The continuing rise in turbine entry temperatures has necessitated the development of ever-more advanced cooling techniques. Effusion cooling is an example of such a system and is characterised by a high density of film cooling holes that operate at low blowing ratios, thereby achieving high overall cooling effectiveness. This paper presents both an experimental and computational investigation into the cooling performance of effusion systems. Two flat-plate geometries (with primary hole pitches of 3.0D and 5.75D) are experimentally investigated via a pressure sensitive paint technique yielding high resolution film effectiveness distributions via heat-mass transfer analogy. A computational fluid dynamics (CFD) scalar tracking method was used to model the setup computationally with the results comparing favourably to those obtained from the experiments. The CFD domain was modified to assess the cooling performance from a single film hole ejection. A superposition method was developed and applied to the resulting two-dimensional film effectiveness distribution that quickly yielded data for an array of closely-packed holes, allowing a rapid assessment of a multi-hole effusion type setup. The method produced satisfactory results at higher pitches, but at lower pitches, high levels of jet interactions reduced the performance of the superposition method.

In this study, thermal stresses in a double-wall cooling system are analyzed. We consider an infinite flat double-wall geometry and assume that it can be represented by an axisymmetric unit cell, wherein the thermal loadings and deformation at the boundaries are determined by periodicity conditions. A thermal model is initially developed to obtain the thermal fields using a combination of empirical correlations and computational fluid dynamics (CFD) analysis. The thermal fields are then analyzed such that both the first-order and higher order approximations are determined. A theoretical solution is derived assuming that the temperature gradient takes place only across the outer skin using the first-order approximations. The solution yields an equibiaxial stress state in the skins, which are driven by the thermal curvature of the outer skin. To investigate other geometrical features and higher order approximations, a finite element model is used to solve Fourier’s law of heat conduction and mechanical equilibrium equations. The numerical and theoretical results are found to be in excellent agreement. We determine that the increase of distance between pedestals reduces the stresses. Furthermore, the stress concentration factor at the fillet increases with the increase of both the radius and pedestal diameter and the decrease of the skin thickness. Increasing the number of film holes limits stresses to the external surface of the outer skin. The increase of the Reynolds number in the impingement hole increases the Biot number in the outer skin, which increases the stresses. The higher order approximations of the heat transfer coefficients play a minor role.

The drive to further increase gas turbine thermal efficiency and specific power output continue to elevate core temperatures well beyond the natural capabilities of the metals employed in their manufacture necessitating increasingly complex cooling systems. One such cooling mechanism is the double-wall, effusion-cooled system which combines in a very compact format, many cooling aspects already implemented in gas turbine cooling. To-date, thermomechanical stresses have provided one of the more significant challenges in the implementation of these systems and needs to be considered — alongside aerothermal performance — at the initial stages of design. This paper presents a novel computational method that has been developed to allow an integrated assessment of both the aerothermal and thermomechanical performance of double-wall cooling geometries. A decoupled conjugate method was developed in which internal cooling performance was ascertained via a conjugate CFD model in which the mainstream flow was not simulated. Instead, external film cooling performance was assessed via a superposition method that was developed and applied to a two-dimensionally varying correlation allowing streamwise film development to be modelled. Results of both the internal and external cooling simulations were then utilised in a conduction model to develop a complete thermal assessment of the geometry. The calculated temperature distribution was used in a thermomechanical FEA analysis permitting an insight into the stress field developed within the double-wall geometry under thermal load. The developed method was demonstrated in the assessment of seven circular pedestal, double-wall geometries in which a range of geometric parameters were investigated. The results provide an insight into the effect of varying these parameters on both the aerothermal performance of the selected geometries, along with the effect on the thermomechanical stress field developed.