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At least 397 records · Page 22

Shape optimization and fluid control of near isothermal compressor for transcritical carbon dioxide cycle

The compressor holds great promise for enhanced energy efficiency over a wide range of vapor compression systems (VCS). However, the majority of them focused on liquid refrigerant injection or inter-stage cooling technologies to improve heat transfer. Increasing the heat transfer area provides another perspective to promote heat dissipation, which commonly involves shape optimization whilst bringing some limitations, mainly from the manufacturing side. To fill the research gap, this paper compares the performance of isothermal compressors under different compression chamber shapes and chamber connection configurations. Additionally, the fluid control of the liquid piston was combined with shape optimization to explore the potential for further heat transfer enhancement. The simulation results have demonstrated that the COP improvements can reach up to 9% compared with the baseline case by optimizing the chamber shape and properly controlling the liquid piston speed, which provides a guideline for designing and customizing the isothermal compression chamber.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

High-Speed and Dynamic Diaphragm Compressor for High-Capacity Fueling (Final Technical Report)

Goal of the project is to scale the NEL hydrogen compressor technology from 1.1 kg/minute to 5.5 kg/minute capacity (scale 1:5). This will enable achievement of 330 kg/hour capacity, sufficient to achieve fast high-capacity heavy-duty vehicle (HDV) fueling. The technology readiness level (TRL) maturity objective is to develop and test a scaled-up compressor that is to advance from TRL3 to TRL7.

08 HYDROGEN↗

Detailed Simulations of a Three-Stage Supercritical Carbon Dioxide Axial Compressor with a Focus on the Shrouded Stator Cavities Flow

This paper describes the findings of detailed simulations performed to investigate the impact of seal teeth cavity leakage flow on the aerodynamic and thermal performance of a three-stage supercritical CO 2 axial compressor. The study compares a shrouded stator configuration (with cavities) to a cantilevered stator configuration (without cavities) to highlight their differences. High-fidelity computational fluid dynamics simulations were performed using non-linear harmonic (NLH) and mixing plane assumptions, considering various possible rotor/stator interface configurations for mixing plane calculations. The key performance parameters for each case were compared, and the best-performing configuration selected for further analysis. The individual stage performance parameters are also examined and compared between the cantilevered and shrouded configurations. It was observed that in the shrouded case, the leakage flow enters the cavity downstream of the stator trailing edge and gets entrained into the primary flow upstream of the stator, leading to boundary layer changes at the hub and degradation of stator and downstream rotor performance. Vortical flow structures were also observed in the stator wells, which tended to change the flow angles around the region, thereby affecting mixing and velocity distribution, resulting in a slight deterioration of compressor performance. Additionally, the study examines windage heating due to shear work from rotating walls, including the seal teeth surface. The amount of shear work done on the leakage flow and the corresponding rise in fluid temperature were quantified, tabulated, and further compared with a simple analytical model, showing good agreement between them and, hence, validating the numerical approach used.

42 ENGINEERING↗

Effect of Mach number on over-all performance of single-stage axial-flow compressor designed for high pressure ratio

A complete stage of an axial-flow compressor designed to produce a high pressure ratio was investigated at speeds from 110 to 130 percent of design speed (836 ft/sec). The data obtained and the results of a previous investigation of the same compressor at speeds from 50 to 100 percent of design speed were used to determine the effect of Mach number on over-all performance. The peak total-pressure ratio increased from 1.095 to 1.515 and the peak adiabatic efficiency decreased from 0.93 to 0.89 as the relative inlet Mach number increased from 0.34 to 0.77. At a relative inlet Mach number of 0.91, a total-pressure ratio of 1.635 was obtained at an adiabatic efficiency of 0.74.

COMPRESSORS - AXIAL FLOW↗

Discussion of boundary-layer characteristics near the casing of an axial-flow compressor

Boundary-layer velocity profiles on the casing of an axial-flow compressor behind the guide vanes and rotor were measured and resolved into two components: along the streamline of the flow and perpendicular to it. Boundary-layer thickness and the deflection of the boundary layer at the wall were the generalizing parameters. By use of these results and the momentum-integral equations, the characteristics of boundary on the walls of axial-flow compressor are qualitatively discussed. Important parameters concerning secondary flow in the boundary layer appear to be turning of the flow and the product of boundary-layer thickness and streamline curvature outside the boundary layer. Two types of separation are shown to be possible in three dimensional boundary layer.

