The over-tip-leakage (OTL) flow characteristics for a typical squealer tip of a high-pressure turbine blade, which consists of subsonic and transonic flow, have been numerically investigated in the present study, in comparison with the corresponding flat tip results. For the squealer tip employed, flow choking behavior still exists above the tip surface, even though the Mach number is lower and the transonic region is smaller than that for the flat tip. Detailed flow structure analysis shows that most of the fluid entering the squealer cavity is from the frontal leading edge region. The fluid migrates along the cavity and is ejected at various locations near the suction side rim. These fluids form a large subsonic flow zone under the supersonic flow passing over the tip gap which reduces the OTL flow flux. The squealer design works even in the presence of choked OTL flow. Comparisons between results from three different cavity depths with and without relative casing motion suggest that the over-tip-leakage flow flux has much dependence upon the cavity depth for the subsonic region, but is less sensitive to the depth for the transonic tip flow region. Such behavior has been confirmed with and without the existence of relative casing motion.

A large portion of the over-tip leakage flow is often transonic for a typical high pressure (HP) turbine blade. It has been observed that the tip heat transfer is noticeably lower in a high speed flow tip region than in a low speed region. The present study therefore investigates the feasibility of controlling blade heat transfer by tip shaping to locally accelerate the flow to a transonic regime. The results show that a significant heat load reduction can be achieved by the local flow acceleration. Such over-tip-shaping provides a great potential as an effective means to control heat load distribution (and hence thermal stress) over the blade tip surface. The feasibility of the concept and flow physics have been demonstrated in detail by CFD analyses, with and without the effect of moving casing. The experimental results obtained from a high speed linear cascade facility have also been presented. The novel tip-shaping concept proposed in this paper could provide a potential for promoting choking inside the tip gap as a new way to control the over-tip leakage mass flow.

This paper presents an experimental investigation of the aerothermal performance of a cooled winglet tip under transonic conditions (exit Mach number of 1.0, and an exit Reynolds number of 1.27 × 10⁶, based on axial chord). Spatially resolved heat transfer data and film cooling effectiveness data are obtained using the transient infrared thermography technique in the Oxford High-Speed Linear Cascade test facility. Aerodynamic loss data are obtained by traversing a specially made and calibrated three-hole pressure probe and a single-hole probe one axial chord downstream of the blade. Detailed contours of Nusselt number show that for an increase in tip clearance, with and without film cooling, and for coolant injection, for both tip clearances, the Nusselt number increases. Also the smaller tip clearance observes higher film cooling effectiveness overall. Detailed distributions of kinetic energy losses as well as pitch-wise averaged loss coefficients and loss coefficients at a mixed-out plane indicate that the size of the loss core associated with the over-tip leakage vortex decreases with cooling injection.

Currently the aerodynamics and heat transfer over a turbine blade tip tend to be analyzed separately with the assumption that the wall thermal boundary conditions do not affect the over-tip-leakage (OTL) flow field. There are some existing correlations for correcting the wall temperature effect on heat transfer when scaled to engine realistic conditions. But they were either developed to account for the temperature dependence of fluid properties largely empirically, or based on a boundary-layer model. It would be difficult (if not impossible) to define a boundary layer in many parts of a realistic blade passage with marked three-dimensional (3D) end wall and secondary flows (including those within a blade tip and around it). The questions to be asked here are: is the OTL aerodynamics significantly affected by the wall thermal condition? And if it is, how can we count this effect consistently in turbine blade tip design and analysis using modern CFD methods? In the present study the problem has been examined for typical high-pressure turbine blade tip configurations. An extensively developed RANS code (HYDRA) is employed and validated against the experimental data from a high speed linear cascade testing rig. The numerical analysis reveals that the wall–gas temperature ratio could greatly affect the transonic OTL flow field and there is a strong two-way coupling between aerodynamics and heat transfer. The feedbacks of the thermal boundary condition to aerodynamics behave differently at different flow regimes over the tip, clearly indicating a highly localized dependence of the convective heat transfer coefficient (HTC) upon wall temperatures. This implies that to use HTC for blade metal temperature predictions without resorting a fully conjugate solution, the temperature dependence needs to be corrected locally. A nonlinear correction approach has been adopted in the present work, and the results demonstrate its effectiveness for the transonic turbine tip configurations studied.

The relative casing motion can greatly vary the over-tip-leakage (OTL) flow structure and aerothermal performance. The existing tip experimental research facilities including stationary linear cascade, cascade rigs with low-speed moving belt, or high-speed rotor rigs are either not capable of reproducing the high relative casing Mach number or extremely expensive and still difficult for optical measurement. This paper presents a high-speed disk rotor design that can simulate the high casing relative speed. The unique feature of this rig design concept is that it enables full optical access of the tip surface under the engine-representative OTL flow condition. In this paper, the feasibility of the design concept is demonstrated and assessed by Reynolds-averaged Navier–Stokes computational fluid dynamics (RANS CFD) simulation, both in component level and in whole rig system level. First-of-its-kind experimental results of spatially resolved tip heat transfer coefficient distribution at high relative casing Mach number are reported. The disk rotor rig design demonstrated in this paper can also be useful for other tip leakage flow studies.

Most of the previous researches of inlet turbulence effects on blade tip have been carried out for low speed situations. Recent work has indicated that for a transonic turbine tip, turbulent diffusion tends to have a distinctively different impact on tip heat transfer than for its subsonic counterpart. It is hence of interest to examine how inlet turbulence flow conditioning would affect heat transfer characteristics for a transonic tip. The present work is aimed to identify and understand the effects of both inlet freestream turbulence and end wall boundary layer on a transonic turbine blade tip aerothermal performance. Spatially-resolved heat transfer data are obtained at aerodynamic conditions representative of a high-pressure turbine, using the transient infrared thermography technique with the Oxford High-Speed Linear Cascade research facility. With and without turbulence grids, the turbulence levels achieved are 7%–9% and 1%, respectively. On the blade tip surface, no apparent change in heat transfer was observed with high and low inlet turbulence intensity levels investigated. On the blade suction surface, however, substantially different local heat transfer distributions for the suction side near tip surface have been observed, indicating a strong local dependence of the local vortical flow structure on the freestream turbulence. These experimentally observed trends have also been confirmed by CFD examinations using the Rolls-Royce HYDRA. A further CFD analysis suggests that the level of inflow turbulence alters the balance between the passage vortex associated secondary flow and the over tip leakage (OTL) flow. Consequently, an enhanced inertia of near wall fluid at a higher inflow turbulence weakens the cross-passage flow. As such, the weaker passage vortex leads the tip leakage vortex to move further into the mid passage, with the less spanwise coverage on the suction surface, as consistently indicated by the heat transfer signature. Different inlet end wall boundary layer profiles are employed in the computational study with HYDRA. All CFD results indicate the inlet boundary layer thickness has little impact on the heat transfer over the tip surface as well as the pressure side near-tip surface. However, noticeable changes in heat transfer are observed for the suction side near-tip surface. Similar to the inlet turbulence effect, such changes can be attributed to the interaction between the passage vortex and the OTL flow.