Stator Blade Research Articles

Numerical investigation of noise reduction of a pump-jet propulsor using porous metal

A novel strategy for noise reduction in pump-jet propulsor (PJP) is proposed through the design of porous metal trailing edges on stator blades. The interference between stator wake vortices and rotor blades is one of the primary mechanisms for noise generation in PJP. The goal is to use a porous medium to diminish the intensity of turbulent vortices behind the stator blades, control the interaction between these shedding vortices and the rotor blades downstream of the stator, and ultimately suppress the rotor noise generation source. Large eddy simulation and acoustic analogy analysis of the entire propulsion system based on the Ffowcs-Williams and Hawkings equation are performed. It is found that with the use of porous stator trailing edges, the wake flow pattern of the stator is notably altered, the strong impact of the turbulent vortices on the rotor blades is weakened, and the wall pressure fluctuations on the rotor blades and duct are significantly reduced. As a result, the far-field radiation noise and tonal noise are both effectively reduced, with the maximum reduction in total and tonal sound pressure levels reaching 3.8 dB and 12.53 dB, respectively, corresponding to percentage reductions of 6.0% and 21.69%. These findings demonstrate that porous media have great potential for practical engineering applications in PJP noise control.

Development and Assessment of a Miniaturized Test Rig for Evaluating Noise Reduction in Serrated Blades Under Turbulent Flow Conditions

The implementation of serrated stator blades in axial compressor and fan stages offers significant advantages, such as enhanced performance and reduced noise levels, making it a practical and cost-effective solution. This study explores the impact of serrated blade design on noise reduction under specific engine operating conditions. A small-scale experimental test setup with a turbulence-inducing grid was designed for testing multiple grid sizes in order to identify the most promising configuration which replicates rotor–stator interaction. Numerical simulations and early experimental tests in an anechoic chamber using a four-blade cascade configuration at an airflow speed of 50 m/s revealed a small but notable noise reduction in the 1–6 kHz range for a partially matched grid–blade geometry. Serrated blades demonstrated an overall sound pressure level reduction of 1.5 dB and up to 12 dB in tonal noise, highlighting the potential of cascade configurations to improve acoustic performance in gas turbine applications.

Reliability calculation and error analysis of VSV adjustment mechanism motion accuracy

The adjustable stator vane (VSV) adjustment mechanism of an aircraft engine was taken as the research object, and a kinematic model with kinematic pair clearance was established. Considering the randomness of factors such as drive error, dimensional error and assembly clearance, a VSV adjustment mechanism motion accuracy reliability model considering the failure correlation of each stator blade motion accuracy was established. The BP neural network proxy model was introduced, and the Monte Carlo method was used to calculate the reliability of the mechanism, and the variation law of the reliability with the number of stator blades and the failure threshold was given. By comparing with the system model with independent unit failure assumptions and the fully correlated system model, the rationality of the mechanism system motion accuracy reliability model considering failure correlation was verified. Finally, a method for estimating the reliability error of the complex system caused by the proxy model error was proposed, and it was proved that the reliability calculation result of the VSV adjustment mechanism is accurate and reliable.

Experimental investigation on the effect of the rotor-stator matching mode on velocity pulsation in the centrifugal pump with a vaned diffuser

Centrifugal pumps play an indispensable role in nuclear power plants, where severe turbulent pulsations induced by the rotor-stator interference(RSI) can generate a substantial threat to the safe and stable operation of these facilities.In this study, in order to elucidate the effect of the match of rotor and stator blade number on the unsteady velocity pulsation characteristics inside a vaned diffuser centrifugal pump, three different schemes of rotor and stator matching modes were investigated using LDA measurement technology. The findings indicate that the match of rotor and stator blades exerts a substantial influence on the flow field structure inside the pump, leading to significant variations in the velocity maps near the tongue region. By comparing the blade passing frequency amplitudes of the three pumps, with fewer stator blades leading to a rapid increase in blade passing frequency amplitude.This study demonstrates that altering the match of rotor and stator blades can significantly change the RSI effect and alters the velocity distribution within the pump, and consequently changes the unsteady turbulence intensity in the interaction region. The research findings greatly enhance the understanding of velocity pulsation within the pump and provide effective support for mitigating RSI effect.