BOUNDARY LAYER CHARACTERISTICS - INTERNAL AERODYNA↗

Investigation of Unsteady Tip Clearance Flow in a Low-Speed One and Half Stage Axial Compressor with LES And PIV

The primary focus of this paper is to investigate how a rotor's unsteady tip clearance flow structure changes in a low speed one and half stage axial compressor when the rotor tip gap size is increased from 0.5 mm (0.49% of rotor tip blade chord, 2% of blade span) to 2.4 mm (2.34% chord, 4% span) at the design condition are investigated. The changes in unsteady tip clearance flow with the 0.62 % tip gap as the flow rate is reduced to near stall condition are also investigated. A Large Eddy Simulation (LES) is applied to calculate the unsteady flow field at these three flow conditions. Detailed Stereoscopic PIV (SPIV) measurements of the current flow fields were also performed at the Johns Hopkins University in a refractive index-matched test facility which renders the compressor blades and casing optically transparent. With this setup, the unsteady velocity field in the entire flow domain, including the flow inside the tip gap, can be measured. Unsteady tip clearance flow fields from LES are compared with the PIV measurements and both LES and PIV results are used to study changes in tip clearance flow structures. The current study shows that the tip clearance vortex is not a single structure as traditionally perceived. The tip clearance vortex is formed by multiple interlaced vorticities. Therefore, the tip clearance vortex is inherently unsteady. The multiple interlaced vortices never roll up to form a single structure. When phased-averaged, the tip clearance vortex appears as a single structure. When flow rate is reduced with the same tip gap, the tip clearance vortex rolls further upstream and the tip clearance vortex moves further radially inward and away from the suction side of the blade. When the tip gap size is increased at the design flow condition, the overall tip clearance vortex becomes stronger and it stays closer to the blade suction side and the vortex core extends all the way to the exit of the blade passage. Measured and calculated unsteady flow fields inside the tip gap agree fairly well. Instantaneous velocity vectors inside the tip gap from both the PIV and LES do show flow separation and reattachment at the entrance of tip gap as some earlier studies suggested. This area at the entrance of tip gap flow (the pressure side of the blade) is confined very close to the rotor tip section. With a small tip gap (0.5mm), the gap flow looks like a simple two-dimensional channel flow with larger velocity near the casing for both flow rates. A small area with a sharp velocity gradient is observed just above the rotor tip. This strong shear layer is turned radially inward when it collides with the incoming flow and forms the core structure of the tip clearance vortex. When tip gap size is increased to 2.4 mm at the design operation, the radial profile of the tip gap flow changes drastically. With the large tip gap, the gap flow looks like a two-dimensional channel flow only near the casing. Near the rotor top section, a bigger region with very large shear and reversed flow is observed.

compressor↗

Investigation of Unsteady Tip Clearance Flow in a Low-Speed One and Half Stage Axial Compressor with LES And PIV

