Here we report on the application of non-axisymmetric endwall contouring to mitigate the endwall losses of one conventional- and two high-lift low-pressure turbine airfoil designs. The design methodology presented combines a gradient-based optimization algorithm with a three-dimensional CFD flow solver to systematically vary a free-form parameterization of the endwall. The ability of the CFD solver employed in this work to predict endwall loss modifications resulting from non-axisymmetric contouring is demonstrated with previously published data. Based on the validated trend accuracy of the solver for predicting the effects of endwall contouring, the magnitude of predicted viscous losses forms the objective function for the endwall design methodology. This system has subsequently been employed to optimize contours for the conventional-lift Pack B and high-lift Pack D-F and Pack D-A low-pressure turbine airfoil designs. Comparisons between the predicted and measured loss benefits associated with the contouring for Pack D-F design are shown to be in reasonable agreement. Additionally, the predictions and data demonstrate that the Pack D-F endwall contour is effective at reducing losses primarily associated with the passage vortex. However, some deficiencies in predictive capabilities demonstrate here highlight the need for a better understanding of the physics of endwall loss-generation and improved predictive capabilities. More detailed analysis of the contouring results for the Pack B design is presented in a companion paper (Knesevici et al. [1]).

An approach to endwall contouring has been developed with the goal of reducing secondary losses in highly loaded axial flow turbines. The present paper describes an experimental assessment of the performance of the contouring approach implemented in a low-speed linear cascade test facility. The study examines the secondary flows of a cascade composed of Pratt & Whitney PAKB airfoils. This airfoil has been used extensively in low-pressure turbine research, and the present work adds intrapassage pressure and velocity measurements to the existing database. The cascade was tested at design incidence and at an inlet Reynolds number of 126,000 based on inlet midspan velocity and axial chord. Quantitative results include seven-hole pneumatic probe pressure measurements downstream of the cascade to assess blade row losses and detailed seven-hole probe measurements within the blade passage to track the progression of flow structures. Qualitative results take the form of oil surface flow visualization on the endwall and blade suction surface. The application of endwall contouring resulted in lower secondary losses and a reduction in secondary kinetic energy associated with pitchwise flow near the endwall and spanwise flow up the suction surface within the blade passage. The mechanism of loss reduction is discussed in regard to the reduction in secondary kinetic energy.

An approach to endwall contouring has been developed with the goal of reducing secondary losses in highly loaded axial turbo-machinery. The present paper describes an experimental assessment of the performance of the contouring approach implemented in a low speed linear cascade test facility. The study examines the secondary flows of a cascade composed of Pratt and Whitney PAKB airfoils. This airfoil has been used extensively in low pressure turbine research and the present work adds intra-passage pressure and velocity measurements to the existing database. The cascade was tested at design incidence and at an inlet Reynolds number of 126,000 based on inlet midspan velocity and axial chord. Quantitative results include seven hole pneumatic probe pressure measurements downstream of the cascade to assess blade row losses, and detailed seven hole probe measurements within the blade passage to track the progression of flow structures. Qualitative results take the form of oil surface flow visualization on the endwall and blade suction surface. The application of endwall contouring resulted in lower secondary losses and caused a reduction in secondary kinetic energy associated with pitchwise flow near the endwall and spanwise flow up the suction surface within the blade passage. The mechanism of loss reduction is discussed in regards to the reduction of secondary kinetic energy.

Here, we report on the application of nonaxisymmetric endwall contouring to mitigate the endwall losses of one conventional and two high-lift low-pressure turbine airfoil designs. The design methodology presented combines a gradient-based optimization algorithm with a three-dimensional computational fluid dynamics (CFD) flow solver to systematically vary a free-form parameterization of the endwall. The ability of the CFD solver employed in this work to predict endwall loss modifications resulting from nonaxisymmetric contouring is demonstrated with previously published data. Based on the validated trend accuracy of the solver for predicting the effects of endwall contouring, the magnitude of predicted viscous losses forms the objective function for the endwall design methodology. This system has subsequently been employed to optimize contours for the conventional-lift Pack B and high-lift Pack D-F and Pack D-A low-pressure turbine airfoil designs. Comparisons between the predicted and measured loss benefits associated with the contouring for Pack D-F design are shown to be in reasonable agreement. Additionally, the predictions and data demonstrate that the Pack D-F endwall contour is effective at reducing losses primarily associated with the passage vortex. However, some deficiencies in predictive capabilities demonstrated here highlight the need for a better understanding of the physics of endwall loss-generation and improved predictive capabilities.

This paper is the second in a series from the same authors studying the mitigation of endwall losses using the low-speed linear cascade test facility at Carleton University. The previous paper documented the baseline test case for the study. The current work investigates the secondary flow in a cascade of more highly-loaded low-pressure turbine airfoils with and without the implementation of endwall profiling. This study is novel in two regards. First, the contouring is applied to low-pressure turbine airfoils, whereas studies conducted by other researchers have focused their endwall profiling efforts on the high-pressure turbine. Second, while previous researchers have optimized contouring designs for a given airfoil, the current work demonstrates the potential to open the design space by employing high-lift airfoils in conjunction with endwall contouring. Seven-hole pneumatic probe measurements taken within the blade passage and downstream of the trailing edge track the progression of the secondary flow and losses generated. The contouring divides the vorticity associated with the passage vortex into two weaker vortices, and reduces the secondary kinetic energy. Overall the secondary losses are reduced and the loss reduction is discussed with regards to changes in the flow physics. A detailed breakdown of the mixing losses further demonstrates the benefits of endwall contouring.