Film-cooling technology is used in high-temperature components of gas turbines to extend their service lives. Hot-gas path components are susceptible to damage or failure in the absence of film cooling. Much of the optimization research efforts have been focused on film hole shapes, heat/mass transfer measurement techniques, and film cooling performance under various mainstream and coolant side operating conditions. Due to recent rapid advancements in the areas of measurement techniques (e.g., pressure-sensitive paints and fast high-resolution imaging) and metal additive manufacturing (AM), film cooling technology has undergone significant changes and shows potential new development. In this review, a historical perspective is discussed covering over five decades of innovation: the geometrical effects from injection angle and hole shapes; flow effects from density ratio, momentum-flux ratio, blowing ratio, advective capacity ratio, and freestream conditions; and more items related to AM. The impact of AM on film hole design strategies, the challenges posed by state-of-the-art AM technology, and pathways for future research are discussed. A comparative analysis of AM assisted film hole fabrication and conventionally manufactured film holes is elaborated.

Particle-to-supercritical carbon dioxide (sCO₂) heat exchanger is a critical component in next-generation concentrating solar power (CSP) plants. The inherently low heat transfer between falling particles and sCO₂ imposes a challenge towards economic justification of levelized cost of electricity produced through solar energy. Introduction of integrated porous media with the walls bounding particle flow has the potential to enhance the overall particle-to-sCO₂ heat exchanger performance. This paper presents an experimental study on heat transfer characterization of additively manufactured lattice frame material based on Octet-shaped unit cell with particles and air as working fluids. The lattice structures were additively manufactured in Stainless Steel (SS) 316L and SS420 (with 40% bronze infiltration) via Binder jetting process, where the lattice porosities were varied between 0.75 and 0.9. The mean particle diameters were varied from 266-966 μm. The effective thermal conductivity and averaged heat transfer coefficient were determined through steady-state experiments. It was found that the presence of lattice enhances the effective thermal conductivity by 2-4 times when compared to packed bed of particles alone. Furthermore, for gravity-assisted particle flow through lattice panel, significantly high convective heat transfer coefficients ranging from 200-400 W/m2K were obtained for the range of particle diameters tested. The superior thermal transport properties of Octet-shape-based lattice frame for particle flow makes it a very promising candidate for particle-to-sCO₂ heat exchanger for CSP application.

High-porosity metal foams have been extensively studied as an attractive candidate for efficient and compact heat exchanger design. With the advancements in additive manufacturing, such foams can be manufactured with controlled topology to yield highly tailorable mechanical and transport properties. In this study, a lattice Boltzmann method (LBM)-based pore-scale model is implemented to simulate the fluid flow in additively manufactured (AM) metal foams with unit cell topologies of Cube, Face Diagonal (FD)-Cube, Tetrakaidecahedron (TKD), and Octet lattices. The pressure gradient versus average velocity profiles predicted by the LBM model were validated against in-house measurements on the AM lattice samples with the same unit cell topologies. Based on the simulation results, a novel hybrid model is proposed to accurately predict the volume averaged flow properties (permeability and inertial coefficients) of the four structures. Specifically, the linear LBM (neglecting inertial forces) is first implemented to obtain the intrinsic permeability, and then the standard LBM is applied to obtain the inertial coefficient. Convenient correlations for those flow properties as a function of porosity and fiber diameter are constructed. The effects of the AM print qualities on the flow properties are also discussed. The advantages of the hybrid model compared to the polynomial fitting approach for determining flow properties are discussed and compared quantitatively. The hybrid model and presented results are valuable for flow and thermal transport evaluation when designing new metal foams for specific applications and with different materials and topologies. The presented correlations based on pore-scale simulations can also be conveniently used in volume-averaged models to predict the macroscale flow behavior in such complex structures.

