Search

Carbon particles, a primary component of diesel engine emissions, cause persistent erosion in the exhaust piping system, inevitably leading to performance degradation. This erosion can result in reduced fuel economy and increased emissions. The effects of three key parameters including solid particle size, turbine U/C operating conditions and rotational speed on the erosion characteristics of the flow channels of a radial turbine for vehicle diesel engine applications and their impact on performance were investigated through numerical simulations in the study. The findings indicate that larger particle size and higher rotational speed can significantly lead to the higher erosion rate density of the volute channel and casing wall surfaces. Reducing U/C does not substantially affect the distribution of erosion rate density. Centrifugal force will play an important role in the variation of erosion distribution characteristics. Compared to U/C, the other two key parameters are sensitive factors affecting turbine performance degradation. Under the same condition for operating 5000 h, 10 μm particles cause a 7.5-fold increase in efficiency loss change rate compared to 0.5 μm particles. The efficiency loss at 140 krpm is 16 times greater than that at 40 krpm. [ABSTRACT FROM AUTHOR]

The deposition of combustion residues in the nozzle ring (NR) of a turbocharger turbine stage changes the NR geometry significantly in a random manner. The resultant complex and highly asymmetric geometry induces low engine order (LEO) excitation, which may lead to resonance excitation of rotor blades and high cycle fatigue (HCF) failure. Therefore, a suitable prediction workflow is of great importance for the design and validation phases. The prediction of LEO excitation is, however, computationally expensive as high-fidelity, full annulus CFD models are required. Previous investigations showed that a steady-state computational model consisting of the volute, the NR, and a radial extension is suitable to reduce the computational costs massively and to qualitatively predict the level of LEO forced response. In the current paper, the aerodynamic excitation of 69 real contaminated NRs is analyzed using this simplified approach. The results obtained by the simplified simulation model are used to select 13 contaminated NR geometries, which are then simulated with a model of the entire turbine stage, including the rotor, in a transient time-marching manner to provide high-fidelity simulation results for the verification of the simplified approach. Furthermore, two contamination patterns are analyzed in a more detailed manner regarding their aerodynamic excitation. It is found that the simplified model can be used to identify and classify contamination patterns that lead to high blade vibration amplitudes. In cases where transient effects occurring in the rotor alter the harmonic pressure field significantly, the ability of the simplified approach to predict the LEO excitation is not sufficient. [ABSTRACT FROM AUTHOR]

The global push to reduce greenhouse gas emissions has led to the ban of high global warming potential (GWP) refrigerants in the refrigeration sector, prompting the adoption of low-GWP alternatives. However, as regulations are expected to tighten, technologies like the Reverse Brayton cycles (RBC) are emerging. RBCs can operate with safe fluids and can reach very low temperatures through compressions, regeneration, and expansion, requiring only electricity. This research presents results from an RBC equipped with a radial turbine using natural air (R-729), a hazard-free fluid with zero ozone depletion potential (ODP) and emission potential. The cycle utilizes automotive components, offering a cost-effective, high-tech solution. The study evaluates the cycle COP at a design point and performs an exergetic analysis at 173K. Using a thermal and fluid dynamic model of the cycle, the critical components of the cycle influencing the COP are identified, and potential improvements are explored. [ABSTRACT FROM AUTHOR]

In the present study, a 100 kW organic Rankine cycle is suggested to recover heat energy from commercial ships. A radial-type turbine is employed with R1233zd(E) and back-to-back layout. To improve the performance of an organic Rankine power system, the efficiency of the turbine is significant. With the conventional approach, the optimization of a turbine requires a considerable amount of time and involves substantial costs. By combining design of experiments, an artificial neural network, and Latin hypercube sampling, it becomes possible to reduce costs and achieve rapid optimization. A radial basis neural network with machine learning technique, known for its advantages of being fast and easily applicable, has been implemented. Using such an approach, an increase in efficiency greater than 1% was achieved with minimal design changes at the first and second turbines. [ABSTRACT FROM AUTHOR]

The turbine is a crucial component in harnessing ocean thermal energy (OTE), and the impact of the nozzle on turbine performance is significant. TC-profile nozzles have been proven to operate efficiently in air turbines under high-temperature and high-pressure conditions. However, their performance in ocean thermal energy conversion (OTEC) turbines using organic working fluids (low-temperature and low-pressure) still requires further research. Therefore, we focused on a practical 100 kW OTEC turbine equipped with different types of TC-profile nozzles. Three-dimensional numerical models were established, and the simulation results demonstrated that the turbine efficiency using TC-3A was generally higher than other turbines, reaching an optimal efficiency of 89.4%. The turbine can operate efficiently at deviations from the design point of + 10.27% or −31.39% in mass flow rate, ±3°C in inlet temperature, and + 20% or −11.43% in rotor speed during off-design conditions. The results revealed the adaptability of TC-3A nozzles to the OTEC environment and their excellent off-design performance. The study could provide valuable guidance and references for the application of TC-type nozzles in the field of OTEC turbines. [ABSTRACT FROM AUTHOR]

In this paper, a 100 kW radial inflow turbine is designed for an ocean thermal energy conversion (OTEC) power plant based on the organic Rankine cycle (ORC) with ammonia as the working fluid. Based on one-dimensional (1D) and three-dimensional computational fluid dynamics (3D-CFD) modeling, the mechanical structure design, static and modal analyses of the turbine and its components are carried out to investigate its mechanical performance. The results show the stress and strain distribution in the volute, stator and rotor, and their maximum values appear, respectively, at the inlet cutout, the tip of the stator outlet and the connection position between the rotor and the shaft. After optimization, all the stresses in the above components are below the allowable values. The frequencies from the first order to the sixth order of the rotor and whole turbine were obtained through modal analysis without prestress and under prestress. The maximum frequency of the rotor and whole turbine is 707.75 Hz and 40.22 Hz, both of which are far away from the resonance frequency range that can avoid resonance. Therefore, the structure of the designed turbine is safe, feasible and reliable so as to better guide actual production. [ABSTRACT FROM AUTHOR]

In response to the continually increasing thermal load caused by the rising gas temperature in the inlet of radial-flow turbines, this paper proposes the use of axial hole air-entraining cooling to cool the turbine shaft and turbo wheel back-disc. The cooling effect of this technique, as well as its influence on the aerodynamic performance of turbines, were investigated through numerical simulations. The results demonstrate that the axial hole air-entraining cooling technique can significantly improve the local cooling efficiency of the turbine back-disc. Under a blowing ratio of 0.25 %, the local cooling efficiency increased by 154 %, and the temperature decreased by up to 233 K. The maximum temperature on the surface of the turbine shaft at the floating bearing location decreased significantly, thus reducing the coking risk of the lubricating oil. When the blowing ratio was within 0.5 %, the impact of this cooling technique on the overall turbine performance was negligible. [ABSTRACT FROM AUTHOR]

