Jet engines with boundary layer ingestion (BLI) could offer significant reductions in aircraft fuel burn compared with podded turbofans. However, the engine fans must run continuously with severe inlet distortion, which is known to reduce stability. In this paper, an experimental study has been completed on a low-speed rig fan operating with a BLI-type inlet distortion. Unsteady casing static pressure measurements have been made at multiple locations during stall events. Steady-state, full-annulus area traverses have also been performed at rotor inlet and exit at a near-stall operating point. The reduction in stability caused by BLI is found to be small. It is found that with BLI the fan can operate stably despite the presence of localized regions where the rotor operating point lies beyond the stability boundary measured in clean flow. With the BLI-type distortion applied, the measured rotor incidence varies around the annulus due to nonuniform upstream velocity and swirl. The measured amplitude of unsteady casing pressure fluctuations just prior to stall is found to correlate with the circumferential variation of rotor incidence, suggesting that rotor incidence is a key variable affecting the creation and growth of flow disturbances. In regions of high incidence, disturbances resembling local flow separations are initiated. However, in regions of low or negative incidence, any disturbances decay rapidly. Full rotating stall with BLI occurs when high incidence regions are widespread enough to sustain disturbances which can propagate around the entire annulus.

Boundary layer ingestion (BLI) potentially offers significant reductions in fuel burn and pollutant emissions. The propulsive fuselage concept features a fan at the back of the airframe that ingests the 360 deg fuselage boundary layer. Consequently, the distortion at the fan face during cruise is close to radial. This article aims to devise and test a fan design philosophy that is tuned to this inflow distortion. Initially, a free-vortex fan design matched to clean inflow is presented. The effects of BLI on the aerodynamics of this fan are investigated. A series of design steps are then presented to develop the baseline fan into a new design matched to fuselage BLI inflow. Both fan designs have been tested within a low-speed rig. The impact of the fan design changes on the aerodynamics and the performance with BLI are evaluated using the test results. This article presents the successful application of a unique experimental facility for the analysis of BLI fuselage fans. It shows that it is possible to design a fan that accepts the radial distortion caused by fuselage BLI with a modified profile of work input. The new fan design was found to increase the work input by 4.9% and to improve the efficiency by 2.75% relative to a fan designed for clean flow. This new fan design has reduced loading near the hub to account for the incoming distortion and increased mid span loading and negative incidence toward the tip for tolerance to circumferential distortion off-design.

This paper investigates the surface boundary layer and wake development of a compressor blade at a range of low Reynolds number from 45,000 to 120,000. Experiments in a miniature linear compressor cascade facility have been performed with detailed surface pressure measurements and flow visualization to track variations in the separation bubble size. These have been combined with high-resolution pneumatic pressure and hot-wire probe traverses in the downstream wake. High-fidelity direct numerical simulations have been completed on the same compressor blade section across the same range of operating conditions. The results show that large laminar separation bubbles exist on both blade surfaces. As Reynolds number increases, these separation bubbles shorten in length and reduce in thickness. Correspondingly, the downstream wake narrows, although the peak wake loss coefficient remains approximately constant. As the Reynolds number is increased from 45,000 to 120,000, the bubble length on the suction side reduced from 48% to 28% chord and on the pressure side reduced from 35% to 20% chord, while the loss coefficient reduced from 9% to 5%. The flow features are examined further within the high-fidelity computations, which reveal the dependence of the wake turbulence on the laminar separation bubbles. The separation bubbles are found to generate turbulent kinetic energy, which convects downstream to form the outer part of wake. As Re increases, a shorter bubble produces less turbulence in the outer part of the boundary layer leading to a narrower wake. However, the trailing edge separation is largely independent of Reynolds number, leading to the constant peak loss coefficient observed. The overall loss is shown to vary linearly with the total turbulence production, and this depends on the size of the separation bubbles. Overall, this research provides new insight into the connection between the blade surface flow field and the wake characteristics at low Reynolds number. The findings suggest that changes that minimize the extent of the blade separation bubbles could provide significant improvements to both the steady and unsteady properties of the wake.

