Control of Shroud Leakage Loss and Windage Torque in a Low-Pressure Turbine Stage

As new aeroengine architectures move to larger diameter fans and rotors, the associated increase in weight will need to be counterbalanced by lighter, more compact, and more efficient low-pressure turbines (LPT). Efficiency gains in LPTs can be achieved by reducing the losses associated with the shroud leakage flows. Flow control studies on the topic have traditionally focused on reducing the mixing loss, which constitutes a considerable proportion of the total loss. Nonetheless, increasing engine speeds are driving additional gains obtained by also targeting the reduction of windage losses. Developing a flow control solution with the dual objective of reducing over-tip cavity mixing and windage losses has not previously been attempted. This is a challenge due to conflicting flow control requirements and geometric constraints. Reducing windage loss generally requires increasing the swirl-ratio of the leakage flow, while reducing mixing loss requires reducing this ratio to match that of the main gas path. The current work proposes a novel flow control solution to successfully achieve this purpose through the emerging technology of additive manufacturing. The successful flow control concept was developed through numerical simulation, printed using an additive manufacturing process, and validated in a purpose-built rig. Experiments and computations were consistent with a cumulative reduction in cavity windage of 16%. The FCC is estimated to increase the mechanical efficiency of the turbine stage in isolation by 1%.