The deposition of combustion residues in the nozzle ring (NR) of a turbocharger turbine stage changes the NR geometry significantly in a random manner. The resultant complex and highly asymmetric geometry induces low engine order (LEO) excitation, which may lead to resonance excitation of rotor blades and high cycle fatigue (HCF) failure. Therefore, a suitable prediction workflow is of great importance for the design and validation phases. The prediction of LEO excitation is, however, computationally expensive as high-fidelity, full annulus CFD models are required. Previous investigations showed that a steady-state computational model consisting of the volute, the NR, and a radial extension is suitable to reduce the computational costs massively and to qualitatively predict the level of LEO forced response. In the current paper, the aerodynamic excitation of 69 real contaminated NRs is analyzed using this simplified approach. The results obtained by the simplified simulation model are used to select 13 contaminated NR geometries, which are then simulated with a model of the entire turbine stage, including the rotor, in a transient time-marching manner to provide high-fidelity simulation results for the verification of the simplified approach. Furthermore, two contamination patterns are analyzed in a more detailed manner regarding their aerodynamic excitation. It is found that the simplified model can be used to identify and classify contamination patterns that lead to high blade vibration amplitudes. In cases where transient effects occurring in the rotor alter the harmonic pressure field significantly, the ability of the simplified approach to predict the LEO excitation is not sufficient.

The proper design of a Concentrated solar power (CSP) plant and the associated thermal energy storage requires a careful analysis of the yearly expected irradiance and environmental conditions. System simulations based on accurate components models allow the prediction of the performance of the plant and the analysis of the components interactions. The simulations of various scenarios provide information that will help tuning the design of the components to improve the performance of the whole system at design and off-design conditions. In this paper, the focus is set on the radial turbine expander which is one of the most important component. Classical system simulation approaches use map based performance model for the turbine. This require to generate the performance map either with meanline models, CFD simulations or experiments. This is not very convenient when iterating on the system design and if the actual turbine does not exist yet. In this work, a meanline model for radial inflow turbine operating with real gas has been implemented in MODELICA language for the first time to the authors’ best knowledge. This turbine model has been coupled with the available CSP sCO2 Brayton cycle model in MODELON ThermalPower library. A parametric study on a virtual test bench show the turbine performances for various rotational speed and inlet guide vane angle. The study focus then on the performance prediction of on and off design of the system with a 8 MW turbine obtained with a simple preliminary design calculation. The investigations showed that for the varying load conditions in the solar plant system, an improved operating point has been identified by adjusting the rotational speed and the inlet guide vane angle. Future work will focus on the use such system model with multi objective meta heuristic optimization.

Organic Rankine cycle (ORC) is an effective technology to harness low-grade energy. Turbine, as a key component of ORC, takes advantages of its high efficiency and compact size compared with other expanders. Currently, developing suitable turbines with a high performance and a low cost is one of the bottlenecks for wide applications of various ORCs. In this context, technical progress on radial inflow turbines (RITs), axial turbines (ATs), and radial outflow turbines (ROTs) is introduced, and loss models used in the preliminary design are compared, especially for small-scale ORCs. RIT is recommended for medium and small ORCs with an expansion pressure ratio of <10. The power outs and rotational speeds of the designed RITs spanned the ranges of 9.3–684 kW and 3000–114,000 r/min with an efficiency of 56.1–91.75%. In comparison, the power outputs and speeds of ATs were 3–2446 kW and 3000–91,800 r/min with an efficiency of 63–89.1%. AT is suitable for large-scale ORCs with a power output of greater than hundreds of kW. However, AT with impulse stages is feasible for small-scale ORCs when the pressure ratio is high, and the mass flow rate is small. The power outputs of the designed ROTs were relatively small, at 10–400 kW with a speed of 7200–42,700 r/min and an efficiency of 68.7–85%. For organic working fluids with a large expansion pressure ratio, ROT might be employed. Conventional mean-line models may neglect the effects of supersonic flow, which will be encountered in many ORC turbines. Therefore, adequate models for supersonic expansion loss and shock loss need to be added. Meanwhile, a proper multivariable optimization algorithm such as a gradient-based or stochastic search method should be selected. Finally, the challenges and potential research directions are discussed. The outcomes can provide some insights for the development of ORC turbines and the optimization of ORC systems. [ABSTRACT FROM AUTHOR]

The organic Rankine cycle (ORC) is an efficient technology for electricity generation from low- and medium-temperature heat sources. In this type of power cycle, the radial inflow turbine is the option usually selected for electricity generation. As a critical ORC component, turbine performance markedly affects the efficiency of the system. Therefore, the challenge is to model the behavior of the radial inflow turbine operating with organic fluids for heat recovery applications. In this context, various groups of fluids are highlighted in the scientific literature, including R-123, R-245fa, and R-141b, which are the fluids used in this research. Since little research has focused on the turbine efficiency effect on the power cycle design and analysis, this study presents an analysis of a radial inflow turbine based on a mathematical model of a one-dimensional design of the turbine. From this analysis, geometric, thermal, and operating parameters were determined, as well as volute, stator, and rotor losses. For this purpose, an algorithm was implemented in MATLAB to calculate the one-dimensional parameters of the turbine. Using these parameters, a 3D model of the turbine was designed in ANSYS-CFX, with performance curves of each projected turbine under design and off-design conditions. The numerical results suggest that the isentropic efficiency of all the proposed turbines under design conditions can surpass 75%. Additionally, the findings indicate that different design conditions, such as specific speed, pressure ratio, and turbine size, can affect the efficiency of radial inflow turbines in ORC systems. [ABSTRACT FROM AUTHOR]

