Research of the past decades has shown that the operating range of modern fans and compressors is often limited by aeroelastic phenomena before the onset of pure aerodynamic instability. Prediction of these mechanisms is challenging for state-of-the-art numerical methods, particularly for configurations with flexible wide-chord blades. To provide a benchmark configuration for the community, the composite-material fan stage ECL5, representative of near future ultra-high-bypass ratio architectures has been designed at Ecole Centrale de-Lyon and recently shared as an open-test-case. In research program CATANA, different configurations with variable tuning and intake geometries are investigated experimentally, and here we present a comprehensive aeroelastic study of the tuned reference configuration. The study encompasses the investigation of the whole subsonic and transonic operating range using multiphysical instrumentation. A characterization of structural properties under running conditions is analyzed in comparison to individual blade measurements and FEM-predictions. The stability limit is investigated at different speedlines. At transonic conditions, rotating stall occurred without aeroelastic precursors. Severe nonsynchronous-vibrations were observed at subsonic speeds and limited the operating range before the onset of rotating stall. Through a detailed analysis of the aeroelastic coupling mechanism, a full characterization of interacting modes is presented. The challenging prediction of this coupled phenomenon and the discrepancy to aeroelastic simulations are discussed. The results are a promising benchmark for future method development, particularly involving high-fidelity methods.

Non-synchronous vibration (NSV), flutter, or rotating stall can cause severe blade vibrations and limit the operating range of compressors and fans. To enhance the understanding of these phenomena, this study investigated the corresponding mechanisms in modern composite ultra-high-bypass-ratio (UHBR) fans based on the ECL5/CATANA test campaign. Extensive steady and unsteady instrumentation such as stereo-PIV, fast-response pressure probes, and rotor strain gauges were used to derive the aerodynamic and structural characteristics of the rotor at throttled operating conditions. The study focused on the analysis of the transition region from transonic to subsonic speeds where two distinct phenomena were observed. At transonic design speed, rotating stall was encountered, while NSV was observed at 90% speed. At the intermediate 95% speedline, a peculiar behavior involving a single stalled blade was observed. The results emphasize that rotating stall and NSV exhibit different wave characteristics: rotating stall comprises lower wave numbers and higher propagation speeds at around 78% rotor speed, while small-scale disturbances propagate at 57% rotor speed and lock-in with blade eigenmodes, causing NSV. Both phenomena were observed in a narrow range of operation and even simultaneously at specific conditions. The presented results contribute to the understanding of different types of operating range-limiting phenomena in modern UHBR fans and serve as a basis for the validation of numerical simulations.

A comprehensive understanding of aerodynamic instabilities, such as flutter, non-synchronous vibration (NSV), rotating stall, and forced response, is crucial for the safe and efficient operation of turbomachinery, particularly fans and compressors. These instabilities impose significant limitations on the operating envelope, necessitating precise monitoring and accurate quantification of vibration amplitudes during experimental investigations. This study addresses the challenge of measuring these amplitudes by comparing multiple measurement systems applied to the open-test case of the ultra-high bypass ratio (UHBR) fan ECL5. During part-speed operation, the fan exhibited a complex aeromechanical phenomenon, where an initial NSV of the second blade eigenmode near peak pressure transitioned to a dominant first-mode vibration. This mode shift was accompanied by substantial variations in blade vibration patterns, as evidenced by strain gauge data and unsteady wall pressure measurements. These operating conditions provided an optimal test environment for evaluating measurement systems. A comprehensive and redundant experimental setup was employed, comprising telemetry-based strain gauges, capacitive tip timing sensors, and a high-speed camera, to capture detailed aeroelastic behaviour. This paper presents a comparative analysis of these measurement systems, emphasizing their ability to capture high-resolution, accurate data in aeroelastic experiments. The results highlight the critical role of rigorous calibration procedures and the complementary use of multiple measurement technologies in advancing the understanding of turbomachinery instabilities. The insights derived from this investigation shed light on a complex evolution of instability mechanisms and offer valuable recommendations for future experimental studies. The open-test case has been made accessible to the research community, and the presented data can be used directly to validate coupled aeroelastic simulations under challenging operating conditions, including non-linear blade deflections.

The operational capabilities of turbofan engines encounter limitations due to instabilities arising from tightly coupled interactions among aerodynamics, acoustics, and structural mechanics. Modern fans and compressors exhibit non-synchronous vibration (NSV), leading to safety-critical blade oscillations. In contrast to self-excited phenomena such as flutter, NSV stems from the convection of aerodynamic disturbances that synchronize with blade eigenmodes. Understanding this phenomenon is challenging, as its intricate interaction patterns and the occurrence of flow separations constrain the predictive capabilities of current state-of-the-art methods. To establish a comprehensive benchmark dataset on the aeroelastic behavior of modern ultra-high bypass ratio (UHBR) architectures, the European CleanSky-2 project CATANA aimed to examine a carbon composite fan stage, ECL5, utilizing multiphysical instrumentation. Recently, experiments on a structurally tuned reference configuration were conducted, revealing high-amplitude NSV at multiple subsonic speedlines. The observed interaction modes and instability onset differed significantly from numerical predictions using both linearized Reynolds-averaged Navier–Stokes and unsteady Reynolds-averaged Navier–Stokes with prescribed harmonic blade motion. In an effort to enhance the dataset, two additional fan configurations with identical blade profile geometries were investigated: one featured a structurally mistuned rotor with approximately doubled frequency variation of all eigenmodes compared to the reference, and the other involved a case with locally increased tip clearance on individual blades. This paper presents the experimental results of a sensitivity study and explores the influence of structural mistuning and tip clearance variation associated with manufacturing tolerances. Contrary to the intended outcome, it will be demonstrated that the mistuned case exhibited higher blade vibration amplitudes than the reference case during NSV. Detailed instrumentation reveals that the mistuning pattern was effectively transferred to the rotating system, but aerodynamic mistuning, particularly concerning tip clearance, emerged as a dominant factor. The non-synchronous forced-response nature of NSV during highly throttled operation ultimately dictates the observed response levels under different conditions, necessitating a thorough analysis to evaluate the robustness of a specific configuration. These results contribute valuable insights to the open dataset for the ECL5 configuration, benefiting the research community. Particularly noteworthy is the detailed capture of blade-to-blade variations in this research, which will prove instrumental in validating numerical methods.

Experimental monitoring of blade vibration in turbomachinery is typically based on blade-mounted strain gauges. Their signals are used to derive vibration amplitudes which are compared to modal scope limits, including a safety factor. According to industrial guidelines, this factor is chosen conservatively to ensure safe operation of the machine. Within the experimental campaign with the open-test-case composite fan ECL5/CATANA, which is representative for modern lightweight Ultra High Bypass Ratio (UHBR) architectures, measurements close to the stability limit have been conducted. Investigation of phenomena like non-synchronous vibrations (NSV) and rotating stall require a close approach to the stability limit and hence demand for accurate (real-time) quantification of vibration amplitudes to ensure secure operation without exhaustive safety margins. Historically, short-time Fourier transforms of vibration sensors are used, but the complex nature of the mentioned coupled phenomena has an influence on amplitude accuracy, depending on evaluation parameters, as presented in a previous study using fast-response wall-pressure transducers. The present study investigates the sensitivity of blade vibration data to evaluation parameters for different spectral analysis methods and provides guidelines for fast and robust surveillance of critical vibration modes.