Stephen T. McClain

The Many Faces of Turbine Surface Roughness

Results are presented for contact stylus measurements of surface roughness on in-service turbine blades and vanes. Nearly 100 turbine components were assembled from four land-based turbine manufacturers. Both coated and uncoated, cooled and uncooled components were measured, with part sizes varying from 2 to 20 cm. Spanwise and chordwise two-dimensional roughness profiles were taken on both pressure and suction surfaces. Statistical computations were performed on each trace to determine centerline averaged roughness, rms roughness, and peak to-valley height. In addition, skewness and kurtosis were calculated; as well as the autocorrelation length and dominant harmonics in each trace. Extensive three-dimensional surface maps made of deposits, pitting, erosion, and coating spallation expose unique features for each roughness type. Significant spatial variations are evidenced and transitions from rough to smooth surface conditions are shown to be remarkably abrupt in some cases. Film cooling sites are shown to be particularly prone to surface degradation.

Effect of Density Ratio on Flat Plate Film Cooling With Shaped Holes Using PSP

Detailed film-cooling effectiveness distributions are obtained on a flat plate using the pressure sensitive paint (PSP) technique. The applicability of the PSP technique is expanded to include a coolant-to-mainstream density ratio of 1.4. The effect of density ratio on the film-cooling effectiveness is coupled with varying blowing ratio (M=0.25–2.0), freestream turbulence intensity (Tu=1–12.5%), and film hole geometry. The effectiveness distributions are obtained on three separate flat plates containing either simple angle, cylindrical holes, simple angle, fanshaped holes (α=10 deg), or simple angle, laidback, fanshaped holes (α=10 deg and γ=10 deg). In all three cases, the film-cooling holes are angled at θ=35 deg from the mainstream flow. Using the PSP technique, the combined effects of blowing ratio, turbulence intensity, and density ratio are captured for each film-cooling geometry. The detailed film-cooling effectiveness distributions, for cylindrical holes, clearly show that the effectiveness at the lowest blowing ratio is enhanced at the lower density ratio (DR=1). However, as the blowing ratio increases, a transition occurs, leading to increased effectiveness with the elevated density ratio (DR=1.4). In addition, the PSP technique captures an upstream shift of the coolant jet reattachment point as the density ratio increases or the turbulence intensity increases (at moderate blowing ratios for cylindrical holes). With the decreased momentum of the shaped film-cooling holes, the greatest film-cooling effectiveness is obtained at the lower density ratio (DR=1.0) over the entire range of blowing ratios considered. In all cases, as the freestream turbulence intensity increases, the film effectiveness decreases; this effect is reduced as the blowing ratio increases for all three film hole configurations.

Assessment of Ice Shape Roughness Using a Self-Orgainizing Map Approach

Self-organizing maps are neural-network techniques for representing noisy, multidimensional data aligned along a lower-dimensional and nonlinear manifold. For a large set of noisy data, each element of a finite set of codebook vectors is iteratively moved in the direction of the data closest to the winner codebook vector. Through successive iterations, the codebook vectors begin to align with the trends of the higher-dimensional data. Prior investigations of ice shapes have focused on using self-organizing maps to characterize mean ice forms. The Icing Research Branch has recently acquired a high resolution three dimensional scanner system capable of resolving ice shape surface roughness. A method is presented for the evaluation of surface roughness variations using high-resolution surface scans based on a self-organizing map representation of the mean ice shape. The new method is demonstrated for 1) an 18-in. NACA 23012 airfoil 2 AOA just after the initial ice coverage of the leading 5 of the suction surface of the airfoil, 2) a 21-in. NACA 0012 at 0AOA following coverage of the leading 10 of the airfoil surface, and 3) a cold-soaked 21-in.NACA 0012 airfoil without ice. The SOM method resulted in descriptions of the statistical coverage limits and a quantitative representation of early stages of ice roughness formation on the airfoils. Limitations of the SOM method are explored, and the uncertainty limits of the method are investigated using the non-iced NACA 0012 airfoil measurements.