The efficiency of hybrid electric vehicles may be substantially increased if the energy of exhaust gases, which do not complete the expansion inside the cylinder of the internal combustion engine, is efficiently recovered using a properly designed turbo-generator and employed for vehicle propulsion. Previous studies, carried out by the same authors of this work, showed a potential hybrid vehicle fuel efficiency increment up to 15% employing a 20 kW turbine on a 100 HP-rated power thermal unit. The innovative thermal unit proposed here is composed of a supercharged engine endowed with a properly designed turbo-generator, which comprises two fundamental elements: an exhaust gas turbine expressly designed and optimized for the application, and a suitable electric generator necessary to convert the recovered energy into electric energy, which can be stored in the on-board energy storage system of the vehicle. In this two-part work, the realistic efficiency of the innovative thermal unit for hybrid vehicles is evaluated and compared to a traditional turbocharged engine. In Part 1, the authors presented a model for the prediction of the efficiency of a dedicated radial turbine, based on a simple but effective mean-line approach; the same paper also reports a design algorithm, which, thanks to some assumptions and approximations, allows fast determination of the right turbine geometry for a given design operating condition. It is worth pointing out that, being optimized for quasi-steady power production, the exhaust gas turbine here considered is quite different from the ones commonly employed for turbocharging applications; for this reason, and in consideration of the required power size, such a turbine is not available on the market, nor has its development been previously carried out in the scientific literature. In this paper, Part 2, a radial turbine geometry is defined for the thermal unit previously calculated, employing the design algorithm described in Part 1; the realistic energetic advantages that could be achieved by the implementation of the turbo-generator on a hybrid propulsion system are evaluated through the performance prediction model under different operating conditions of the thermal unit. As an overall result, it was estimated that, compared to a reference traditional turbocharged engine, the turbo-compound system could gain vehicle efficiency improvement between 3.1% and 17.9%, according to the output power delivered, with an average efficiency increment of 10.9% evaluated on the whole operating range. [ABSTRACT FROM AUTHOR]

In this work, a new two-dimensional method is presented for turbine volute design. In this method, the continuity equation, energy equation, free vortex equation, and streamline equation are employed to solve the velocity field and to generate the volute profile. The physical model and mathematic solution to the governing equations are described in detail. A new volute for a turbocharger turbine is generated using this method and compared with the original, well-designed baseline volute. Different turbine operating conditions, including equal and unequal admission cases, were studied by CFD to compare turbine aerodynamic performance using the new and baseline volutes. The simulation results show that the efficiency of the new volute is about 0.4%–0.6% higher than the baseline under equal admission conditions. It is found that the improvement in turbine performance is mainly due to the more reasonable A/R distribution, which reduces the losses in the turbine. This work demonstrates that the proposed new method provides an effective way for radial turbine volute design, and can quickly create high performance volutes. [ABSTRACT FROM AUTHOR]

Internal combustion engine (ICE) exhaust gases provide a high amount of energy which is partially lost to the environment. Such energy can be recovered with a turbocharger turbine or other after-treatment device. As the engine exhaust flow varies not only with the engine load but also with the opening and closing of the exhaust valves, a proper matching between the engine and the turbine should be established to maximize the recovery of waste energy. That is why a twin-scroll or dual turbocharging system is implemented, especially in multi-cylinder engines. Such systems require a very complex pipeline to eliminate the interference of the exhaust pulses between the adjacent cylinder ignitions. In this study, the two-stage, multi-channel turbine system was investigated for two different rotor geometries: the old, high-performance rotor A and the smaller but more modern rotor B, which was scaled to match rotor A. Both geometries were compared at three different turbine speeds and variable turbine geometry (VTG) vane positions. It was found that the two-stage turbine system with rotor B geometry provided an 8% higher total efficiency than rotor A due to the lower flow losses within the rotor passage. [ABSTRACT FROM AUTHOR]

Aiming at the high-efficiency OTEC application, a 30 kW radial-inflow turbine using ammonia was constructed via the one-dimensional design. In addition, a 3D CFD simulation was carried out to research the turbine performance. Furthermore, the effects of blade tip clearance on the flow characteristic in turbine were elucidated and the turbine performance under the off-design conditions was examined. It is indicated that the performance of the designed turbine is satisfactory with a theoretical isentropic efficiency of 85.2% under the design condition. The leakage flow encounters the scraping flow after leaving the tip clearance, forming the vortexes in the cross-section of the flow passage, which decreases the turbine efficiency, and the best ratio of blade tip clearance to inlet blade height is suggested to be 0.04–0.06. When the rotational speeds deviated from the design value, the vortexes appear in the flow passage of the turbine, resulting in non-negligible impact loss of blade and the consequent efficiency reduction. At the design rotational speed, the turbine shows a good adaptability to the inlet temperature variations with the inlet temperature varying from T 0 = 296K to T 0 = 304K. When the inlet pressure increases, the rotational speed corresponding to the maximum efficiency is also increased. [ABSTRACT FROM AUTHOR]

In the present study, a 100 kW organic Rankine cycle is suggested to recover heat energy from commercial ships. A radial-type turbine is employed with R1233zd(E) and back-to-back layout. To improve the performance of an organic Rankine power system, the efficiency of the turbine is significant. With the conventional approach, the optimization of a turbine requires a considerable amount of time and involves substantial costs. By combining design of experiments, an artificial neural network, and Latin hypercube sampling, it becomes possible to reduce costs and achieve rapid optimization. A radial basis neural network with machine learning technique, known for its advantages of being fast and easily applicable, has been implemented. Using such an approach, an increase in efficiency greater than 1% was achieved with minimal design changes at the first and second turbines.

To address the increasing interest towards more environmentally friendly naval transportation and the introduction of IMO2020 restrictions on pollutant emissions onboard ships, the present work details the preliminary design of a mini gas turbine engine, i.e., a gas turbine engine with an output power up to 5 MW, for onboard energy generation. In comparison to conventional propulsion systems, gas turbine units benefit from known compactness, which can be further enhanced by employing single-stage uncooled radial machines, according to similar works in the field. As such, the present paper aims to set up a complete procedure that allows a reliable and fast (i.e., requiring a limited computational effort) preliminary design of one-stage centrifugal compressors and radial turbines operating at a high pressure ratio via the use of classical one-dimensional theory. The aerodynamic design outputs in terms of forces and torques are then used to perform a preliminary mechanical design of the shaft by means of a one-dimensional finite element model with commercial software to estimate the corresponding shaft line stress. Despite some necessary geometrical and modeling simplification of the design problem, which results in the unavailability of detailed information on individual components, the employed procedure nevertheless allows a comprehensive overview of the possibilities in terms of maximum machine performance achievable at an early design stage with the associated limited computational requirements. The design procedure and the geometry achieved for the application are presented along with aerodynamic and structural results. [ABSTRACT FROM AUTHOR]

