11

Current Research

at Turbomachinery Aero-Heat Transfer Laboratory

at Penn StateAERONAUTICAL PROPULSION & ENERGY PRODUCTION

Dr. Cengiz Camci

22

TURBOMACHINERY AERO-HEAT TRANSFER LABORATORY

Department of Aerospace Engineering

THE PENNSYLVANIA STATE UNIVERSITY

TEACHING & RESEARCH

Prepared by : Dr. Cengiz Camci

Professor of Aerospace Engineering223 Hammond Building cxc11@psu.edu

28-KASIM-2007 ODTU

33

ASTRONAUTICSAERONAUTICS

RESEARCH ACTIVITIESAEROSPACE ENGINEERING DEPARTMENT

SPACE PROPULSION

FLIGHTVEHICLE DESIGN

AIRBREATHING

PROPULSION&

TURBOMACHINERY

AEROACOUSTICS

ROTORCRAFT ENGINEERING

STRUCTURALDYNAMICS

COMPUTING,INFORMATION &

COMMUNICATIONS

EXPERIMENTALCOMPUTATIONAL

ANALYTICALFLUID MECHANICS

SPACECRAFT &

SATELLITE DESIGN

SPACE ENVIRONMENT

&RE-ENTRY

ASTRODYNAMICS

STRUCTURES&

MATERIALS

DYNAMICS&

CONTROLS

COMPUTATIONAL FLUIDS

&RAREFIED GAS

DYNAMICS

44

TURBOMACHINERY RELATED TEACHING EFFORTS

�Finite Element Method in Fluid Mechanics and Heat TransferAERSP 560

� Foundations of Fluid Mechanics AERSP 508

� Aerospace Propulsion AERSP 410

� Turbulent Flow AERSP 412

� Theory and Design of Turbomachinery AERSP 507

� Aero-thermo-mechanical Design of Small Gas Turbinesfor UAV Applications AERSP 597-K

� Propulsion System Design and Analysis forUnmanned Air Vehicles AERSP 597-E

55

The objectives of a course and lifelong learning:

TEACHING OBJECTIVES

The objective of a course is

not to cover a certain set of topics,

but rather

to facilitate student learning.

66

but rather with

learning that can be applied and usedin situations outside the course examinations.

Good teachers are not only concerned with the learning of a set of facts,

77

The teachers need to stimulate interest in further learning.

TEACHING OBJECTIVES

The students need to develop skills that will help themin a lifelong learning process.

Offering a base of concepts and skills that will facilitate

further learning and thinkingis an important part of college teaching.

88

MAJOR TURBOMACHINERY RESEARCH FACILITIES

� HEAT TRANSFER WIND TUNNEL

� LOW SPEED LINEAR CASCADE

� HIGH SPEED FLOW facility 600 HP blower, dP=225 ” of H2OMach 0.8 flow at cascade exit

� A 36 INCH DIAM. TURBINE RESEARCH FACILITY(a large scale, rotating, cold flow turbine rig)

� PLANAR AND STEREOSCOPIC PIV SYSTEMS

� VARIOUS PROBE CALIBRATION SYSTEMS

� LIQUID CRYSTAL AND PSP CALIBRATION SYSTEMS

� AXIAL FLOW FAN RESEARCH FACILITY

99

FLUID DYNAMICS & HEAT TRANSFER STUDIESAPPLIED TO TURBOMACHINERY SYSTEMS

� Aero-heat transfer studies of turbine casing treatments

� Turbine blade tip aero-heat transfer studies includingnovel 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 ahigh performance computer cluster

1010

Two new projects

funded by :

VERTICAL LIFT ROTORCRAFT CENTER OF EXCELLENCE

VLRCOE (2007)

1. DUCTED FAN AEROYNAMICS

2. HELICOPTER BLADE TIP AERODYNAMICS

1111

Another new project

funded by :

SIEMENS POWER SYSTEMS (2007)

NON-AXISYMMETRICTURBINE ENDWALL CONTOURING

Secondary flow minimization inturbine passages (NGV)

1212

For further details contact to Dr.Cengiz CamciDept. of Aerospace Engineering

cxc11@psu.edu

814 865 9871

http://www.personal.psu.edu/cxc11/AFTRF

TURBOMACHINERY AERO-HEAT TRANSFER LABORATORY

Dept.of Aerospace Engineering

1313

1414

CENGIZ CAMCI

BURSA ERKEK LISESI 1972

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 EngineeringPennsylvania State University

Dept. of Aerospace EngineeringTURBOMACHINERY AERO-HEAT TRANSFER LABORATORY

ABD

1515

1616

AERO-THERMAL STUDIES ATPSU 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.

1717

AERO-THERMAL STUDIES ATPSU TURBOMACHINERY AERO-HEAT TRANSFER LABORATORY

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 treatmentsTurbine blade tip aerodynamics including novel squealer tips and

leakage de-sensitization devicesTurbine disk cavity flows and intra-stage leakage aerodynamics

Turbine blade tip injection studies and secondary flow minimizationEndwall contouring including non-axisymmetric contouring

Potential Impact :

Significant stage efficiency gains in turbomachinery are possibleby minimizing the tip leakage flow mass flow rate,

reducing the secondary kinetic energy of passage vorticity at the stage exit andusing effective turbine cooling schemes.

1818

DUCTED FAN RESEARCH FOR MAV/OAV

SAND EROSION OF HELICOPTER BLADES

NON-AXISYMMETRIC TURBINE ENDWALL PROFILING

EMERGING AREAS

2007

1919

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 aero-

thermal research and fully operational.