Study on the transition mechanism of vibrating low-pressure turbine blades based on large Eddy simulation

The low-pressure turbine blades are susceptible to vibration issues due to their thin profiles and large aspect ratios. Blade vibration will significantly affect the evolution of the boundary layer and the flow state. This paper utilizes large eddy simulation to predict the development of the boundary layer on the suction side of low-pressure turbine blades at low Reynolds numbers (Re = 25,000). It introduces different vibration cases to elucidate the mechanisms by which blade vibrations influence boundary layer separation and transition. The study demonstrates that the introduction of vibration cases significantly reduces both the size of the overall spanwise vortices and their roll-up height. A staggered distribution of spanwise vortices, characterized by alternating high and low regions, is observed near the trailing edge of the vibrating blades. The shorter spanwise vortices develop rapidly, nearly traversing the process of hairpin vortices (Λ vortex) generation and development, and directly breaking down into smaller-scale vortices. This accelerates the transition process. Blade vibration primarily promotes turbulence reattachment by facilitating the transition process dominated by the K-H instability mechanism within the separating shear layer. Consequently, it effectively restricts the growth of the separation bubble on the suction side of the blades, significantly reducing aerodynamic losses. Moreover, increasing the vibration frequency within a certain range can amplify these effects, achieving up to a 23% reduction in total pressure loss compared to stationary blades.

An Efficient Uncertainty Quantification Method Based on Inter-Blade Decoupling for Compressors

Abstract A compressor usually contains multiple blade rows, and its uncertainty dimensionality grows proportionally with the number of blade rows, leading to a rapid increase in required sample size for uncertainty quantification analysis. This paper proposes a new dimensionality reduction method based on inter-blade decoupling, by analyzing uncertainty propagation in compressors. Traditionally, a surrogate model with uncertainty variables of all blade rows as input is directly established and the dimensionality is high. To solve this problem, this study decomposes the compressor domain into sub-domains, each containing one blade row. For each sub-domain, a sub-model introduces aerodynamic uncertainties at the interfaces connecting different sub-domains. The dimensionality of a sub-model is roughly equal to the uncertainty factors in a single row, significantly reducing the required sample size. The uncertainties in the rotor and stator blade rows of a one-stage compressor are investigated to verify this method. Using principal component analysis and machine learning, the projection amplitudes of the interface aerodynamic flow field onto the principal modes are extracted, and sub-models are established. Results show that the original 25-dimensional model can be decoupled into a 13-dimensional sub-model for the rotor and a 16-dimensional sub-model for the stator, reducing the required sample size from 600 to 90 with similar accuracy. This dimensionality reduction method greatly reduces the cost of predicting compressor performance with uncertainty, laying a foundation for comprehensive analysis and effective control of uncertainty factors in engineering applications.

Reaction mechanisms and mechanical properties of SiCf/SiC composite and GH536 superalloy joints using CoFeNiCrMn high-entropy alloy filler

To meet the service conditions and strength requirements of turbine stator blades and the inner and outer rings of aero engine casings, CoFeNiCrMn high-entropy alloy filler was used to braze SiCf/SiC/GH536 joints. This study investigated the effects of holding time on the joints' microstructure and mechanical properties. Key phases identified in the welded joints include MoNiSi, FCC, and Cr23C6 near the composites, with brittle Ni3Si and Fe2Si intermetallic compounds forming due to filler diffusion. Optimal brazing parameters were found to be 1220 °C for 30 min with a shear strength of 64.28 MPa. The study also highlighted that increased holding time at the same temperature enhances diffusion at the joint, increasing brittle intermetallic compounds, initially improving shear strength, which then declines. Microstructural and fracture morphology analyses revealed that insufficient insulation time leads to poor welding and stress concentration at pores, causing cracks. Excessive insulation time results in joint fractures due to the brittleness of Ni3Si and Fe2Si intermetallic. Thus, joint shear strength correlates with welding quality and intermetallic compound distribution.

