INJECTION ALSO HAS MEASURABLE AERODYNAMIC PERFORMANCE BENEFITS.
TIP INJECTION CAN EFFECTIVELY REDUCE TIP LEAKAGE MASS FLOW RATE.
25

Tip cooling geometry used for
aerodynamic tip de-sensitization studies
in AFTRF © ASME
26

Simulating Advanced Tip Forms in PSU Turbine Rig AFTRF
Objective: Better tip designs
For reduced tip clearance mass
flow rate
• Look at larger clearances (up to ~3%)
• Include squealer tip, inclined sq. tips, etc.
• Six blades, in two groups of three, have the tips cut off and replaced with
SLA plastic tips (Stereo-lithographically manufactured plastic tip models)
• SLA tips are shortened to test larger clearances; shimmed for smaller cl’s
• Some SLA tips will have advanced tip cavities and other new concepts
27

AFTRF WITH SQUEALER TIP INSERTS
IN THE ROTOR
removable precision window allows to
investigate the influence of various casing patterns
28

AFTRF blades could be retrofitted with
any new tip design in a time and cost effective manner
GT2005-68333 © ASME
INCLINED SHELF CONCEPT
ON THE PRESSURE SIDE
29

INCLINED SHELF
SQUEALER TIP
CONCEPT
AS IMPLEMENTED INTO
THE AFTRF ROTOR
Tip B
Green stereolithography based advanced tips
are inserted into the selected blades for further 30
Performance improvement quantification

Recent emphasis areas are:
Aero-heat transfer studies of turbine casing treatments
Turbine blade tip aero-heat transfer studies including
novel squealer tips and tip leakage de-sensitization devices
Turbine disk cavity flows and intra-stage leakage aerodynamics
Turbine blade tip injection studies
Secondary flow minimization
(NGV and blade) Endwall contouring including non-axisymmetric contouring
Non-intrusive turbine aero-heat transfer measurements
including, LDA, PIV, thermographic liquid crystals, pressure sensitive paints and
infrared thermography
Numerical prediction of turbomachinery flow and heat transfer in a high performance
computer
31

DUCTED FAN RESEARCH FOR
MAV/OAV SYSTEMS
DUCTLET AREA
FAN OFF-DESIGN
OFF DESIGN
PERFORMANCE
DURING
HORIZONTAL FLIGHT
32
ALI AKTURK Ph.D. student

HELISPY
Duct Diameter = 11 inch
Weight = 6 lbs
Height = 27 inch
Hover Endurance =25 min
Radius of action = 25 miles
The HeliSpy is a VTOL (Vertical Take Off
Landing) air vehicle that uses the MP2028g
autopilot. The HeliSpy has capabilities of
both a helicopter and an airplane. The
HeliSpy can take off and land vertically and
maneuvers laterally like a helicopter.
For high speed forward flight, the HeliSpy
can be tilted nearly horizontally and in this
configuration the main body and the rotor
guard act like a wing and the HeliSpy flies
in a manner similar to a fixed wing aircraft.

Honeywell MAV
Duct Diameter = 13 inch
Weight = 16 lbs
Altitude range =10-500 ft
Honeywell’s MAV can be
carried in a backpack and
is equiped with video
cameras.
The MAV can launch in 15
knot winds and operate in
20 knot winds.
The MAV’s ground
proximity sensors let it get
close enough to the
ground then it just drops
and land.

GOLDEN EYE-50 AURORA FLIGHT SCIENCE
Duct Diameter = ----- inch
Weight = 22 lbs
Height = 27.5 inch
Endurance = 1 Hour @100 km/h
Wing Span = 55 inch
GoldenEye-50 is unique among current ducted
fan UAS because it is able to take off vertically,
autonomously transition to high-speed
wingborne flight and then return to hover flight
in the target area to collect imagery and sensor
readings.
GoldenEye-50 was designed as a technology
development platform for Aurora's larger
ducted fan aircraft, the GoldenEye-OAV.
GoldenEye-50 was instrumental in the
development of the flight control system and
acoustic signature reduction for Aurora's
GoldenEye-OAV program.

