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.

Integrated additional cooling channels offer precise thermal management for solid-oxide fuel cells (SOFCs), mitigating temperature gradients. This research studies the thermal–hydraulic performance of cooling channels integrated between SOFC interconnectors, including a Diamond-type triply periodic minimal surface (TPMS), a conventional topology-optimized structure, and a topology-optimized lattice-filled structure. A conjugate heat transfer analysis is employed to investigate the influences of flow rate within the range of Reynolds numbers from 300 to 5000, and the effects of coolant type, including air and liquid metals, as well as the impacts of structural material. The results demonstrate that the topology-optimized lattice-filled structure, generating high turbulence mixing, achieves superior temperature uniformity, especially at high flow rates, despite having higher thermal resistance and pressure loss than the conventional topology-optimized design. The coolant types show the largest influence on thermal–hydraulic performance, and the use of liquid gallium in the conventional optimized design obtains the best temperature uniformity, yielding differences between the maximum and minimum temperatures of less than 5 K. Moreover, the higher-thermal-conductivity material improves temperature uniformity, even at low flow rates. Overall, the optimized-baffle designs in the conventional topology-optimized model, utilizing high-conductivity coolant and structural materials, could be the most suitable for thermal management of the SOFC.

This research numerically investigates the cooling performance of Diamond-type triply periodic minimal surface (TPMS) networks as a gas turbine effusion cooling layer, augmented with various jet impingement configurations. The study analyzes the internal and external flow characteristics, pressure loss, and overall cooling effectiveness using conjugate heat transfer simulations. The Diamond design is compared to conventional film cooling and micro-hole models within a blowing ratio range of 0.5 to 2.0. The jet hole diameter and jet-to-plate distance are varied to identify an optimal double-wall cooling configuration. The results reveal that the Diamond hole mitigates the strong discharge of coolant, resulting in a more adherent cooling film, which provides excellent surface coverage. While jet impingement enhances internal heat transfer, its contribution to cooling effectiveness is minor compared to the benefit of film coverage. At an equivalent total pressure loss coefficient, the Diamond with impinging jets demonstrates 101% higher cooling effectiveness than the film hole. The thermal-mechanical analysis indicates that the Diamond model exhibits a more uniform distribution of thermal stress and displacement. The average stress is reduced by 44.7% compared to the film hole. This work confirms the TPMS-based effusion as an advanced cooling solution for next-generation gas turbines.