This paper presents a comprehensive validation and verification study of turbomachinery Reynolds-averaged Navier-Stokes flow solvers on the transonic axial compressor TUDa-GLR-OpenStage. Two commercial solvers namely Ansys CFX and Numeca FineTurbo are adopted to provide the benchmark solutions, which can be used for verification of other RANS solvers in the future. Based on these solvers, five sets of grids, two advection schemes (i.e., central difference and second-order upwind), four turbulence models (i.e., SA, SA-RC, SST and EARSM) and two rotor-stator interface models (i.e., mixing plane and sliding plane) are investigated to quantify their effects on predicting the performance and the flow field of the compressor stage. Results show that the choices of grid density and turbulence model are most sensitive to the prediction, leading to 5% and 7% variation in compressor performance characteristics, respectively. Regarding the choice of grid density, a method to estimate the grid discretization error is demonstrated, which is transferrable to other cases. Regarding the choice of turbulence model, the EARSM model is found overall most accurate among the investigated models, and the limitations and deficiencies of the rest models are discussed in detail based on the analysis of the mean flow fields and the eddy viscosity fields. The grids and the major CFD results presented in this work are open-accessed to the community for further research. The results and discussions presented in this paper provide a useful reference for future practices of RANS simulations for compressors.

The influence of the moving endwall on the behavior of the tip leakage flow in compressors holds substantial significance. This work investigates the unsteadiness of the compressor's tip leakage flow under the impact of the moving endwall, employing both experimental methods and unsteady Reynolds-averaged Navier–Stokes (URANS) simulations. First, a numerical decomposition technique is proposed to isolate the tip leakage flow within a controlled diffusion airfoil (CDA) cascade. Subsequently, URANS simulations based on the CDA cascade are conducted at various incidence angles (−6° to +7°), tip clearances (clearance to chord: 0.83% to 3.33%), and flow coefficients (0.4 to 0.6), and additional URANS simulations based on the Virginia Tech cascade are also performed. The results indicate that the moving endwall induces a greater inclination of the tip leakage flow in the pitchwise direction, allowing it to impinge upon the pressure side of the adjacent blade. The impingement, if sufficiently intense, leads to the periodic generation of unsteady tip leakage flow by altering the blade loading. Moreover, the degree of unsteadiness diminishes significantly as the endwall speed and clearance height decrease. Additionally, it is observed that the breakdown of the tip leakage vortex does not serve as the root cause of the periodic unsteadiness. These findings underscore the critical role played by the moving endwall in the unsteadiness of the compressor's tip leakage flow.

The corner separation and the related secondary flow have great impact on the compressor performance, and non-axisymmetric endwall contouring is proved effective in improving compressor efficiency. The aim of the study is to improve the compressor performance by two local endwall contouring strategies at the design and off-design conditions. The endwall is parameterized and the Bezier curve is used to loft the endwall surface. The design of the contoured endwall is based on a multi-point optimization method to minimize the aerodynamic pressure loss. In order to identify the influence of the contoured endwall, a detailed flow analysis is conducted on four effective contoured endwall designs. The selected endwall geometries exhibit great control ability on the corner separation and significantly reduce the pressure loss at the two operating conditions. The directional concave near the leading edge can induce strong streamwise pressure gradient and accelerate the endwall flow, greatly reducing the cross-passage pressure gradient. The convex structures near the concave edge and at the outlet can block the cross-flow and prevent the interaction between the cross-flow and the suction corner flow. The benefit of the contoured endwall is mainly due to the re-distributed endwall static pressure and blocking of the cross-flow movement. In terms of the control effect, the shape of the concave also matters and better control effect is observed on the deep and wide concave. The flow will be guided by the concave, and the best suppression on corner separation is observed on the concave which follows the suction side. The results also indicate that the relief of the hub corner separation slightly increases the shroud pressure loss.

The cavity flow of shrouded stators is quite complex and not yet completely understood, especially for its loss characteristics. In this paper, a matrix of numerical simulations was designed and conducted to investigate the loss characteristics of the cavity flow in a compressor cascade, with a wide range of incidence, two flow coefficients, and three seal clearances. The effect of the skewed boundary layer was introduced to simulate the practical compressor environment as far as possible. The results show that the total pressure loss coefficient is unable to evaluate the cavity leakage loss correctly since it ignores the temperature rise. With the reduction of the flow coefficient, the entropy loss coefficient and thermal entropy generation rate tend to increase, while the change of the viscous entropy generation rate is dependent on the incidence since the high tangential velocity deteriorates the flow of the pressure side at large negative incidence but significantly improves the flow of the suction side as the incidence increases. In addition, there is a significant difference in loss sensitivity to the seal clearance at various incidences. One of the major reasons is the change of pressure difference between the downstream and upstream. And the other major reason is the distribution difference of the high-loss fluid caused by the variation in the passage vortex. These key findings are able to provide insights leading to reducing the compressor loss due to the cavity leakage flow.

Determination of a scalable Nusselt number (based on “adiabatic heat transfer coefficient”) has been the primary objective of the most existing heat transfer experimental studies. Based on the assumption that the wall thermal boundary conditions do not affect the flow field, the thermal measurements were mostly carried out at near adiabatic condition without matching the engine realistic wall-to-gas temperature ratio (TR). Recent numerical studies raised a question on the validity of this conventional practice in some applications, especially for turbine blade. Due to the relatively low thermal inertia of the over-tip-leakage (OTL) flow within the thin clearance, the fluids' transport properties vary greatly with different wall thermal boundary conditions and the two-way coupling between OTL aerodynamics and heat transfer cannot be neglected. The issue could become more severe when the gas turbine manufacturers are making effort to achieve much tighter clearance. However, there has been no experimental evidence to back up these numerical findings. In this study, transient thermal measurements were conducted in a high-temperature linear cascade rig for a range of tip clearance ratio (G/S) (0.3%, 0.4%, 0.6%, and 1%). Surface temperature history was captured by infrared thermography at a range of wall-to-gas TRs. Heat transfer coefficient (HTC) distributions were obtained based on a conventional data processing technique. The profound influence of tip surface thermal boundary condition on heat transfer and OTL flow was revealed by the first-of-its-kind experimental data obtained in the present experimental study.