A novel wide flow matching approach of hydrogen-powered F-class gas turbine based on multistage installation angle

To achieve excellent power performance of F-class gas turbine when using pure H2 or H2-rich fuel, this work develops a novel and flexible flow matching approach by modifying the turbine multistage installation angle, with obvious features of easy implementation and low cost. An accurate thermodynamic model of heavy-duty gas turbine considering turbine-stage cooling is established and verified by the actual operation data from Ban-Shan power plant, and to investigate variable condition property and emission characteristic of gas turbine with natural gas and H2-rich fuel. Faced with the inefficiency and narrow working area caused by the flow mismatch between 18-stage compressor and 3-stage turbine when natural gas is switched to H2-rich fuel, the scheme of modifying the installation angles of multistage rotary blade and static blade is proposed. By calculating the pressure and temperature at each turbine stage, the gas turbine power, efficiency, Mach number and NOx emission with different H2 concentration are predicted. Results show that, as the H2 concentration increases, the fuel volume flow required to reach the same turbine inlet temperature increases.When H2-rich fuel increases the turbine inlet volume flow by 3.23 %, the cooling effect significantly decreases, and the turbine outlet temperature rises by about 13.60 K, which deviates from the appropriate operating point. The most serious is the phenomenon of over Mach number and airflow blocking at the outlet of the 2-stage and 3-stage turbine static blades. The installation angle variation increases with the increase of H2, and the higher the stage, the bigger the angle change. The gas turbine can be realized the wide flow matching feature corresponding to the installation angle variation of 0.19°/-0.41°, 0.38°/-0.48°, and 0.53°/-0.94°, respectively for all stages static/rotary blades. After re-matching, the maximum fluctuation of rated power and efficiency are 1.5 % and 1.7 %, and the NOx emission will reach the maximum value of 14.3 ppm with 70 % H2. Research work will provide a novel and feasible retrofit scheme for the heavy-duty gas turbine using clean and low-carbon fuel to widen flow matching scenario.

Study on the preparation and mechanical behavior of carbon fiber reinforced aluminum matrix composites stator blade

The advancement of high-performance stator blades stands as a critical avenue for enhancing the efficacy of aero engines. This study aims to prepare carbon fiber reinforced aluminum matrix (CF/Al) composite stator blades with high-quality shapes and properties, optimize the lay-up design using Fibersim software, and investigate the effect of extrusion temperature on the forming quality. The mechanical properties and damage behavior were systematically analyzed by tensile, compression, and interlaminar shear tests. In addition, the vibration mode simulation reveals the force state under the 1st to 8th-order vibration modes. Results indicate that the [0°/+45°/0°/-45°/90°/-45°/0°/+45°/0°] lay-up parameters were optimal, achieving excellent shape and performance of curved preforms after curing. Composite blades fabricated at an extrusion temperature of 680°C exhibited clear contours, consistent dimensions, and no macro defects. SEM and EDS analyses showed uniform impregnation in all regions of the blade, high density, and good densification. Compared with the matrix alloy, the tensile strength of the composite blade was improved by 64.94%, the compressive strength by 35.7%, and the interlayer shear strength was as low as 72.6 MPa. The vibration mode simulation verified the applicability of the blade in the first-order vibration mode, which provides strong support for the application of composite materials in the aerospace field.

Analysis of coupling supersonic turbine stage with rotating detonation combustor under different turbine parameters

The rotating detonation gas turbine boasts several advantageous characteristics, including self-pressurization, minimal entropy increase, high thermal efficiency, and a high thrust-to-weight ratio. These features make it a promising candidate for the next generation of aerospace power devices. This study investigates the flow characteristics and performance attributes of the supersonic turbine stage coupled with a rotating detonation chamber based on different rotational speeds, blade ratio of rotor and stator, and hub radius, and uses DMD (Dynamic Mode Decomposition) to analyze the main modes of the supersonic turbine. The research identifies distinct wave modes in both the stator and rotor blades of the supersonic turbine. In the stator blades, the modes include waveless contact modes, opposite side λ-wave oblique shock wave modes, and derived modes from opposite side λ-wave oblique shock waves. In the rotor blades, the modes encompass non-separation modes (waveless modes, asymmetric dual λ-wave modes, oblique cut wave modes, and single-side λ-wave modes on the pressure surface), leading-edge stator excitation single separation bubble modes, saddle-type separation modes, and dual separation bubble modes. The efficiency and power of the supersonic turbine stage increase with the rotational speed. The turbine efficiency is highest when the blade ratio is 10:7. Under multi-wave mode conditions, detonation waves demonstrate adaptive self-regulation abilities, ultimately achieving equilibrium in speed, detonation wave height, and spacing. The dominant modes in the stator blades and combustion chamber are governed by detonation waves and slip lines, while in rotor blades, the primary mode is the flow-directional vortex mode governed by detonation waves and slip lines at a frequency lower than their propagation frequency. This research holds certain reference significance for understanding the internal flow characteristics of rotating detonation gas turbines, as well as discussing the patterns of efficiency, power, and load characteristics, thereby offering valuable insights for the practical application of rotating detonation gas turbines.