The air-management system of a proton exchange membrane fuel cell (PEMFC) is responsible for supplying the fuel cell stack with ambient air at appropriate conditions. The compressor of the air-management system can be partly driven by utilizing the fuel cell exhaust gas in a turbine. The fuel cell exhaust is partially or fully saturated with water vapor. When the exhaust gas is expanded in the turbine, supersaturation occurs. This leads to the nucleation of droplets and their subsequent growth by condensation. This study provides an overview and understanding of the various phenomena caused by condensation and liquid water in the turbine of a PEMFC air-management system. The basis for this work is previously published numerical simulations that focused on individual aspects of the above phenomena. The present work revisits these results and puts them in context to provide a comprehensive understanding. Important phenomena are the effects of condensation on turbine performance through phase change losses, release of latent heat and thermal throttling. In addition, the released latent heat offers a power potential for downstream turbine stages. Through these effects, condensation can also impact the entire air-management system. However, condensation may occur unevenly, causing a circumferential asymmetry of the turbine outflow. Liquid water in the turbine can lead to droplet erosion, corrosion, and water-induced damage. In summary, it is essential to consider condensation and liquid water when developing turbines for PEMFC air-management systems. [ABSTRACT FROM AUTHOR]

This work presents the development and application of a machine learning model to predict the unsteady performance of a turbocharger radial turbine subject to on-engine pulsating flow conditions. The model proposed, based on a fully connected neural network, predicts the instantaneous turbine torque and circumferentially-averaged relative inflow angle when given, as only inputs, the total pressure and temperature pulses and the time derivative of the total pressure pulse upstream of the turbine.The training data set for the model is obtained from an experimentally-validated Reynolds-averaged Navier–Stokes model and consists of various operating conditions characterized by different pulse amplitudes and frequencies. Heat transfer effects are neglected by the use of adiabatic boundary conditions while the rotational speed of the rotor is otherwise maintained fixed. Based on the results obtained, the model is shown capable of accurately predicting the turbine torque and local properties of the flow, such as the relative inflow angle, with a high degree of accuracy (coefficient of determination larger than 0.98). At first, the model is tested for both interpolation and extrapolation conditions. Given a training data set constituted by only three pulses characterized by different amplitudes, the model accurately predicts the turbine performance both for conditions inside and outside the range of amplitudes of the training data set. Lastly, the model is trained with a larger data set, including both variations of the pulse amplitude and frequency, in order to predict the performance of the turbine subject to a more general pulse shape. The error indicators show an improvement with respect to the extrapolation case due to the larger size of the training data set, showing also a great capability of the model to predict the unsteady performance of the turbine for a more general pulse shape. The model represents a fast and efficient approach for predicting the unsteady turbine performance as compared to more complex experimental set-ups and time-consuming 3D numerical simulations and a valid alternative to the more common 0D-1D models.

The widespread trend of pursuing higher efficiencies in radial turbochargers led to the prompting of this work. A 3D-printed model of the static parts of a radial variable geometry turbine, the vaned nozzle, and the volute, was developed. This model was up-scaled from the actual reference turbine to place sensors and characterize the flow around the nozzle vanes, including the tip gap. In this study, a computational model of the scaled-up turbine was carried out to verify the results in two ways. For this model, firstly compared with an already validated CFD turbine model of the real device (which includes a rotor), its operating range was extended to different nozzle positions, and we checked the issues with rotor–stator interactions as well as the influence of elements such as the screws of the turbine stator. After showing results for different nozzle openings, another purpose of the study was to check the effect of varying the clearance over the tip of the stator vanes on the tip leakage flow since the 3D-printed model has variable gap height configurations. [ABSTRACT FROM AUTHOR]

• A jet impingement cooling technology for radial turbines was proposed. • The temperature distribution on the surface of a rotating turbine was measured using an IR camera. • The wall temperature of the turbo wheel could be significantly reduced by consuming acceptable mass flow rates of the coolant. • The temperature distribution periodically fluctuates under the combined effects of cooling, rotation, and thermal inertia. Increasing the inflow temperature of a turbine is an effective approach for enhancing the thermal efficiency of devices operating in the Brayton cycle, such as micro-gas-turbines and waste heat recovery systems. However, elevated temperatures also pose a significant risk of thermal fatigue failure. This paper presents an experimental investigation of impingement cooling for radial turbines, aiming to achieve high cooling performance with a simple structure. High-frequency infrared thermal imaging technology was employed to measure temperature distribution in the turbine rotor under various operational conditions. The results indicate that jet-impingement cooling can substantially reduce the solid temperature of the radial turbine, with a maximum temperature reduction of approximately 44 K achieved by consuming the coolant with ṁ re = 5%. Increasing the mass flow rate of the coolant consistently lowers the rotor temperature; however, an increase in rotational speed results in higher thermal inertia, thereby diminishing the cooling enhancement effect. The temperature distribution on the turbine surface exhibits significant periodic characteristics over time, leading to temperature fluctuations of 5 K to 30 K at the hub position. Furthermore, the cooling performance is further enhanced near the jet hole on the back-disc side of the inducer region, while the tip side closer to the exducer obtains better cooling effects. [ABSTRACT FROM AUTHOR]

The organic Rankine cycle (ORC) is an efficient technology for electricity generation from low- and medium-temperature heat sources. In this type of power cycle, the radial inflow turbine is the option usually selected for electricity generation. As a critical ORC component, turbine performance markedly affects the efficiency of the system. Therefore, the challenge is to model the behavior of the radial inflow turbine operating with organic fluids for heat recovery applications. In this context, various groups of fluids are highlighted in the scientific literature, including R-123, R-245fa, and R-141b, which are the fluids used in this research. Since little research has focused on the turbine efficiency effect on the power cycle design and analysis, this study presents an analysis of a radial inflow turbine based on a mathematical model of a one-dimensional design of the turbine. From this analysis, geometric, thermal, and operating parameters were determined, as well as volute, stator, and rotor losses. For this purpose, an algorithm was implemented in MATLAB to calculate the one-dimensional parameters of the turbine. Using these parameters, a 3D model of the turbine was designed in ANSYS-CFX, with performance curves of each projected turbine under design and off-design conditions. The numerical results suggest that the isentropic efficiency of all the proposed turbines under design conditions can surpass 75%. Additionally, the findings indicate that different design conditions, such as specific speed, pressure ratio, and turbine size, can affect the efficiency of radial inflow turbines in ORC systems.

