The adoption of lean-burn technology in modern aero-engines influences the already critical aerothermal conditions at turbine entry, where the absence of dilution holes preserves the swirl component generated by burners and prevents any control on pattern factor. The associated uncertainty and lack of confidence entail the application of wide safety margins in turbine cooling design, with a detrimental effect on engine efficiency. Computational fluid dynamics (CFD) can provide a deeper understanding of the physical phenomena involved in combustor–turbine interaction, especially with hybrid Reynolds-averaged Navier–Stokes (RANS) large eddy simulation (LES) models, such as scale adaptive simulation (SAS), which are proving to overcome the well-known limitations of the RANS approach and be a viable approach to capture the complex flow physics. This paper describes the numerical investigation on a test rig representative of a lean-burn, effusion cooled, annular combustor developed in the EU Project Full Aerothermal Combustor-Turbine interactiOns Research (FACTOR) with the aim of studying combustor–turbine interaction. Results obtained with RANS and SAS were critically compared to experimental data and analyzed to better understand the flow physics, as well as to assess the improvements related to the use of hybrid RANS-LES models. Significant discrepancies are highlighted for RANS in predicting the recirculating region, which has slight influence on the velocity field at the combustor outlet, but affects dramatically mixing and the resulting temperature distribution. The accuracy of the results achieved suggests the exploitation of SAS model with a view to the future inclusion of the nozzle guide vanes in the test rig.

Modern lean burn aero-engine combustors make use of relevant swirl degrees for flame stabilization. Moreover, important temperature distortions are generated, in tangential and radial directions, due to discrete fuel injection and liner cooling flows respectively. At the same time, more efficient devices are employed for liner cooling and a less intense mixing with the mainstream occurs. As a result, aggressive swirl fields, high turbulence intensities, and strong hot streaks are achieved at the turbine inlet. In order to understand combustor-turbine flow field interactions, it is mandatory to collect reliable experimental data at representative flow conditions. While the separated effects of temperature, swirl, and turbulence on the first turbine stage have been widely investigated, reduced experimental data is available when it comes to consider all these factors together.In this perspective, an annular three-sector combustor simulator with fully cooled high pressure vanes has been designed and installed at the THT Lab of University of Florence. The test rig is equipped with three axial swirlers, effusion cooled liners, and six film cooled high pressure vanes passages, for a vortex-to-vane count ratio of 1:2. The relative clocking position between swirlers and vanes has been chosen in order to have the leading edge of the central NGV aligned with the central swirler. In order to generate representative conditions, a heated mainstream passes though the axial swirlers of the combustor simulator, while the effusion cooled liners are fed by air at ambient temperature. The resulting flow field exiting from the combustor simulator and approaching the cooled vane can be considered representative of a modern Lean Burn aero engine combustor with swirl angles above ±50 deg, turbulence intensities up to about 28% and maximum-to-minimum temperature ratio of about 1.25. With the final aim of investigating the hot streaks evolution through the cooled high pressure vane, the mean aerothermal field (temperature, pressure, and velocity fields) has been evaluated by means of a five-hole probe equipped with a thermocouple and traversed upstream and downstream of the NGV cascade.

In order to deepen the knowledge of the interaction between modern lean burn combustors and high pressure turbines, a real scale annular three sector combustor simulator has been assembled at University of Florence, with the goal of investigating and characterizing the generated aerothermal field and the hot streaks transport between combustor exit and the high pressure vanes location. To generate hot streaks and simulate lean burn combustors behavior, the rig is equipped with axial swirlers, fed by main air flow that is heated up to 531 K, and liners with effusion cooling holes that are fed by air at ambient temperature. The three sector configuration is used to reproduce the periodicity on the central sector and to allow to perform measurements inside the chamber, through the lateral walls. Ducts of different length have been mounted on the swirlers, preserving the hot mainflow from the interaction with coolant. Such configurations, together with the one without ducts, have been tested, using different measurement techniques, in order to highlight the differences in the resulting flow fields. First of all, isothermal PIV measurements have been performed on the combustion chamber symmetry plane, to highlight the mixing phenomena between the mainflow and cooling flows. Then a detailed investigation of the mean aerothermal field at combustor exit has been carried out, for nominal operating conditions, by means of a five hole pressure probe provided with a thermocouple, installed on an automatic traverse system. With the aim of analyzing the hot streaks transport and the flow field modification towards the vanes location, such measurements have been performed on two different planes: one located in correspondence of the combustor exit and the further one placed downstream, in the virtual location of the vanes leading edges. Therefore, an experimental database, describing the evolution of the flow field in a combustor simulator with typical traits of modern lean burn chambers, for different injector geometries, has been set up.