The primary focus of this paper is to investigate how a rotor's unsteady tip clearance flow structure changes in a low speed one and half stage axial compressor when the rotor tip gap size is increased from 0.5 mm (0.49% of rotor tip blade chord, 2% of blade span) to 2.4 mm (2.34% chord, 4% span) at the design condition are investigated. The changes in unsteady tip clearance flow with the 0.62 % tip gap as the flow rate is reduced to near stall condition are also investigated. A Large Eddy Simulation (LES) is applied to calculate the unsteady flow field at these three flow conditions. Detailed Stereoscopic PIV (SPIV) measurements of the current flow fields were also performed at the Johns Hopkins University in a refractive index-matched test facility which renders the compressor blades and casing optically transparent. With this setup, the unsteady velocity field in the entire flow domain, including the flow inside the tip gap, can be measured. Unsteady tip clearance flow fields from LES are compared with the PIV measurements and both LES and PIV results are used to study changes in tip clearance flow structures. The current study shows that the tip clearance vortex is not a single structure as traditionally perceived. The tip clearance vortex is formed by multiple interlaced vorticities. Therefore, the tip clearance vortex is inherently unsteady. The multiple interlaced vortices never roll up to form a single structure. When phased-averaged, the tip clearance vortex appears as a single structure. When flow rate is reduced with the same tip gap, the tip clearance vortex rolls further upstream and the tip clearance vortex moves further radially inward and away from the suction side of the blade. When the tip gap size is increased at the design flow condition, the overall tip clearance vortex becomes stronger and it stays closer to the blade suction side and the vortex core extends all the way to the exit of the blade passage. Measured and calculated unsteady flow fields inside the tip gap agree fairly well. Instantaneous velocity vectors inside the tip gap from both the PIV and LES do show flow separation and reattachment at the entrance of tip gap as some earlier studies suggested. This area at the entrance of tip gap flow (the pressure side of the blade) is confined very close to the rotor tip section. With a small tip gap (0.5mm), the gap flow looks like a simple two-dimensional channel flow with larger velocity near the casing for both flow rates. A small area with a sharp velocity gradient is observed just above the rotor tip. This strong shear layer is turned radially inward when it collides with the incoming flow and forms the core structure of the tip clearance vortex. When tip gap size is increased to 2.4 mm at the design operation, the radial profile of the tip gap flow changes drastically. With the large tip gap, the gap flow looks like a two-dimensional channel flow only near the casing. Near the rotor top section, a bigger region with very large shear and reversed flow is observed.

unsteady↗

Impact of Wake Dispersion on Axial Compressor Performance

Detailed development of wakes and their impact on the performance of a low-speed one and half stage axial compressor are investigated with a large eddy simulation (LES). To investigate effects of wake mixing recovery and wake interaction with the boundary layer of the downstream blade, spacing between the rotor blade and the stator is varied. The calculated LES flow fields based on a fine computational grid are compared with related measurements and analyzed in detail at several radial locations. The current LES calculates the effects of wake recovery very well. The effects of wake recovery vary significantly in the radial direction. Loss generation is higher on the pressure side at the stator exit at both near design and near stall condition. The current investigation indicates that better management of wake development can be achieved for improved compressor performance.

LES↗

Viscous Three-Dimensional Simulation of Flow in an Axial Low Pressure Compressor at Engine Icing Operating Points

Viscous three-dimensional simulations of the Honeywell ALF502R-5 low pressure compressor (sometimes called a booster) using the NASA Glenn code GlennHT have been carried out. A total of ten simulations were produced. Five operating points are investigated, with each point run with two different wall thermal conditions. These operating points are at, or near, points where engine icing has been determined to be likely. In the future, the results of this study will be used for further analysis such as predicting collection efficiency of ice particles and ice growth rates at various locations in the compressor. A mixing plane boundary condition is used between each blade row, resulting in convergence to steady state within each blade row. The k-omega turbulence model of Wilcox, combined with viscous grid spacing near the wall on the order of one, is used to resolve the turbulent boundary layers. For each of the operating points, heat transfer coefficients are generated on the blades and walls. The heat transfer coefficients are produced by running the operating point with two different wall thermal conditions and then solving simultaneously for the heat transfer coefficient and adiabatic wall temperature at each point. Average Nusselt numbers are calculated for the most relevant surfaces. The values are seen to scale with Reynolds number to approximately a power of 0.7. Additionally, images of surface distribution of Nusselt number are presented. Qualitative comparison between the five operating points show that there is relatively little change in the character of the distribution. The dominant observed effect is that of an overall scaling, which is expected due to Reynolds number differences. One interesting aspect about the Nusselt number distribution is observed on the casing (outer diameter) downstream of the exit guide vanes (EGVs). The Nusselt number is relatively high between the pairs of EGVs, with two lower troughs downstream of each EGV trailing edge. This is of particular interest since rather complex ice shapes have been observed in that region.

compressor↗

NASA Phase2 Unlimited Rights Final Report Research and Technology for Aerospace Propulsion Systems (RTAPS) Task Order: ERA Advanced Core Compressor Technology Program