Single unit cell thick lattice frame materials have applications in efficient heat exchangers. This study is focused on strut-based sandwich-type configurations obtained through reticulation of unit cell topologies of tetrakaidecahedron (TKD), octet, and rhombic dodecahedron (DDC) shapes at a porosity of 0.9 with water as the working fluid. Interfacial heat transfer coefficient values on struts and endwalls were determined by imposing constant temperature boundary condition. Averaged heat transfer coefficient on the endwall was the highest for tetrakaidecahedron lattice whereas rhombic dodecahedron lattice exhibited the highest average interfacial heat transfer coefficients on the struts. Flow analysis showed the presence of strong secondary flow features on planes normal to the mean flow direction that demonstrated the unique flow mixing capabilities of these lattices. Reported interfacial heat transfer coefficient at struts and endwall can be used in volume-averaged computations of metal foams (representative of lattices' flow and thermal properties) under local thermal nonequilibrium.

This paper presents the convective heat transfer coefficient of cubic lattices under both buoyancy-induced and forced convection. Additionally, it examines the effective thermal conductivity, permeability, and inertial coefficient of a cubic unit cell of porosity ∼0.87. The test specimens were additively manufactured using stainless steel 420 (with 40% bronze infiltration) using the binder jetting technique. In the buoyancy-driven convection experiments, three different aspect ratios (width/height) varying from 0.5 to 2 were tested across three different heating orientations, viz., bottom wall (0 deg), side wall (90 deg), and top wall (180 deg). The lattice with the lowest aspect ratio had the highest convective heat transfer coefficient in all three heating orientations. The forced convection heat transfer coefficient was determined for an additively manufactured part comprising 10 × 10 cubic unit cell array in the plane perpendicular to the flow and 20 unit cells in the streamwise direction. Additionally, the flow characteristics of the cubic lattice were characterized through permeability (K) and inertial coefficient (Cf), determined by conducting separate pressure drop experiments over a wide range of flow velocities. The thermal hydraulic performance (THP) of the cubic lattice was assessed by combining the periodic regime convective heat transfer coefficient with the pressure drop data obtained from the experimentally determined values of K and Cf. The comprehensive characterization of flow and thermal transport, including K and Cf, along with hsf, keff, presented in this paper, provides a robust foundation for their application in volume-averaged computations for detailed parametric study.

In typical turbulent flow problems, detailed heat transfer coefficient (h) maps obtained through short-duration experiments are based on inverse heat transfer methods that take the wall temperatures measured via liquid crystals or infrared thermography as input, and an error minimization routine is adopted to determine the best value of h that satisfies the wall temperature temporal evolution under a certain change in fluid temperature. A common practice involves modeling the solid as a one-dimensional semi-infinite medium by selecting the solid material that has low thermal conductivity and low thermal diffusivity. However, in certain flow scenarios, the neglection of the lateral heat diffusion may lead to significant errors in the deduced h values. It is imperative to understand the reasons behind large errors that may be incurred by using the 1D heat conduction assumption in order to accurately determine high-resolution h maps for better heat exchanger designs in a wide range of thermal management applications. This paper presents a computational heat transfer study on different jet impingement scenarios to demonstrate the errors incurred in the determination of h when calculated under the assumption of one-dimensional (1-d) heat conduction into a solid. To this end, three different cases are studied: (a) single jet, (b) array jet (theoretical distribution), (c) array jet (experimental distribution), along with three different mainstream temperature evolution profiles representing step change, moderately fast transient and slow transient nature of flow driving the heat transfer in the solid. A known distribution of heat transfer coefficient (“true h”) for each of the three cases is considered, and three-dimensional transient heat diffusion equations were solved to populate temperatures of each node in the solid at every time step. It is found that stagnation zones’ h_1d calculations were lower than the “true h” while the low heat transfer zones exhibited significantly higher h_1d compared to the “true h”. For the array jet (experimental distribution) case, it was observed that errors can be as high as 10% in certain low heat transfer zones. Different data reduction procedures, configurations, and conditions explored in this study indicate that a suitable balance can be achieved if shorter time durations in transient experiments are used as a reference for tracking in h_1d calculations to keep the deviations from the “true h” low.