Fans that are designed to maintain thrust at the high angle of attack (AOA) flight condition could exploit the cruise fuel burn benefit of a shorter intake design. This article considers how the fan rotor radial pressure ratio distribution and tip velocity triangle can be designed to improve thrust when coupled to a short intake operating at high AOA. Two AOA values are investigated using unsteady computational fluid dynamics: 20 deg (attached flow) and 35 deg (separated flow). Thrust at high AOA is governed by three key loss and work input mechanisms. (i) Rotor choking loss: flow is accelerated around the intake bottom lip and enters the rotor with high Mach numbers. Fans designed with a tip-high radial pressure ratio distribution reduced choking loss with a separated intake compared to a mid-high design, particularly when the tip velocity triangle was designed with high diffusion instead of high camber. (ii) Rotor–separation interaction loss: the rotor ingests low mass flow when operating inside the separation and the casing boundary layer separates. High diffusion tip designs strengthened the casing separation, but this penalty did not outweigh improved choking loss. (iii) Work input in radial flows: high AOA generates strong radial flows through the rotor, which alter both the amount and the way work is imparted on the flow. Fans designed with a mid-high radial pressure ratio distribution imparted high work on streamlines migrating toward the hub. Consolidating these findings, we propose two design philosophies for improved thrust at high AOA: high work (mid-high radial pressure ratio distribution) or low loss (tip-high radial pressure ratio distribution with high diffusion tip velocity triangle).

The contrarotating open rotor is, once again, being considered as an alternative to the advanced turbofan to address the growing pressure to cut aviation fuel consumption and carbon dioxide emissions. One of the key challenges is meeting community noise targets at takeoff. Previous open rotor designs are subject to poor efficiency at takeoff due to the presence of large regions of separated flow on the blades as a result of the high incidence needed to achieve the required thrust. This is a consequence of the fixed rotor rotational speed constraint typical of variable pitch propellers. Within the study described in this paper, an improved operation is proposed to improve performance and reduce rotor-rotor interaction noise at takeoff. Three-dimensional computational fluid dynamics (CFD) calculations have been performed on an open rotor rig at a range of takeoff operating conditions. These have been complemented by analytical tone noise predictions to quantify the noise benefits of the approach. The results presented show that for a given thrust, a combination of reduced rotor pitch and increased rotor rotational speed can be used to reduce the incidence onto the front rotor blades. This is shown to eliminate regions of flow separation, reduce the front rotor tip loss and reduce the downstream stream tube contraction. The wakes from the front rotor are also made wider with lower velocity defect, which is found to lead to reduced interaction tone noise. Unfortunately, the necessary increase in blade speed leads to higher relative Mach numbers, which can increase rotor alone noise. In summary, the combined CFD and aeroacoustic analysis in this paper shows how careful operation of an open rotor at takeoff, with moderate levels of repitch and speed increase, can lead to improved front rotor efficiency as well as appreciably lower overall noise across all directivities.

Contrails are responsible for a significant proportion of aviation’s climate impact. This paper uses data from the European Centre for Medium-Range Weather Forecasts to identify the altitudes and latitudes where formed contrails will not persist. This reveals that long-lived contrails may be prevented by flying lower in equatorial regions and higher in non-equatorial regions. Subsequently, it is found that the lighter fuel and reduced seating capacity of hydrogen-powered aircraft lead to a reduced aircraft weight, which increases the optimal operating altitude by about 2 km. In non-equatorial regions, this would lift the aircraft’s cruise point into the region where long-lived contrails do not persist, unlocking hydrogen-powered, low-contrails operation. The baseline aircraft considered is an A320 retrofitted with in-fuselage hydrogen tanks. The impacts of the higher-altitude cruise on fuel burn and the benefits unlocked by optimizing the wing geometry for this altitude are estimated using a drag model based on theory proposed by Cavcar, Lock, and Mason, and verified against existing aircraft. The weight penalty associated with optimizing wing geometry for this altitude is estimated using Torenbeek’s correlation. It is found that thinner wings with higher aspect ratios are particularly suited to this high-altitude operation and are enabled by the relaxation of the requirement to store fuel in the wings. An example aircraft design for the non-equatorial region is provided, which cruises at a 14 km altitude at Mach 0.75 with a less than 1% average probability of generating long-lived contrails when operating at latitudes more than 35° from the equator. Compared to the A320, this concept design is estimated to have a 20% greater cruise lift–drag ratio, due to the 33% thinner wings with a 50% larger aspect ratio, enabling just 5% more energy use per passenger-km, despite fitting 40% fewer seats.