A Novel Image-Based Long-Range Continuously Scanning Laser Doppler Vibrometer for Operational Modal Analysis of a Rotating Structure

ABSTRACT A novel image-based long-range tracking continuously scanning laser Doppler vibrometer (CSLDV) is developed to measure vibration of a rotating structure with a complex background. The image-based long-range tracking CSLDV can track and scan the rotating structure by processing its images captured by a camera in the image-based long-range tracking CSLDV. A novel image-processing method with a background averaging technique is developed to extract the rotating structure from the background in captured images and determine its location. A one-dimensional scan scheme is used to scan along a straight line along the rotating structure. An improved demodulation method is used to process measurements of the image-based long-range tracking CSLDV to estimate modal parameters of the rotating structure, including damped natural frequencies and undamped mode shapes. Experiments of tracking and scanning a rotating blade are conducted to validate vibration measurement of a rotating blade using the image-based long-range tracking CSLDV. Measured responses of the rotating blade are processed to estimate its speeds and modal parameters. The first three damped natural frequencies of out-of-plane vibration of the rotating blade and the first three undamped mode shapes of the rotating blade along its middle line are successfully estimated and compared with results from the finite element model of the corresponding stationary blade.

Improving the thermodynamic efficiency and turboexpander design in bottoming organic Rankine cycles: The impact of working fluid selection

In the contemporary context, significant importance is attributed to micro and small-scale Organic Rankine Cycle (ORC) units that are specifically designed for decentralized electricity generation. An essential component within each ORC system is the expander, available in both volumetric and turboexpander configurations. In the existing biogas plant with an Internal Combustion Engine (ICE), the ORC, functioning as a bottoming cycle (BORC) on ICE waste heat, is installed. The BORC utilizes the heat from exhaust gases and the cooling water of the ICE. The paper investigates the effects of various working fluids on both the thermodynamic efficiency of the BORC and the isentropic efficiency of the turboexpander, thus influencing the design parameters of the turboexpander (e.g., number of stages, stator and rotor blade heights, etc.). The BORC, employing the working fluid R141b, has exhibited superior thermodynamic performance, demonstrating a commendable 63.5 kW in net power with a thermodynamic efficiency of 13 %, and ultimately increased the power of the ICE (537 kW) by approx. 12 %. Regarding the turbine component, the turbine operating with the R141b working fluid demonstrated the highest power output and isentropic efficiency, achieving values of 64.14 kW and 67.4 %, respectively. A design was developed for the same turbine, with aerodynamically perfect profiles specially designed for the stator and rotor blades.

Research on the design of hydraulic heater and optimization of energy matching of internal combustion engine heated steam generator

A novel internal combustion engine heated steam generator (ICEHSG) and the energy-matching optimization method are proposed in this paper. In the ICEHSG, the energy generated by the internal combustion engine (ICE) of the vehicle is converted to thermal energy as the heating source of the steam generator. Firstly, the prototype model of the hydraulic heater (HH) of the ICEHSG is established, and the relevant structural parameters are optimized based on computational fluid dynamics (CFD). Secondly, the energy matching between HH and ICE is optimized based on the particle swarm algorithm with compression factors (CFPSO). Finally, the energy provided by the ICEHSG and the required energy of the steam generation process is optimized, and the analysis is combined with the actual engineering case. The simulation results show that when the inclination angle of the blade is 45°, the number of rotor and stator blades is 31–33, and the diameter of the circular circle is 386 mm, the torque performance and heating performance of the HH are optimal. Meanwhile, the maximum thermal power can be obtained when the liquid filling rate of the HH is 100%. After optimization, the maximum torque of the HH working with the ICE is increased by 8.07%. Compared with the traditional boiler steam generator, the ICEHSG system proposed in this paper can increase the thermal efficiency by 1.3%–2.7% and reduce the cost by 37%.