Turbine stage characteristics and other research details can be

obtained fromhttp://www.personal.psu.edu/cxc11/AFTRF

Axial Flow Turbine Research Facility AFTRF

����� �

BARIS GUMUSEL Ph.D. Student

2020

Phase-locked LDA measurements showing the tip

vortices and passage vortex system in the AFTRF © ASME.

AFTRFDetailed aero-thermal stage flow physics

Fully instrumented and equipped with non-intrusive measurement systems

2121

PSU’s AFTRF rig simulates both tip and passage loss producing vortices

Distinct effect of tip clearance on total pressure drop across blade row

--

Higher values of Cp (less negative) �Less pressure loss, i.e., goodness

INSTANTANEOUS STAGE EXIT FLOW MAPPINGA phase-locked 150 Khz total pressure mapping system

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

2222

Intra-stage coolant injection system in

AFTRF

Disk impingementRadial injectionRoot injection

© ASME

2323

Air-transfer system used in tip cooling/de-sensitization studiesin AFTRF © ASME

Stationary to rotating air-transfer system allowscooling air to pass to

the rotating blade plenum chambers

Tip cooled blades

2424

AFTRF Air-transfer system details © ASME

2525

AFTRF blade tip injection system

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.

LEAKAGE FLOWIMPINGEMENT ON THE

SUCTION SIDE

TIP LEAKAGE

2626

Tip cooling geometry used foraerodynamic tip de-sensitization studies

in AFTRF © ASME

2727

Simulating Advanced Tip Forms in PSU Turbine Rig AFTRF

• Six blades, in two groups of three, have the tips cut off and replaced withSLA 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

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.

2828

AFTRF WITH SQUEALER TIP INSERTSIN THE ROTOR

removable precision window allows toinvestigate the influence of various casing patterns

2929GT2005-68333 © ASME

AFTRF blades could be retrofitted withany new tip design in a time and cost effective manner

INCLINED SHELF CONCEPTON THE PRESSURE SIDE

3030

Tip BINCLINED SHELFSQUEALER TIPCONCEPT

AS IMPLEMENTED INTOTHE AFTRF ROTOR

Green stereolithography based advanced tipsare inserted into the selected blades for further

Performance improvement quantification

3131

Aero-heat transfer studies of turbine casing treatments

Turbine blade tip aero-heat transfer studies includingnovel 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 measurementsincluding, LDA, PIV, thermographic liquid crystals, pressure sensitive paints and

infrared thermography

Numerical prediction of turbomachinery flow and heat transfer in a high performance computer

Recent emphasis areas are:

3232

ALI AKTURK Ph.D. student

DUCTED FAN RESEARCH FORDUCTED FAN RESEARCH FOR

MAV/OAV SYSTEMSMAV/OAV SYSTEMS

DUCTLET AREADUCTLET AREA

FAN OFFFAN OFF--DESIGNDESIGN

PERFORMANCEPERFORMANCE

DURINGDURING

HORIZONTAL FLIGHTHORIZONTAL FLIGHT

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 HeliSpycan 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.

HELISPY

Duct Diameter = 11 inchWeight = 6 lbsHeight = 27 inchHover Endurance =25 minRadius of action = 25 miles

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.

Honeywell MAV

Duct Diameter = 13 inchWeight = 16 lbsAltitude range =10-500 ft

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.

GOLDEN EYE-50 AURORA FLIGHT SCIENCE

Duct Diameter = ----- inchWeight = 22 lbsHeight = 27.5 inchEndurance = 1 Hour @100 km/h

Wing Span = 55 inch

ALLIED AEROSPACE – ISTAR

Duct Diameter = 9 inchWeight = 5 lbsHeight = 12 inchRadius of action = 5.5 miles

3737

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 maybe carried in either the nose, tail or duct of the

vehicle.

BAE -60 Ducted FanDuct Diameter = 30 inchWeight = 100 lbs

http://www.vtol.org/news/issues206.html

BAE was one of the contractors for DARPA Project.

Dragon Stalker - Gatech

Duct Diameter = ….inchWeight = 200 lbsAltitude range =…….

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 co-axial 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.

Skorsky Cypher Duct Diameter = 78.7 inchWeight = 253.5 lbsEndurance = 3 hours

Dragon Warrior – Sikorsky & NRL

Duct Diameter = 9 inchWeight = 5 lbsHeight = 12 inchRadius 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.

REQUIRED POWER BASED

Duct Diameter =12 inchWeight =20 lbsAltitude =Sea Level

Required Power to hover is given by (Simple momentum theory)�P = (T3 / (2ρA)) ½

Where Thrust= Weight for analysis at hover

P=4.1765 kWP=5.6 HP

FAN & PROPELLER MANUFATURERS

http://www.hoverhawk.com/

http://www.powerfinprops.com/

http://www.warpdriveprops.com/index.html

4545

4646

4747

4848

4949

5050

5151

5252

5353

NONNON--AXISYMMETRICAXISYMMETRIC

TURBINE ENDWALL PROFILINGTURBINE ENDWALL PROFILING

IN AXIAL FLOW TURBINESIN AXIAL FLOW TURBINES

�� HOT SECTIONHOT SECTION

�� HP TURBINEHP TURBINE

OZHAN TURGUT Ph.D. student

5454

Phase-locked LDA measurements showing the tip

vortices and passage vortex system in the AFTRF © ASME.

AFTRFDetailed aero-thermal stage flow physics

Fully instrumented and equipped with non-intrusive measurement systems

5555

5656

5757

5858

5959

6060

6161

6262

6363

7272

7373

7474

7575

7676

7777

7878

7979

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