The Effect of Real Turbine Roughness With Pressure Gradient on Heat Transfer

Experimental measurements of heat transfer (St) are reported for low speed flow over scaled turbine roughness models at three different freestream pressure gradients: adverse, zero (nominally), and favorable. The roughness models were scaled from surface measurements taken on actual, in-service land-based turbine hardware and include samples of fuel deposits, TBC spallation, erosion, and pitting as well as a smooth control surface. All St measurements were made in a developing turbulent boundary layer at the same value of Reynolds number (Re x ≅ 900,000). An integral boundary layer method used to estimate c f for the smooth wall cases allowed the calculation of the Reynolds analogy (2St/c f ). Results indicate that for a smooth wall, Reynolds analogy varies appreciably with pressure gradient. Smooth surface heat transfer is considerably less sensitive to pressure gradients than skin friction. For the rough surfaces with adverse pressure gradient, St is less sensitive to roughness than with zero or favorable pressure gradient. Roughness-induced Stanton number increases at zero pressure gradient range from 16-44% (depending on roughness type), while increases with adverse pressure gradient are 7% less on average for the same roughness type. Hot-wire measurements show a corresponding drop in roughness-induced momentum deficit and streamwise turbulent kinetic energy generation in the adverse pressure gradient boundary layer compared with the other pressure gradient conditions. The combined effects of roughness and pressure gradient are different than their individual effects added together. Specifically, for adverse pressure gradient the combined effect on heat transfer is 9% less than that estimated by adding their separate effects. For favorable pressure gradient, the additive estimate is 6% lower than the result with combined effects. Identical measurements on a simulated roughness surface composed of cones in an ordered array show a behavior unlike that of the scaled real roughness models. St calculations made using a discrete-element roughness model show promising agreement with the experimental data. Predictions and data combine to underline the importance of accounting for pressure gradient and surface roughness effects simultaneously rather than independently for accurate performance calculations in turbines.

Predicting Skin Friction and Heat Transfer for Turbulent Flow Over Real Gas-Turbine Surface Roughness Using the Discrete-Element Method

The discrete element method considers the total aerodynamic drag on a rough surface to be the sum of shear drag on the flat part of the surface and the form drag on the individual roughness elements. The total heat transfer from a rough surface is the sum of convection through the fluid on the flat part of the surface and the convection from each of the roughness elements. The discrete element method has been widely used and validated for predicting heat transfer and skin friction for rough surfaces composed of sparse, ordered, and deterministic elements. Real gas turbine surface roughness is different from surfaces with sparse, ordered, and deterministic roughness elements. Modifications made to the discrete element roughness method to extend the validation to real gas turbine surface roughness are detailed. Two rough surfaces found on high-hour gas turbine blades were characterized using a Taylor-Hobson Form Talysurf Series 2 profilometer. Two rough surfaces and two elliptical-analog surfaces were generated for wind tunnel testing using a three-dimensional printer The printed surfaces were scaled to maintain similar boundary layer thickness to roughness height ratio in the wind tunnel as found in gas turbine operation. The results of the wind tunnel skin friction and Stanton number measurements and the discrete element method predictions for each of the four surfaces are presented and discussed. The discrete element predictions made considering the gas turbine roughness modifications are within 7% of the experimentally measured skin friction coefficients and are within 16% of the experimentally measured Stanton numbers.

Ice Roughness in Short Duration SLD Icing Events

Ice accretion codes depend on models of roughness parameters to account for the enhanced heat transfer during the ice accretion process. While mitigating supercooled large droplet (SLD or Appendix O) icing is a significant concern for manufacturers seeking future vehicle certification due to the pending regulation, historical ice roughness studies have been performed using Appendix C icing clouds which exhibit mean volumetric diameters (MVD) much smaller than SLD clouds. Further, the historical studies of roughness focused on extracting parametric representations of ice roughness using multiple images of roughness elements. In this study, the ice roughness developed on a 21-in. NACA 0012 at 0deg angle of attack exposed to short duration SLD icing events was measured in the Icing Research Tunnel at the NASA Glenn Research Center. The MVDs used in the study ranged from 100 micrometer to 200 micrometers, in a 67 m/s flow, with liquid water contents of either 0.6 gm/cubic meters or 0.75 gm/cubic meters. The ice surfaces were measured using a Romer Absolute Arm laser scanning system. The roughness associated with each surface point cloud was measured using the two-dimensional self-organizing map approach developed by McClain and Kreeger (2013) resulting in statistical descriptions of the ice roughness.

The Importance of the Mean Elevation in Predicting Skin Friction for Flow Over Closely Packed Surface Roughness

The discrete-element surface roughness model is used to provide insight into the importance of the mean elevation of surface roughness in predicting skin friction over rough surfaces. Comparison of experimental data and extensive computational results using the discrete-element model confirm that the appropriate surface for the imposition of the no-slip condition is the mean elevation of the surface roughness. Additionally, the use of the mean elevation in the Sigal-Danberg approach relating their parameter to the equivalent sand-grain roughness height results in replacing three different piecewise expressions with a single relation. The appropriate mean elevation for closely-packed spherical roughness is also examined.

