A novel test facility for transonic fans has been constructed and commissioned at École Centrale de Lyon (ECL) within the Project PHARE-2. The facility is instrumented with multi-physical measurement systems to deeply investigate aeroelastic and aeroacoustic phenomena. To enable long-term fundamental research, the composite material open-test-case rotor ECL5 is currently under development, which shall be established as a new reference case for method development. Within the present publication, the project objectives, the current rotor design, ECL5v2, and details on the test facility are presented. With the goal to establish future academic collaborations, the authors aim to initiate a discussion in the research community in an early stage of the test case development to receive constructive feedback on the design and research approach.

The application of composite fans enables disruptive design possibilities but increases sensitivity to multi-physical resonance between aerodynamic, structure dynamic and acoustic phenomena. As a result, aeroelastic problems increasingly set the stability limit. Test cases of representative geometries without industrial restrictions are a key element of an open scientific culture but are currently non-existent in the turbomachinery community. In order to provide a multi-physical validation benchmark representative of near-future UHBR fan concepts, the open-test-case fan stage ECL5 was developed at Ecole Centrale de Lyon. The design intention was to develop a geometry with high efficiency and a wide stability range that can be realized using carbon fibre composites. This publication aims to introduce the final test case, which is currently fabricated and will be experimentally tested. The fan blades are composed of a laminate made of unidirectional carbon fibres and epoxy composite plies. Their structural properties and the ply orientations are presented. To characterize the test case, details are given on the aerodynamic design of the whole stage, structure dynamics of the fan and aeroelastic stability of the fan. These are obtained with a state-of-art industrial design process: static and modal FEM, RANS and LRANS simulations. Aerodynamic analysis focuses on performance and shows critical flow structures such as tip leakage flow, radial flow migration and flow separations. Mechanical modes of the fan are described and discussed in the context of aeroelastic interactions. Their frequency distribution is validated in terms of resonance risk with respect to synchronous vibration. The aeroelastic stability of the fan is evaluated at representative operating points with a systematic approach. Potential instabilities are observed far from the operating line and do not compromise experimental campaigns.

A research centrifugal compressor stage designed and built by Safran Helicopter Engines is tested at three inlet guide vanes (IGV) stagger angles. The compressor stage includes four blade rows: axial inlet guide vanes, a backswept splittered impeller, a splittered vaned radial diffuser (RD), and axial outlet guide vanes (OGVs). The methodology for calculating the performance is detailed, including the consideration of humidity in order to minimize errors related in particular to operating atmospheric conditions. The shift of the surge line toward lower mass flow rate as the IGV stagger angle increases highly depends on the rotation speed. The surge line shift is very small at low rotation speeds, whereas it significantly increases at high rotation speeds. A first-order stability analysis of the impeller and diffuser sub-components shows that the diffuser (resp. impeller) is the first unstable component at low (resp. high) rotation speeds. This situation is unaltered by increasing the IGV stagger angle. At low rotation speeds below a given mass flow rate, rotating instabilities (RI) at the impeller inlet are detected at zero IGV stagger angle. Their occurrence is conditioned by the relative flow angle at the tip of the leading edge of the impeller. As the IGV stagger angle increases, the mass flow decreases to maintain a given inlet flow angle. Therefore, the onset of the rotating instabilities is delayed toward lower mass flow rates. At high rotation speeds, the absolute flow angle at the diffuser inlet near surge decreases as the IGV stagger angle increases. As a result, the flow is highly alternate over two adjacent channels of the radial diffuser beyond the surge line at IGV stagger angle of 0 deg.

The flow in the vaned diffuser of an aeronautical centrifugal compressor designed by Safran Helicopter Engines is analyzed through steady and unsteady pressure measurements at different rotation speeds. The analysis leads to the identification of different operating zones thanks to a new variable, the alternate rate $\mathcal{A}$. It allows the characterization of a specific behavior of the vaned diffuser consisting of an alternate stall pattern in two adjacent channels of the diffuser. While it is close to zero at low speed, the alternate rate reaches a maximum value at a higher speed before collapsing with a further increase in the rotation speed. Depending on the value reached by the alternate rate, three distinct regimes of the flow within the diffuser can be distinguished. For low $\mathcal{A}$ values, the regime is the most common one with an equivalent flow pattern in each channel of the diffuser. For moderate $\mathcal{A}$ values, a mild difference of the flow fields which develop in two adjacent channels can be observed but it remains time independent. Finally, for high values of $\mathcal{A}$, the alternate pattern is amplified and becomes time dependent, pulsating together with the mild surge of the entire compressor.

Boundary-layer flow separation is a common flow feature in many engineering applications. The consequences of flow separation in turbomachinery can be disastrous in terms of performance, stability and noise. In this context, flow separation is particularly difficult to understand because of its three-dimensional and confined aspects. Analyzing the skin friction lines is one key point to understanding and controlling this phenomenon. In the case of separation, the flow at the wall agglutinates around a manifold while the fluid from the boundary layer is ejected toward the flow away from the wall. The analysis of a three-dimensional separation zone based on topology is well addressed for a simple geometry. This paper aims at providing simple rules and methods, with a clear vocabulary based on mathematical background, to conduct a similar analysis with complex turbomachinery geometry (to understand a surface with a high genus). Such an analysis relies on physical principles that help in understanding the mechanisms of flow separation on complex geometries. This paper includes numerous typical turbomachinery surfaces: the stator row, vaneless diffuser, vaned diffuser, axial rotor and shrouded and unshrouded centrifugal impeller. Thanks to surface homeomorphisms, the generic examples presented can easily be converted into realistic shapes. Furthermore, classical turbomachinery problems are also addressed, such as periodicity or rotor clearance. In the last section, the proposed methodology is conducted on a radial diffuser of an industrial compressor. The flow at the wall is extracted from LES computations. This study presents the different closed separation zones in a high-efficiency operating condition.

Purpose: The choke flutter is a fluid-structure interaction that can lead to the failure of fan or compressor blade in turbojet engines. In ultra high bypass ratio (UHBR) fans, the choke flutter appears at part-speed regimes and at low or negative incidence when a strong shock-wave chokes the blade to blade channel. The purpose of this study is to locate the main excitation sources and improving the understanding of the different work exchange mechanisms. This work contributes to avoiding deficient and dangerous fan design. Design/methodology/approach: In this paper, an UHBR fan is analyzed using a time-linearized Reynolds-averaged Navier–Stokes equation solver to investigate the choke flutter. The steady-state and the imposed vibration (inter blade phase angle, reduced frequency and mode shape) are selected to be in choke flutter situation. Superposition principle induced by the linearization allow to decompose the blade in numerous small subsections to track the contribution of each local vibration to the global damping. All simulations have been performed on a two-dimensional blade to blade extraction. Findings: Result analysis points to a restricted number of excitation sources at the trailing edge which induce a large part of the work exchange in a limited region of the airfoil. Main phenomena suspected are the shock-wave motion and the shock-wave/boundary layer interaction. Originality/value: An original excitation source tracking methodology allowed by the linearized calculation is addressed and applied to a UHBR fan test case.