Transitional flow in a two-stage low-pressure axial turbine under different clocking of blades

Different modes of transitional flows are numerically analyzed in a two-stage low-pressure axial turbine, while being exposed to various clocking of second stator blades and results are presented in this paper. The numerical method utilizes coupled approach of SST k-ω turbulence andγ−Re˜θt transitional models. Kinematic of the wake flow in the blades passage and flow topology are presented and discussed. Different types of transitional flows including “separation induced transition” (i.e., “laminar separation bubble”), “reverse transition” and “bypass transition” are distinguished. Results of surface distribution of pressure and skin friction coefficients, turbulence intensity, intermittency and also transition momentum thickness Reynolds number are presented for the worst and optimum clocking cases, in detail. Results show that the onset points of separation induced transition and bypass transition move upstream by 6.64% and 5.47% in the optimum clocking in comparison to the worst case, respectively. In the optimum clocking the separation bubble length decreases by 1.57% and the onset point of the reverse transition moves downstream by 1.2%. All these beneficial effects happen basically as a result of impinging the first stage wake flow on the leading edge of the second stator blade suction side, which in turn, causes transition from laminar to turbulent to occur within the boundary layer.

Research on the excitation force and vortex dynamics characteristics of pump-jet propulsor induced by shafting whirling vibration: Non-uniform blade tip clearance

The propulsion shafting whirling vibration causes non-uniform dynamic changes in the rotor tip clearance, which directly have a significant influence on the excitation force and vortex dynamic characteristics of the pump-jet propulsor. In the current study, based on improved delay detached eddy simulation, the influence of non-uniform blade tip clearance on the excitation force and vortex dynamics characteristics of the pump-jet propulsor is studied under design conditions. The results show that the application of propulsion shafting whirling vibration induces significant changes in the excitation force of the pump-jet propulsor. The rotor blades modulate the excitation forces of the stator blades and duct. The transverse and vertical excitation forces are more significant than the longitudinal excitation force. The magnitude change in the circular orbit shows a linear relationship with the excitation force magnitude. The characteristic frequency of the transverse and vertical excitation forces of each component is the shaft rotation frequency. In contrast, the characteristic frequency of the longitudinal excitation force is twice the shaft rotation frequency. In the elliptical orbit, the excitation force of each component is compressed or stretched in the time domain, and the dominant frequency is shifted in the frequency domain; there is no longer a linear relationship between the vibration magnitude change and the excitation force magnitude. Furthermore, an energy generation mechanism in the wake field of the pump-jet propulsor induces vortex frequency due to the whirling vibration of the propulsion shafting system.

Design and optimization of slot number in supercooled vapor suction in steam turbine blades for reducing the wetness

An enormous amount of the world's electricity is produced by steam power plants. The existence of a liquid phase in the steam turbine results in an efficiency drop and mechanical losses, which are very expensive due to its high price. Creating a suction slot in the stationary blade of the steam turbine for sucking the supercooled vapor and wetness fraction in the low-pressure stages of the turbine is one of the most effective methods of preserving the rotor blades against corrosion and erosion. The Eulerian-Eulerian method is employed for modeling the condensing flow. In the current research, the impact of the suction slot location and number on the surfaces of the turbine blades is investigated on condensation, total suction ratio, liquid suction ratio, average droplet radius, and condensation losses. Optimization is performed by the TOPSIS algorithm. Based on the results, the location and number of the suction slots affect the flow pattern in the turbine blade. Creating a suction slot in the optimal case has a total suction ratio of 4.1 %, which decreases the liquid suction ratio, condensation losses, and average droplet radius, respectively, by 5.28 %, 6 %, and 25 % compared to the original case.

Numerical Investigation of Rotor and Stator Matching Mode on the Complex Flow Field and Pressure Pulsation of a Vaned Centrifugal Pump

