Analysis of cooling effects and measurement errors in water-cooled thermocouples for total temperature measurement in aviation engine combustion chambers

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Accurate measurement of the total temperature in the main combustion chamber of an aviation engine is crucial for assessing engine performance. However, a significant challenge exists in balancing the heat transfer errors caused by the necessary cooling of the measuring device with measurement precision. The research employs a combination of numerical simulations and experimental methods to investigate this issue. The numerical simulations utilized the Reynolds-averaged Navier Stokes (RANS) coupled with a conjugate heat transfer approach to study the primary flow characteristics and heat transfer properties within the combustion chamber and the probe body. The experiments were conducted in a heat-calibration wind tunnel, validating the results of the numerical simulations. The results show that by implementing water cooling, the probe's body temperature can be reduced from 1200 °C in high-temperature conditions to 400 °C, with localized temperature imbalances still present in the edge areas of the probe. Tracing the cooling water path reveals that the vertical bends in the internal channels lead to an increase in localized pressure loss of the cooling water. The study quantitatively analyzes measurement errors caused by three heat transfer modes: radiation, convection, and conduction. In low-load conditions of the combustion chamber, heat conduction plays a dominant role, with measurement errors due to conduction reaching up to 70 % of the total measurement error. Radiation further increases the temperature measurement errors of the thermocouple's junctions near the chamber wall. As the combustion chamber temperature increases, entering high-load conditions, the cooling effect of water becomes limited, reducing conduction errors and increasing radiation errors. In these conditions, radiation errors constitute 60–70 % of the total measurement error. It suggests the importance of considering temperature corrections when using water-cooled temperature measurement devices. The research reveals several crucial insights regarding the performance and limitations of water-cooled thermocouples.