This study introduces the Gyroid structure, a type of triply periodic minimal surface (TPMS), for enhanced effusion cooling performance. Conjugate heat transfer simulations are used to compare the flow behavior, pressure loss, and overall cooling effectiveness of single- and double-wall Gyroid configurations against a baseline film hole model at blowing ratios of 0.5–2.0. Results show that the Gyroid design eliminates jet lift-off and counter-rotating vortex pairs, ensuring full coolant coverage and a thicker coolant layer than the baseline. The double-wall configuration further improves cooling with jet impingement, yielding higher average Nusselt numbers than the single-wall design. At equal pressure loss, the impingement/Gyroid model outperforms the baseline by 102.7% in cooling effectiveness. To assess manufacturability, a high-resolution CT scan is used to validate a laser powder bed fusion-printed Gyroid sample at gas turbine blade scale, confirming feasibility for industrial application. These findings highlight the superior thermal performance and manufacturability of the 3D-printed Gyroid structure, offering a promising cooling solution for next-generation turbine blades.

To improve the convective heat transfer in internal cooling channels of heavy-duty gas turbine blades, this study experimentally and numerically investigates the thermal performance of rectangular channels with hybrid pin-fins and micro V-ribs turbulators. The transient thermochromic liquid crystal (TLC) technique and ANSYS 2019 R3 (ICEM CFD 2019 R3, Fluent 2019 R3, CFD-Post 2019 R3) were employed under Reynolds numbers ranging from 10,000 to 50,000, with the numerical model rigorously validated against experimental data (the maximum RMSE is 2.5%). It is found that hybrid pin-fins and continuous V-ribs configuration exhibits the maximum heat transfer enhancement of 27.6%, with an average friction factor increase of 13.3% and 21.9% improvement in thermal performance factor (TPF) compared to the baseline pin-fin channel. In addition, compared to the baseline pin-fin channel, hybrid pin-fins and broken V-ribs configuration exhibits average heat transfer enhancement (Nu/Nu0) of 24.4%, an average friction factor increase of 7.2% and 22.5% improvement across the investigated Reynolds number range (10,000~50,000) based on computational results. The synergistic effects of hybrid pin-fin and micro V-rib structures demonstrate superior coolant flow control, offering a promising solution for next-generation turbine blade cooling designs. This work provides actionable insights for high-efficiency gas turbine thermal management.