As part of the NASA Integrated Systems Research Program (ISRP), Environmentally Responsible Aviation (ERA) Project, NASA GRC and GE Aviation have partnered to investigate the technology barriers associated with improved fuel economy of large gas turbine engines. Crucial to improving fuel economy is the increase in pressure ratio (PR) of the core high pressure compressor (HPC). A key enabler to increasing HPC pressure ratios are new technology front stage airfoil designs that have higher efficiency, higher pressure ratios and improvements in front stage part-power operability. The purpose of this work is to design and test two high pressure ratio, high efficiency front block designs. The baseline design, hereafter referred to as Build 1, is similar to what would be found in a high efficiency 30:1 PR class HPC. A redesigned front block with improved blading will also be tested and hereafter be referred to as Build 2. The goal of Build 2 is to increase stage aero loading (increase stage pressure ratio) beyond Build 1 while maintaining equivalent efficiency and stall margin. The detailed inter-stage and traverse data from the two builds will be used to improve understanding of the complex flow physics at high-speed and part-speed conditions that impact performance and operability. By addressing, understanding and solving the challenges associated with aerodynamic losses and stage matching better design strategies can be incorporated in future core compressors with higher efficiency, thereby enabling improvement in mission fuel burn while still meeting operability requirements.

Axial Compressors↗

User’s Guide for the NASA High Efficiency Centrifugal Compressor Data Archive

The datasets contained in this archive are associated with the High Efficiency Centrifugal Compressor (HECC) in the Small Engine Components Compressor Test Facility, colloquially referred to as CE-18, at NASA Glenn Research Center. The archive is accessible at https://storage.googleapis.com/hecc-data/NASA-HECC-Data-Archive.zip. The documentation contained herein provides context for the data hosted on data.nasa.gov. The datasets and accompanying content in this document will be updated periodically as additional data is procured analyzed. The revision of the document is provided by date in the footer, and the revision updates are provided in the Revisions section. Please contact Trey Harrison (email: herbert.harrison@nasa.gov) for inquiries related to the dataset and documentation or to be added to an email list to be notified of updates and additions to the archive.

radial turbomachinery↗

Experimental and Numerical Investigation of the NASA High Efficiency Centrifugal Compressor Vaned Stage Geometry and Aerodynamic Performance

Since its inception in the early 2010s, the NASA High Efficiency Centrifugal Compressor (HECC) has been enigmatic for the propulsion research community: experimental data and numerical simulations of the stage have generally not aligned in their quantifications of performance metrics. Typically, the fault for these disagreements is assigned to the numerical simulations as the simulations are models, and models are inherently incomplete representations of the experiment. This “incompleteness” may manifest in assumptions regarding roughness or heat transfer, simplifications of the flow path (i.e., neglecting bleed flows), or the oft-scapegoated turbulence model. In the case of HECC, recent work showed unexpected discrepancies between the intended impeller geometry defined in the design report (termed Design-Intent) and the manufactured impeller used in the experimental campaigns (termed As-Manufactured). That work used numerical simulations to establish that the geometric differences between the Design-Intent and As-Manufactured impellers were significant enough to result in drastically different performance predictions for the HECC vaneless diffuser configuration. The Design-Intent impeller simulations over predicted the performance relative to the experiment, whereas the As-Manufactured simulations better represented the experimental data, both in terms of one-dimensional performance metrics and spanwise flow profiles. This effort expands on that work by examining in detail the geometry and aerodynamic performance of the HECC vaned diffuser configuration. Further differences between the Design-Intent and As-Manufactured geometries have been discovered in the vaned diffuser and exit guide vanes, and these differences are documented herein. The summations of the geometric differences for all of the components were used to create two numerical models of HECC vaned diffuser configuration: the Design-Intent simulations which are generated from the original geometry definitions given in the design report and the As-Manufactured simulations which are the best available representation of the manufactured compressor hardware used in the experimental test campaigns. In congruence with the earlier vaneless diffuser work, the numerical predictions of the Design-Intent choked mass flow rate, total pressure ratio, and efficiency were notably greater than that of the As-Manufactured simulations. To increase confidence in the experimental dataset, measurements from a recent test campaign conducted in 2024 are used to validate the original experimental data acquired from 2012 to 2014 with good repeatability overall, especially considering the passage of time and differences in the data acquisition systems between the test campaigns. Both numerical simulations were then extensively evaluated against the experimental data. The As-Manufactured simulations provided better estimates of the stage performance than the Design-Intent cases in terms of most performance metrics. Nonetheless, more detailed results still show opportunities for improvement. Despite a more accurate representation of the physical hardware, characterization of the impeller work input remains a challenge even for rigorously developed numerical models.

