The role of free-stream turbulence on high pressure turbine aero-thermal stage interaction

Turbulence plays an important role on the aero-thermal performance of modern aircraft engine High Pressure Turbines (HPT). The role of the vane wake and passage turbulence on the downstream blade flow field is an important consideration for both performance and durability. Obtaining measurements to fully characterize the flow field can be challenging and costly in an experimental facility. Advances in Computational Fluid Dynamic (CFD) modeling and High Performance Computing (HPC) are providing opportunity to close these measurement gaps. In order for CFD to be adopted, methods need to be both accurate and efficient. Meshing approaches must also be able to resolve complex HPT geometry while maintaining quality adequate for scale-resolved simulations. Therefore, the accuracy of executing scale-resolved simulations with a second-order code on a mesh of prisms and tetrahedrals in Fluent is considered. Before execution of the HPT computational study, a building block approach is taken to gain quantified predictive performance in the modeling approach as well as understanding limitations in lower computational cost modeling approaches. The predictive capability for Reynolds Averaged Navier Stokes (RANS), Hybrid Large Eddy Simulation (LES), and wall-resolved LES turbulence modeling approaches are first assessed for a cylinder in cross-flow at a Reynolds number of 2580. The flow condition and simple geometry facilitate a quick turn-around for modeling assessment before moving the HPT vane study at high Reynolds and Mach number conditions. Modeling approaches are then assessed relative to the experimental measurements of Arts and Rouvroit (1992) on a pitch-line HPT uncooled vane at high Mach and Reynolds numbers conditions with low (0-6%) free-stream turbulence. The current unstructured second-order LES approach agrees with experimental data and is found to be within the equivalent experimental uncertainty when compared to the structured high-ordered solver FDL3DI. The unstructured Hybrid LES aero-thermal predictions are found to be in close agreement with LES predictions and 4 times more computationally efficient. A sliding mesh approach is then used to understand the complex HPT vane and blade stage aero-thermal interaction at 0 and 20% inlet turbulence. A HPT blade has been designed to pair with the uncooled vane of Arts and Rouvroit (1992) to evaluate the impact of passage turbulence and vane wake on the downstream blade boundary layer as well as wake formation and evolution. The learnings from the statistical 2D pitch-line stage simulations are applied to a 3D annular representation of the geometry including endwalls and blade tip clearance to demonstrate the impact of secondary flows on the overall aero-thermal performance. Compared to the 2D pitchline predictions, the vane and blade overall mass average relative total pressure loss for the 3D geometry increases by 73 and 107%, respectively. The blade loss is shown to be largely driven by the formation of the tip vortex. Hybrid LES predictions show that by increasing stage inlet turbulence by 20% results in up to a 40% increase for the surface heat flux on the vane. However, the impact of stage inlet turbulence is found to be secondary compared to the periodic unsteadiness generated by the vane wake on the downstream blade surface heat transfer and mixing.