The match of rotor and stator blades significantly affects the flow field structure and flow-induced pressure pulsation characteristics inside the pump. In order to study the effects of the rotor and stator matching mode on the complex flow field and pressure pulsation of a centrifugal pump with a vaned diffuser, this paper designs three different vaned diffusers (DY5, DY8 and DY9) and uses the DDES (Delayed Detached Eddy Simulation) numerical method combined with structured grids to simulate the unsteady flow phenomena of the model pump under rated conditions. The results show that, under different rotor and stator matching modes, the pressure pulsation spectrum is dominated by the blade passing frequency and its harmonics. The matching mode of the rotor and stator significantly affects the time–frequency domain characteristics of the pressure pulsation inside the pump, and it is observed that the pressure pulsation energy of vaned diffusers with more blades is significantly smaller than that of fewer-blade vaned diffusers in comparison to the energy of the pressure pulsation at the blade passing frequency and within the 10–1500 Hz frequency band. Combined with the distribution characteristics of the complex flow field inside the pump, it can be found that increasing the number of vaned diffuser blades can reduce the energy of flow-induced pressure pulsation, improve the distribution of high-energy vortices in the interaction zone and stabilize the flow inside the centrifugal pump effectively.

Identification and Optimization Study of Cavitation in High Power Torque Converter

Aiming at the phenomenon that a high-power torque converter is susceptible to cavitation, which leads to performance degradation, first, a transient flow field model of the torque converter is established, and CFD simulation and experimental research on the torque converter are carried out to find out the speed ratio region where cavitation occurs in the torque converter as well as the rule of occurrence of cavitation, and then the cavitation identification method based on the difference between the inlet and outlet flow of the torque converter is proposed. Then, the transient flow process inside the torque converter is analyzed, and it is pointed out that the angle between the inlet angle of the stator and the outlet angle of the turbine of the torque converter, i.e., the fluid inflow injection deviation angle is an important factor affecting the cavitation phenomenon. By adjusting the key parameters of the stator blade bone line, the fluid inflow deviation angle of the torque converter stator is optimized, so that the speed ratio range of cavitation under large load conditions is greatly reduced from the original 0–0.5 (50%) to 0–0.15 (15%). Meanwhile, in terms of test performance, the nominal torque of the torque converter is greatly improved under the premise of ensuring that the performance is basically unchanged, in which the nominal torque of the test zero speed is increased by 28.7%, and the cavitation of the torque converter has been greatly improved.

Passive control of the condensing flows in the three-dimensional steam turbine blade using a suction technique

A great amount of thermodynamic losses and mechanical damages in industrial equipment occur due to the condensation phenomenon and two-phase flows in such equipment. In this study, supercooled vapor suction has been passively used in the 3D (three-dimensional) steam turbine stationary blade. Supercooled vapor suction is one of the techniques used in turbines for resisting corrosion and erosion. For the supercooled flow suction, the design is as follows: an embedded channel inside the turbine blade in the nucleation zone, which has the utmost non-equilibrium mode; furthermore, the impacts of the location and surface of the channels devised in the turbine blade for supercooled vapor suction on the following parameters have been investigated: the two-phase flow, the suction ratio, condensation losses, erosion ratio, the average droplet growth, and kinetic energy. Based on the results, in the optimal case (case F), the condensation losses, erosion ratio, average droplet radius, and kinetic energy decrease by 3%, 24%, 6.5%, and 2%, respectively; also, the suction ratio is 3.6%. The present research reveals that the supercooled vapor suction, due to a decrease in the surface necessary for the condensation, decreases turbine blade corrosion and erosion. This fact can provide the turbine designers with beneficial information.

Smart Blade Count Selection to Align Modal Propagation Angle with Stator Stagger Angle for Low-Noise Ducted Fan Designs

The rotor–stator interaction noise is a major source of fan noise. Especially for low-speed fan stages, the tonal component is typically a dominant noise source. A challenge is to reduce this tonal noise, as it is typically perceived as unpleasant. Therefore, in this paper, we analytically, numerically and experimentally investigate an acoustic effect to lower the tonal noise excitation. Our study on an existing low-speed fan indicates a reduction in tonal interaction noise of more than 9 dB at the source if the excited acoustic modes propagate parallel to the stator leading edge angle. Moreover, a design-to-low-noise approach is demonstrated in order to apply this effect to two new fan stages with fewer stator than rotor blades. The acoustic design of both fans is determined by an appropriate choice of the rotor and stator blade numbers in order to align the modal propagation angle with the stator stagger angle. The blade geometries are obtained from aerodynamic optimization. Both fans provide similar aerodynamic but opposing acoustic radiation characteristics compared to the baseline fan and a significant tonal noise reduction resulting from the impact of the modal propagation angle on noise excitation. To ensure that this effect can also be applied to other low-speed fans, a design rule is derived and validated.