vaned diffuser↗

Experimental and Numerical Investigation of the NASA High Efficiency Centrifugal Compressor Vaned Stage Geometry and Aerodynamic Performance

Since its inception in the early 2010s, the NASA High Efficiency Centrifugal Compressor (HECC) has been enigmatic for the propulsion research community: experimental data and numerical simulations of the stage have generally not aligned in their quantifications of performance metrics. Typically, the fault for these disagreements is assigned to the numerical simulations as the simulations are models, and models are inherently incomplete representations of the experiment. This “incompleteness” may manifest in assumptions regarding roughness or heat transfer, simplifications of the flow path (i.e., neglecting bleed flows), or the oft-scapegoated turbulence model. In the case of HECC, recent work showed unexpected discrepancies between the intended impeller geometry defined in the design report (termed Design-Intent) and the manufactured impeller used in the experimental campaigns (termed As-Manufactured). That work used numerical simulations to establish that the geometric differences between the Design-Intent and As-Manufactured impellers were significant enough to result in drastically different performance predictions for the HECC vaneless diffuser configuration. The Design-Intent impeller simulations over predicted the performance relative to the experiment, whereas the As-Manufactured simulations better represented the experimental data, both in terms of one-dimensional performance metrics and spanwise flow profiles. This effort expands on that work by examining in detail the geometry and aerodynamic performance of the HECC vaned diffuser configuration. Further differences between the Design-Intent and As-Manufactured geometries have been discovered in the vaned diffuser and exit guide vanes, and these differences are documented herein. The summations of the geometric differences for all of the components were used to create two numerical models of HECC vaned diffuser configuration: the Design-Intent simulations which are generated from the original geometry definitions given in the design report and the As-Manufactured simulations which are the best available representation of the manufactured compressor hardware used in the experimental test campaigns. In congruence with the earlier vaneless diffuser work, the numerical predictions of the Design-Intent choked mass flow rate, total pressure ratio, and efficiency were notably greater than that of the As-Manufactured simulations. To increase confidence in the experimental dataset, measurements from a recent test campaign conducted in 2024 are used to validate the original experimental data acquired from 2012 to 2014 with good repeatability overall, especially considering the passage of time and differences in the data acquisition systems between the test campaigns. Both numerical simulations were then extensively evaluated against the experimental data. The As-Manufactured simulations provided better estimates of the stage performance than the Design-Intent cases in terms of most performance metrics. Nonetheless, more detailed results still show opportunities for improvement. Despite a more accurate representation of the physical hardware, characterization of the impeller work input remains a challenge even for rigorously developed numerical models.

centrifugal compressor↗

Hybrid Thermally Efficient Core (HyTEC) Phase 1 3-Stage Compressor Rig Final Report - Unlimited Rights

The HyTEC Phase 1 3-Stage Compressor Rig project was conducted to mature and validate front-stage aerodynamic technologies in support of HyTEC Phase 2 and GEA’s Compact Core compressor. Building on the prior ERA Phase 2 Baseline Rig, GEA and NASA collaborated on the design and testing of the HyTEC rig, incorporating advanced technologies such as increased radius ratio, higher aerodynamic loading, and advanced casing treatment. The HyTEC test campaign leveraged similar design and instrumentation philosophy, test execution approach, and the same facility (NASA W-7) to enable clear comparison with the legacy ERA rig results. The HyTEC rig was designed to deliver benefits in efficiency, tip loading, operability, and aeromechanics, with success measured against defined TPMs that were anchored to the ERA baseline rig data.