ALLIED AEROSPACE – ISTAR
Duct Diameter = 9 inch
Weight = 5 lbs
Height = 12 inch
Radius of action = 5.5 miles

Originally conceived as a vertical takeoff and
landing surveillance system, the air vehicle
has evolved through hundreds of hours of
ground and flight testing.
The design concept is simple and efficient and
makes use of lightweight composite
construction techniques. The structure is
comprised of an outer duct enclosing the
fan system, centerbody (avionics and
subsystems), fixed stators and movable
vanes operated by actuators
(thrust vectoring).
The engine is housed in the centerbody, and
fuel tanks are located in the forward
section of the duct. A variety of payloads may
be carried in either the nose, tail or duct of the
vehicle.
37

BAE -60 Ducted Fan
http://www.vtol.org/news/issues206.html
Duct Diameter = 30 inch
Weight = 100 lbs
BAE was one of the contractors for DARPA Project.

Dragon Stalker - Gatech
Duct Diameter = ….inch
Weight = 200 lbs
Altitude range =…….

Skorsky Cypher Duct Diameter = 78.7 inch
Weight = 253.5 lbs
Endurance = 3 hours
Sikorsky Aircraft developed the Cypher ducted-rotor
VTOL craft in the early 1990s to meet a US close-range
UAV requirement. The Cypher combines Sikorsky's coaxial
advancing-blade concept rotor system and Fantail
ducted tail-rotor technology in a doughnut-shaped
shrouded-rotor UAV tethered tests in front of a wind
generator capable of generating wind speeds of over
50-60 knots.
This was followed by free flights.
Sikorsky is interested in developing commercial roles
for the Cypher, using the safety advantages of a
shrouded-rotor design as one selling point. The
company says its non-defence roles outnumber
potential military missions for the UAV, including
counter-narcotics, ordnance disposal, forestry, law
enforcement and search and rescue.
A publicity movie was briefly circulated in the mid-1990s
showing what appeared to be the Cypher development
demonstrating its capability of shadowing an individual
person in an urban-design demonstration range
scenario.
The Cypher is capable of a speed of 80 kts. and claims
an endurance of 3 hours.

Dragon Warrior – Sikorsky & NRL
Duct Diameter = 9 inch
Weight = 5 lbs
Height = 12 inch
Radius of action = 5.5 miles

Airborne Remotely Operated Device (1982-1988)˫
AROD
The first generation AROD vehicle, developed by Moller as a subcontractor to Perceptronics, was electrically
powered, with power supplied through a tether from the ground station, and was easily small enough to be
carried by one person. The second generation vehicles, developed by Sandia, were much larger and powered
by a 26-horsepower, two-stroke gasoline engine, driving a single lifting propeller. Servo driven vanes located
at the bottom of AROD controlled vehicle attitude, allowing hover, multi-directional translation, and rotation
about its vertical axis. An automatic control system helped maintain vehicle stability. A fiber optic cable
provided a communications to a small Ground Control Unit, with a radio link as backup. A 5 km spool of optical
fiber was carried aboard AROD to support a 2 km round trip or 5 km one-way mission.

Duct Diameter =12 inch
Weight =20 lbs
Altitude =Sea Level
REQUIRED POWER BASED
Required Power to hover is given by (Simple momentum theory)˫
P = (T 3 / (2ρA)) ½
Where Thrust= Weight for analysis at hover
P=4.1765 kW
P=5.6 HP

http://www.hoverhawk.com/
FAN & PROPELLER MANUFATURERS
http://www.powerfinprops.com/
http://www.warpdriveprops.com/index.html

NON-AXISYMMETRIC
NON AXISYMMETRIC
TURBINE ENDWALL PROFILING
IN AXIAL FLOW TURBINES
HOT SECTION
HP TURBINE
53
OZHAN TURGUT Ph.D. student

AFTRF
Detailed aero-thermal stage flow physics
Fully instrumented and equipped with non-intrusive
measurement systems
Phase-locked LDA
measurements showing the tip
vortices and passage vortex system
in the AFTRF © ASME.
54

For further details contact to Dr.Cengiz Camci
Dept. of Aerospace Engineering
The Pennsylvania State University
cxc11@psu.edu 814 865 9871
http://www.personal.psu.edu/cxc11/AFTRF