Organic Rankine cycle (ORC) is an effective technology to harness low-grade energy. Turbine, as a key component of ORC, takes advantages of its high efficiency and compact size compared with other expanders. Currently, developing suitable turbines with a high performance and a low cost is one of the bottlenecks for wide applications of various ORCs. In this context, technical progress on radial inflow turbines (RITs), axial turbines (ATs), and radial outflow turbines (ROTs) is introduced, and loss models used in the preliminary design are compared, especially for small-scale ORCs. RIT is recommended for medium and small ORCs with an expansion pressure ratio of

Adopting back-disk impingement cooling is an effective way to cool small radial turbines. The circumferential uneven flow field caused by the volute leads to an uneven distribution of cooling efficiency on the back disk. To improve the uneven distribution, the arrangement of impinging jet holes on the back disk was studied. The numerical simulation results for conjugated heat transfer (CHT) showed that impingement cooling can effectively cool the high-temperature region of the back disk. Due to the influence of the volute, there is a local low-efficiency cooling zone near the volute tongue of the volute. Changing the distribution of the jet holes can effectively reduce local high-temperature zones and improve uneven local cooling. Compared with other schemes, using a 40° phase angle for the seventh hole has the best cooling effect on the back disk, and the uniformity of the cooling efficiency is improved by 18.5 %. After the cooling fluid flows into the mainstream channel of the turbine, the turbine efficiency is reduced by the cooling fluid, and the effect of impingement cooling on the turbine expansion ratio is negligible. [ABSTRACT FROM AUTHOR]

A 2 MW gas turbine engine has been developed for the distributed power market. This engine features a 7:1 pressure ratio radial inflow turbine. In this paper, influences of various geometry features are investigated including turbine tip and backface clearances. In addition to the clearances, the effects of the inducer deep scallop and exducer rounded trailing edge are investigated. Finally, geometric features associated with a split rotor (separate inducer and exducer) are studied. These geometry features are investigated numerically using CFD. Part of the numerical results is also compared to experimental data acquired during engine test to validate the CFD results. Results indicated that for this specific turbine, the influences of the exducer radial tip clearance, inducer axial tip clearance, and even scalloped blade backface clearance all have negligible influences on performance. In all cases, 1% increase in clearance only attributes to approximately a 0.1% lower efficiency. This finding is very different from former published papers with low pressure ratio turbines, indicating different flow physics apply for a turbine with a relatively high-pressure ratio. [ABSTRACT FROM AUTHOR]

The efficiency of hybrid electric vehicles may be substantially increased if the energy of exhaust gases, which do not complete the expansion inside the cylinder of the internal combustion engine, is efficiently recovered using a properly designed turbo-generator and employed for vehicle propulsion. Previous studies, carried out by the same authors of this work, showed a potential hybrid vehicle fuel efficiency increment up to 15% employing a 20 kW turbine on a 100 HP-rated power thermal unit. The innovative thermal unit proposed here is composed of a supercharged engine endowed with a properly designed turbo-generator, which comprises two fundamental elements: an exhaust gas turbine expressly designed and optimized for the application, and a suitable electric generator necessary to convert the recovered energy into electric energy, which can be stored in the on-board energy storage system of the vehicle. In this two-part work, the realistic efficiency of the innovative thermal unit for hybrid vehicles is evaluated and compared to a traditional turbocharged engine. In Part 1, the authors presented a model for the prediction of the efficiency of a dedicated radial turbine, based on a simple but effective mean-line approach; the same paper also reports a design algorithm, which, thanks to some assumptions and approximations, allows fast determination of the right turbine geometry for a given design operating condition. It is worth pointing out that, being optimized for quasi-steady power production, the exhaust gas turbine here considered is quite different from the ones commonly employed for turbocharging applications; for this reason, and in consideration of the required power size, such a turbine is not available on the market, nor has its development been previously carried out in the scientific literature. In this paper, Part 2, a radial turbine geometry is defined for the thermal unit previously calculated, employing the design algorithm described in Part 1; the realistic energetic advantages that could be achieved by the implementation of the turbo-generator on a hybrid propulsion system are evaluated through the performance prediction model under different operating conditions of the thermal unit. As an overall result, it was estimated that, compared to a reference traditional turbocharged engine, the turbo-compound system could gain vehicle efficiency improvement between 3.1% and 17.9%, according to the output power delivered, with an average efficiency increment of 10.9% evaluated on the whole operating range.

Internal combustion engine (ICE) exhaust gases provide a high amount of energy which is partially lost to the environment. Such energy can be recovered with a turbocharger turbine or other after-treatment device. As the engine exhaust flow varies not only with the engine load but also with the opening and closing of the exhaust valves, a proper matching between the engine and the turbine should be established to maximize the recovery of waste energy. That is why a twin-scroll or dual turbocharging system is implemented, especially in multi-cylinder engines. Such systems require a very complex pipeline to eliminate the interference of the exhaust pulses between the adjacent cylinder ignitions. In this study, the two-stage, multi-channel turbine system was investigated for two different rotor geometries: the old, high-performance rotor A and the smaller but more modern rotor B, which was scaled to match rotor A. Both geometries were compared at three different turbine speeds and variable turbine geometry (VTG) vane positions. It was found that the two-stage turbine system with rotor B geometry provided an 8% higher total efficiency than rotor A due to the lower flow losses within the rotor passage.

In view of the development status of high-reliability and low-cost cooling technology for radial turbine of micro-gas turbine or vehicle turbocharger, the impingement cooling technology of the radial turbine back disc was proposed, and the improvement of the cooling efficiency and thermal stress of the turbine back disc was numerically simulated. The results show that the impingement cooling technology can greatly improve the cooling efficiency of the turbine back disc and reduce the stress level. When the relative cooling flow is 1.0%–3.0%, the average cooling efficiency of the lower part of the turbine back disc is increased by 258%–486% compared with no cooling, which can reduce the thermal stress at the fillet of the back disc by 140–216 MPa. Both the average cooling efficiency and the fillet stress of the back disc increase slightly as the relative position of the jet hole moves outward. When the relative cooling flow is controlled within 2.0%, the effect of this cooling technology on the performance of the turbine can be ignored. [ABSTRACT FROM AUTHOR]

To address the increasing interest towards more environmentally friendly naval transportation and the introduction of IMO2020 restrictions on pollutant emissions onboard ships, the present work details the preliminary design of a mini gas turbine engine, i.e., a gas turbine engine with an output power up to 5 MW, for onboard energy generation. In comparison to conventional propulsion systems, gas turbine units benefit from known compactness, which can be further enhanced by employing single-stage uncooled radial machines, according to similar works in the field. As such, the present paper aims to set up a complete procedure that allows a reliable and fast (i.e., requiring a limited computational effort) preliminary design of one-stage centrifugal compressors and radial turbines operating at a high pressure ratio via the use of classical one-dimensional theory. The aerodynamic design outputs in terms of forces and torques are then used to perform a preliminary mechanical design of the shaft by means of a one-dimensional finite element model with commercial software to estimate the corresponding shaft line stress. Despite some necessary geometrical and modeling simplification of the design problem, which results in the unavailability of detailed information on individual components, the employed procedure nevertheless allows a comprehensive overview of the possibilities in terms of maximum machine performance achievable at an early design stage with the associated limited computational requirements. The design procedure and the geometry achieved for the application are presented along with aerodynamic and structural results.