Axial Compressors↗

Radial Compressors with Advanced Secondary Flow Paths for Extended Operating Range

Adequate range is a critical criterion in determining the proper compressor for a given application. In industries centering on turbochargers, range is often the dominant concern. Many times, significant sacrifices in performance are made at the design point in order to obtain enough range of the machine for the duty required. Active controls, the most common being inlet guide vanes (IGVs), can provide sufficient range extension while generating minimal degradation of performance at the design point. Such devices, however, add significant cost and complexity to the machine as they require an active control mechanism. Other devices, such as recirculating casing treatment (RCT), have the advantage of both cost and simplicity by virtue of their passive nature. They’ve seen widespread adoption in the turbocharger industry, though they are generally less effective than IGVs in extending range. A novel approach to extend compressor range through a passive method is proposed here. The method takes some inspiration from classical RCT applications in that it prompts recirculation at low flow rates and corresponding higher back pressures. This recirculation then occupies a portion of the primary cross-sectional passage area and confines the rest of the non-recirculating flow to a smaller area. This restriction forces a higher meridional velocity and a more favorable incidence angle at the impeller blade leading edge. The recirculation is accomplished by laying out an expanded secondary flow path at the rear of the impeller leading back to the inlet hub region. Vanes on the rear of the impeller disk provide just enough pressure rise to counter the induced pressure from the primary flow at the design point. This yields very low mass flow in the secondary path, a condition known as “shutoff” in the pump industry. At lower primary flow levels, and higher back pressures, the secondary flow is induced back to the impeller inlet setting up the recirculation region and pinching the primary flow. Various vane configurations and layouts in the secondary region are explained, and advantages and disadvantages of each are covered. The range extensions made possible by this method and the corresponding impact on performance is discussed.

compressors, extended operating range↗

Dynamic modeling of near isothermal compressor for Transcritical carbon dioxide cycle to support efficiency improvement

Compressors are the primary components of energy consumption in vapor compression systems, drawing considerable research effort to reduce carbon emissions and improve energy efficiency. This work presents an isothermal compressor that integrates the compression chamber with the gas cooler to achieve near-isothermal compression, resulting in up to 30% energy reduction compared to traditional isentropic compression, according to the experiment results. A detailed dynamic model for the isothermal compression cycle of carbon dioxide (CO 2 ) is first presented, coupled with a liquid-piston model for chamber design. The model is experimentally validated on a 3.5 kW prototype, yielding a 6.2% relative error in chamber pressure and a 0.5 K deviation in chamber temperature. The liquid piston exhibits reduced frictional heating and geometric adaptability relative to the mechanical piston. Leveraging these attributes, the study further evaluates approaches that enhance the heat transfer to achieve isothermal compression by increasing the effective heat transfer area during compression. As a result, simulations demonstrated up to a 5% improvement in the coefficient of performance over the baseline case through chamber design, providing guidelines for design of isothermal compression cycle.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

High‑performance cold‑climate heat pump using tandem compressors with and without vapor injection: Laboratory investigation and field demonstration

Cold‑climate air‑source heat pumps must maintain heating capacity and stable operation at low ambient temperatures for residential applications. This study adapts tandem single-speed compressors—proven in commercial systems —for residential CCHPs, integrating VI and validating performance across laboratory and extreme field conditions to achieve cold-climate targets. That is to achieve ≥75% of the rated heating capacity at −25.0 °C relative to 8.3 °C and heating coefficient of performance (COP) greater than 4.0 at 8.3 °C. Laboratory testing confirmed that both configurations met these targets while operating within acceptable discharge‑temperature limits. Relative to the non‑VI configuration, the VI system provided up to 15% higher heating capacity and up to 9% higher heating COP under identical conditions, yielding a 5.6–9.1% increase in heating seasonal performance factor (HSPF). Field tests in Ohio and Alaska, with minimum outdoor temperatures of −25.0 °C and −34.0 °C, respectively, showed stable operation, minimal supplemental heating (<3.2%), low defrost penalties, and consistent output. Tandem‑compressor architectures proves promising for cold-climate residential heating.

Hu, Yifeng [ORNL] (ORCID:0000000242875185)↗

Plasma-based prism compressor design for high-intensity laser pulses

A concept for a femtosecond pulse compressor based on underdense plasma prisms is presented. An analytical model is developed to calculate the spectral phase incurred and the expected pulse compression. A 2D particle-in-cell simulation verifies the analytical model. Simulated intensities ( ∼10 16 W/cm 2 ) were orders of magnitude higher than the damage threshold for conventional gratings used in chirped pulse amplification. Theoretical geometries for compact (tens of cm scale) compressors for 1, 10 and 100 PW power levels are proposed.

47 OTHER INSTRUMENTATION↗