Convective Enhancement of Surfaces with Realistic Ice Roughness Distributions

Predictions of ice shapes formed during supercooled, large-droplet (SLD) icing conditions made by ice accretion codes currently used in aircraft design must be improved. One area for significant improvement is the model used in ice accretion codes to characterize ice roughness and the convective heat transfer enhancement of the ice roughness. To improve the predictive capabilities of ice accretion codes, the convective heat transfer from ice roughness must be measured and characterized for flows over surfaces with realistic roughness properties and relevant thermal boundary conditions. In a parallel effort, Tecson and McClain [2013] present a method to generate distributions of hemispherical elements with statistical properties similar to ice roughness measured in the Icing Research Tunnel at NASA Glenn Research Center. This paper details measurements of the convective heat transfer from test plates with the hemispherical element distributions for flows with negligible freestream acceleration and nominally constant flux boundary conditions. Three surfaces were studies: a smooth plate and two surfaces generated to match Appendix C icing roughness measured by Anderson et al. [1997]. While Appendix C icing droplet sizes are much smaller than those found in SLD conditions, the measurements of Appendix C roughness convective enhancement will serve an important validation step in interpreting and understanding the convective enhancement of SLD ice roughness.

Characterization of Ice Roughness Variations in Scaled Glaze Icing Conditions

Because of the significant influence of surface tension in governing the stability and breakdown of the liquid film in flooded stagnation regions of airfoils exposed to glaze icing conditions, the Weber number is expected to be a significant parameter governing the formation and evolution of ice roughness. To investigate the influence of the Weber number on roughness formation, 53.3-cm (21-in.) and 182.9-cm (72-in.) NACA 0012 airfoils were exposed to flow conditions with essentially the same Weber number and varying stagnation collection efficiency to illuminate similarities of the ice roughness created on the different airfoils. The airfoils were exposed to icing conditions in the Icing Research Tunnel (IRT) at the NASA Glenn Research Center. Following exposure to the icing event, the airfoils were then scanned using a ROMER Absolute Arm scanning system. The resulting point clouds were then analyzed using the self-organizing map approach of McClain and Kreeger (2013) to determine the spatial roughness variations along the surfaces of the iced airfoils. The roughness characteristics on each airfoil were then compared using the relative geometries of the airfoil. The results indicate that features of the ice shape and roughness such as glazeice plateau limits and maximum airfoil roughness were captured well by Weber number and collection efficiency scaling of glaze icing conditions. However, secondary ice roughness features relating the instability and waviness of the liquid film on the glaze-ice plateau surface are scaled based on physics that were not captured by the local collection efficiency variations.

Convection from Ice Roughness with Varying Flux Boundary Conditions

During in-flight aircraft icing, the solidification process cannot proceed without latent energy being removed from the water. Regions on the aircraft surface where the convection rates are highest will exhibit the greatest rates of ice accumulation. Thus, ice accretion codes such as LEWICE require accurate predictions of the enhanced convection coefficients caused by the ice roughness condition. In the current implementation of LEWICE, the model used for predicting convective heat transfer employs an integral approach that essentially treats the solid-vapor boundary as an isothermal boundary. However, given variable supercooling along the surface and as a result of the complex flow field, the true boundary condition associated with an icing solid-vapor interface is neither constant temperature nor constant flux. Surfaces with roughness are also thought to be more sensitive to the thermal boundary conditions because the roughness elements protrude through the boundary layer and interact with the flow at many elevations in the boundary layer. Further complicating the icing process, the roughness condition is variable along the surface in the direction of the flow. In this study, the convection coefficients associated with nominally non-accelerating flow over a smooth surface and three surfaces with representative ice roughness were measured. The boundary conditions studied include 1) a constant flux condition, 2) a step-wise increasing flux condition, 3) a step-wise decreasing flux condition, and 4) an unheated starting length followed by a constant flux condition. The results for the smooth surface follow the classical predictions for convective heat transfer. The rough surface results demonstrate the importance of the thermal boundary conditions and importance of the smooth-starting distance for a given surface roughness distribution. Surprisingly, the differences in the roughness heat transfer enhancement above the smoothturbulent correlations for the constant flux and unheated starting length cases were not significant for the three rough surfaces studied.