The air-management system of a proton exchange membrane fuel cell (PEMFC) is responsible for supplying the fuel cell stack with ambient air at appropriate conditions. The compressor of the air-management system can be partly driven by utilizing the fuel cell exhaust gas in a turbine. The fuel cell exhaust is partially or fully saturated with water vapor. When the exhaust gas is expanded in the turbine, supersaturation occurs. This leads to the nucleation of droplets and their subsequent growth by condensation. This study provides an overview and understanding of the various phenomena caused by condensation and liquid water in the turbine of a PEMFC air-management system. The basis for this work is previously published numerical simulations that focused on individual aspects of the above phenomena. The present work revisits these results and puts them in context to provide a comprehensive understanding. Important phenomena are the effects of condensation on turbine performance through phase change losses, release of latent heat and thermal throttling. In addition, the released latent heat offers a power potential for downstream turbine stages. Through these effects, condensation can also impact the entire air-management system. However, condensation may occur unevenly, causing a circumferential asymmetry of the turbine outflow. Liquid water in the turbine can lead to droplet erosion, corrosion, and water-induced damage. In summary, it is essential to consider condensation and liquid water when developing turbines for PEMFC air-management systems.

Radial turbines used in automotive fuel cell turbochargers operate with humid air. The gas expansion in the turbine causes droplets to form, which then grow through condensation. The associated release of latent heat and decrease in the gaseous mass flow strongly influence the thermodynamics of the turbine. This study aims to investigate these phenomena. For this purpose, the classical nucleation theory and Young's growth law are integrated into a Euler-Lagrange approach. The main advantages of this approach are the calculation of individual droplet trajectories and a full resolution of the droplet spectrum. The results indicate an onset of nucleation at the blade tip and in the tip gap, followed by nucleation over the entire blade span, depending on the humidity at the turbine inlet. With a saturated turbine inflow, condensation causes the outlet temperature to rise to almost the same level as at the inlet. In addition, condensation losses reduce the efficiency and the latent heat released by condensation leads to significant thermal throttling. [ABSTRACT FROM AUTHOR]

In order to suppress the tip leakage loss and increase the isentropic efficiency in a radial turbine with low aspect ratio blade, a new coupling flow control technology including casing groove and NACA blade profile is proposed and optimized numerically. The coupling effects of casing groove size LS, groove number Numslot, maximum thickness location of profile MLT and leading parameter of profile LP on isentropic efficiency of a radial turbine are obtained with Design of Experiment (DOE) and response surface model. A genetic optimization is achieved and the coupling flow control mechanism is revealed. Complex variation of isentropic efficiency is observed with the coupling effect of groove size and groove number, and maximum isentropic efficiency variation of 0.6% is obtained with the increase of LS when Numslot is 3. The coupling effect between LS and LP, is also significantly influenced by groove number. The lower limit of LP for maximum isentropic efficiency is decreased from 7 to 3 with the increase of groove number. The optimization result illustrates that the isentropic efficiency can be increased by 0.9% at design point when the LS, Numslot, MLT and LP are 0.8 mm, 2, 0.1, and 0.8 respectively. A maximum isentropic efficiency increment of 2.0% is also found when total pressure ratio is 2.1. The optimal casing groove forms a flow opposite to the tip leakage flow to suppress the impact range of the secondary flow near suction surface. At the same time, the optimal NACA profile also decreases the tip leakage velocity near trailing, suppresses the tip leakage vortex generation, and reduces the trailing edge loss. [ABSTRACT FROM AUTHOR]

The work arose initially from an interest in design of radial turbine for small scale gas turbine applications typically suitable for distributed power generation system which demands compact installations. The paper describes an investigation in to the design and performance of radial inflow turbines having a capacity of 25kW at 1,50,000 rpm. First a non-dimensional design philosophy is deduced to design a turbine rotor. The design approach is largely one dimensional along with empirical correlations for estimating losses used to obtain the main geometric parameters of turbine. From the proposed design approach, turbine total-to-static efficiency is calculated as 84.91% which is reasonably good. After that a modified vortex design procedure is developed to derive the non-dimensional volute geometry as a function of azimuth angle for actual flow condition. Once a specific turbine is designed, the flow is analyzed in detail using a three-dimensional Computational Fluid Dynamics (CFD) code in order to assess how accurately the performance is predicted by simple meanline analysis. Finally, a fully instrumented experimental setup is developed. The experimental investigations have been carried out to study the temperature and pressure distribution across turbine and total-to-static efficiency is calculated. The limitations of surging and choking in compressor as well as in the bearings to take up load at such high speed has allowed the tests to be conducted upto 70000 rpm only, with turbine inlet temperatures ranging from 900 K to 1000 K and a pressure ratio upto 1.79, which developed power in the range of 1.69 kW to 10.22 kW. The uncertainty bands are in order of ±13.76% to ±3.12%. It is observed that the CFD results are in good agreement with test results at off design condition. CFD models over predicted total to static efficiency by order of 7-8% at lower speed. These deviations are reduced as turbine runs close to design point.

The widespread trend of pursuing higher efficiencies in radial turbochargers led to the prompting of this work. A 3D-printed model of the static parts of a radial variable geometry turbine, the vaned nozzle, and the volute, was developed. This model was up-scaled from the actual reference turbine to place sensors and characterize the flow around the nozzle vanes, including the tip gap. In this study, a computational model of the scaled-up turbine was carried out to verify the results in two ways. For this model, firstly compared with an already validated CFD turbine model of the real device (which includes a rotor), its operating range was extended to different nozzle positions, and we checked the issues with rotor–stator interactions as well as the influence of elements such as the screws of the turbine stator. After showing results for different nozzle openings, another purpose of the study was to check the effect of varying the clearance over the tip of the stator vanes on the tip leakage flow since the 3D-printed model has variable gap height configurations.

A radial turbine is one of the vital components of a helium liquefaction plant. The design of a turbine becomes critical due to its compact size and high‐speed configuration. In this study, numerical optimization has been performed for the three‐dimensional steady flow of helium gas in the radial inflow turbine of a helium liquefaction plant at a nominal condition. The mean line design is an appropriate method to obtain the approximate results. The computational fluid dynamics simulation algorithm is adopted in this study to reach the final results and Ansys CFX is used for the simulation. From the analysis, it has been reported that the number of rotor blades was overestimated in the mean line design. Performance parameters like total‐ to‐static efficiency and velocity ratio were also found to be optimum numerically under a preliminary design condition. Finally, power of 1.7 kW was achieved at total‐to‐static efficiency of 71.4%. The deviation in analytical and numerical results is within ±10% for performance as well as geometric parameters. [ABSTRACT FROM AUTHOR]

During normal operation, radial turbines may work in off-design conditions. Off-design conditions may be characterised by very low expansion ratios, very high expansion ratios, very low rotational speeds or very high rotational speeds. All of these cases are difficult to characterise experimentally due to high experimental uncertainties or a lack of capabilities in the system feeding pressurised air to the turbine. Also, there are two- and three-dimensional computational fluid dynamics simulations at these operating points but could not be accurate enough due to high turbulence effects, flow detachment and shock wave generation. With a lack of high-quality data, experimental or computational, to fit the reduced-order turbine models used in zero- and one-dimensional engine simulations, there are large uncertainties associated to their results in off-design conditions. This work develops an experimental facility able to characterise the internal flow of radial turbine stators in terms of pressure and velocity fields at off-design and regular working conditions. The facility consists of an upscaled model of a radial turbine volute and stator fed with air in pressure- and temperaturecontrolled conditions, so different sensors can be used inside it with the least amount of flow disturbance. The different restrictions considered in the design of the upscaled model are presented, and their effects in the final experimental apparatus capabilities are discussed. A preliminary comparison between computational fluid dynamics simulations and experimental data shows encouraging results. [ABSTRACT FROM AUTHOR]

Estimating correctly the turbine acoustics can be valuable during the engine design stage; in fact, it can lead to a more optimised design of the silencer and aftertreatment, as well as to better prediction of the scavenging effects. However, obtaining the sound and noise emissions of radial turbocharger turbines with low computational costs can be challenging. To consider these effects in a time-efficient manner, the acoustic response of single-entry radial turbines can be characterised by means of acoustic transfer matrices that change with the operating conditions. Exploiting the different timescales of the acoustic phenomena and the change in the operating point of the turbine, lookup tables of acoustic transfer matrices can be computed. Then, the obtained characterisation can be used in mean-value engine models. This article presents a method for generating these lookup tables by means of fast one-dimensional simulations of thoroughly validated fidelity, in terms of both acoustics and extrapolation capabilities. Due to the inherent behaviour of radial turbines, the number of computations needed to fill the lookup tables is relatively small, so the method can be used as a simple preprocessing phase before mean-value simulation campaigns. [ABSTRACT FROM AUTHOR]

This paper addresses the problem of the design optimization of turbomachinery components under thermo-mechanical constraints, with focus on a radial turbine impeller for turbocharger applications. Typically, turbine components operate at high temperatures and are exposed to important thermal gradients, leading to thermal stresses. Dealing with such structural requirements necessitates the optimization algorithms to operate a coupling between fluid and structural solvers that is computationally intensive. To reduce the cost during the optimization, a novel multiphysics gradient-based approach is developed in this work, integrating a Conjugate Heat Transfer procedure by means of a partitioned coupling technique. The discrete adjoint framework allows for the efficient computation of the gradients of the thermo-mechanical constraint with respect to a large number of design variables. The contribution of the thermal strains to the sensitivities of the cost function extends the multidisciplinary outlook of the optimization and the accuracy of its predictions, with the aim of reducing the empirical safety factors applied to the design process. Finally, a turbine impeller is analyzed in a demanding operative condition and the gradient information results in a perturbation of the grid coordinates, reducing the stresses at the rotor back-plate, as a demonstration of the suitability of the presented method. [ABSTRACT FROM AUTHOR]

This paper presents results of strain gauge measurements, which have been carried out on a full-scale turbocharger test rig. Rotational speed of the turbocharger was ramped up and down through four preliminary anticipated rotor-blade resonances, with a known combination of main order of excitation and corresponding nodal diameter. An analysis of the transient data is presented. An investigation of spectra with high frequency resolutions, centered on individual blade resonance points in time, is presented. In contrast to former research, all blades resonate at the same point in time and thus at the same resonance frequency, if the excitation corresponds to a nodal diameter of zero. Strain data from the shaft is used to support findings, which, in other publications, often solely rely on strain data from individual blades. [ABSTRACT FROM AUTHOR]

A turbocharger's radial turbine has a strong impact on the fuel consumption and transient response of internal combustion engines. This paper summarizes the efforts to design a new radial turbine aiming at high efficiency and low inertia by applying two different optimization techniques to a parametrized CAD model. The first workflow wraps 3D fluid and solid simulations within a meta-model assisted genetic algorithm to find an efficient turbine subjected to several constraints. In the next step, the chosen turbine is re-parametrized and fed into the second workflow which makes use of a gradient projection algorithm to further fine-tune the design. This requires the computation of gradients with respect to the CAD parametrization, which is done by calculating and combining surface sensitivities and design velocities. Both methods are applied successfully, i.e., the first delivers a well-performing turbine, which, by the second method, is further improved by 0.34% in efficiency. [ABSTRACT FROM AUTHOR]

This paper presents the design procedure and analysis of a radial turbine design for a mid-scale supercritical CO 2 power cycle. Firstly, thermodynamic analysis of a mid-range utility-scale cycle, similar to that proposed by NET Power, is established while lowering the turbine inlet temperature to 900 ∘ C in order to remove cooling complexities within the radial turbine passages. The cycle conditions are then considered for the design of a 100 MW t h power scale turbine by using lower and higher fidelity methods. A 510 mm diameter radial turbine, running at 21,409 rpm, capable of operating within a 5% range of the required cycle conditions, is designed and presented. Results from computational fluid dynamics simulations indicate the loss mechanisms responsible for the low-end value of the turbine total-to-total efficiency which is 69.87%. Those include shock losses at stator outlet, incidence losses at rotor inlet, and various mixing zones within the passage. Mechanical stress calculations show that the current blade design flow path of the rotor experiences tolerable stress values, however a more detailed re-visitation of disc design is necessitated to ensure an adequate safety margin for given materials. A discussion of the enabling technologies needed for the adoption of a mid-size radial turbine is given based on current advancements in seals, bearings, and materials for supercritical CO 2 cycles. [ABSTRACT FROM AUTHOR]

Radial inflow turbine and nozzle among the other components of the cryogenic turboexpander has a significant effect on the efficiency of the system. This study proposes an effective one-dimensional design approach of a radial turbine by introducing different loss correlations. The methodology also describes the effect of non-dimensional design variables on the performance of the turbine. These variables (blade speed ratio, pressure ratio, hub and shroud to turbine inlet radius ratio) undergo artificial intelligence-based model to predict their optimal range for better efficiency and power output of the turbine. Based on these optimal ranges, two turbine and nozzle models are generated. The results of the optimized configuration show that the turbine total-to-static efficiency and power output are higher by 4% and 18.9% respectively as compared to the existing literature. Thereafter, the three-dimensional computational fluid dynamics (CFD) analysis is carried out to visualize the fluid flow and thermal characteristics at different inlet temperatures in the flow passage using ANSYS CFX®. The study also focuses to identify the flow separation zone, tip leakage flow, vortex formation, secondary losses and its reasons at different spans of the turbine. An experimental platform is also established to validate the CFD results of a case study. The experimental results show that the mass flow rate and rotational speed has major effect on temperature drop and isentropic efficiency of the turboexpander. The study highlights the importance of the design methodology, the estimation capability of artificial intelligence models, the experimental techniques and benchmarking model for numerical analysis at different cryogenic temperature. [ABSTRACT FROM AUTHOR]

The present article attempts to describe the behavior of wastegated turbines under various steady and pulsating flow conditions. For this, meanline and one-dimensional numerical codes including appropriate modeling approaches for wastegated turbines have been developed with the FORTRAN language. These codes were validated against experiments with an established test rig at the National School of Engineers of Sfax. The discharge coefficient map of the wastegate was determined with a developed correlation built from experiments, and it was served as an input to the developed codes for interpolations during computation. This correlation is based on a two-dimensional non-linear dose-response fitting relationship instead of classical polynomial function which is one novelty of the article in addition to the one-dimensional modeling methodology. The normalized root mean square error (NRMSE) of both cycle-averaged efficiency and mass flow parameter (MFP) remains below 2% which confirms the validity of the proposed calculation approach. The results indicated a large deviation in the turbine performance under pulsating flow conditions compared to the steady state ones. The shape of the hysteresis loop of the turbine efficiency remains unchanged toward the variation of the wastegate valve angle at the same pulse frequency. The mass flow hystereses loop area is decreased by around 50% as the pulse frequency increases from 33 up to 133.33 Hz. An increase of less than 1% of the cycle-averaged efficiency has been reported when the bypass flow through the wastegate increases. The fluctuation of the efficiency is decreased by 1.5% when the wastegate valve becomes fully opened under the whole range of the pulse frequency. [ABSTRACT FROM AUTHOR]

Radial turbines used in automotive fuel cell turbochargers operate with humid air. The gas expansion in the turbine causes droplets to form, which then grow through condensation. The associated release of latent heat and decrease in the gaseous mass flow strongly influence the thermodynamics of the turbine. This study aims to investigate these phenomena. For this purpose, the classical nucleation theory and Young’s growth law are integrated into a Euler–Lagrange approach. The main advantages of this approach are the calculation of individual droplet trajectories and a full resolution of the droplet spectrum. The results indicate an onset of nucleation at the blade tip and in the tip gap, followed by nucleation over the entire blade span, depending on the humidity at the turbine inlet. With a saturated turbine inflow, condensation causes the outlet temperature to rise to almost the same level as at the inlet. In addition, condensation losses reduce the efficiency and the latent heat released by condensation leads to significant thermal throttling.

The design of optimal organic Rankine cycle (ORC) systems requires the simultaneous identification of the optimal cycle architecture, operating conditions and working fluid, whilst accounting for the effect of these parameters on expander performance. In this paper, a novel method for predicting the design-point efficiency of a radial turbine is developed, which can predict the achievable efficiency based only on the thermodynamic conditions. This model is integrated into an optimization framework in which the working fluid is modeled using the Peng-Robinson equation of state and the fluid parameters (i.e., critical temperature) are simultaneously optimized alongside the cycle conditions. This framework can evaluate recuperated and transcritical cycles, whilst heat-transfer area requirements are estimated based on representative overall heat-transfer coefficients. For a range of heat sources, a single-objective optimization is first completed in which power output is maximized, which is then followed by a multi-objective optimization in which the trade-off between power output and total heat-transfer area is investigated. It is demonstrated that the optimization framework can simultaneously optimize the working fluid and cycle parameters, and identify whether a subcritical or transcritical cycle, with or without a recuperator, is best suited for a particular application, whilst accounting for the effect of these variables on the expander performance. This information is critical to identify optimal cycle configurations and working fluids that result in the best thermodynamic performance, yet exist in the design space in which feasible turbines can be designed. It is found that the optimal critical temperature does not vary significantly between different cycle architectures, and is not affected by whether a single or multi-objective optimization is completed. However, including the expander performance model results in significantly different cycles to optimal thermodynamic cycles.

The paper presents a comprehensive numerical and experimental analysis of the Tesla turbine. The turbine rotor had 5 discs with 160 mm in diameter and inter-disc gap equal to 0.75 mm. The nozzle apparatus consisted of 4 diverging nozzles with 2.85 mm in height of minimal cross-section. The investigations were carried out on air in subsonic flow regime for three pressure ratios: 1.4, 1.6 and 1.88. Maximal generated power was equal to 126 W and all power characteristics were in good agreement with numerical calculations. For each pressure ratio, maximal efficiency was approximately the same in the experiment, although numerical methods proved that efficiency slightly dropped with the increase of pressure ratio. Measurements included pressure distribution in the plenum chamber and tip clearance and temperature drop between the turbine’s inlet and the outlet. For each pressure ratio, the lowest value of the total temperature marked the highest efficiency of the turbine, although the lowest static temperature was shifted towards higher rotational speeds. The turbine efficiency could surpass 20% assuming the elimination of the impact of the lateral gaps between the discs and the casing. The presented data can be used as a benchmark for the validation of analytical and numerical models.

In turbocharger design, the accurate determination of thermally induced stresses is of particular importance for life cycle predictions. An accurate, transient, thermal finite element analysis (FEA) of turbocharger components requires transient conjugate heat transfer (CHT) analysis. However, due to the vastly different timescales of the heat transfer mechanisms in fluid and in solid states, unsteady CHT simulations are burdened by high computational costs. Hence, for design iterations, uncoupled CFD and FEA approaches are needed. The quality of the uncoupled thermal analysis depends on the local heat transfer coefficients (HTC) and reference fluid temperatures. In this paper, multiple CFD-FEA methods known from literature are implemented in a numerical model of a turbocharger. In order to describe the heat transfer and thermal boundary layer of the fluid, different definitions of heat transfer coefficients and reference fluid temperatures are investigated with regard to calculation time and accuracy. For the transient simulation of a long heating process, the combination of the CFD-FEA methods with the interpolation FEA approach is examined. Additionally, a structural-mechanical analysis is conducted. The results of the developed methods are evaluated against experimental data and the results of the extensive unsteady CHT numerical method. [ABSTRACT FROM AUTHOR]