The goal of this research was to establish an extensive database for typical engine hardware with a film-cooled first stage vane, which represents the foundation for future turbomachinery film cooling modeling and component heat transfer studies. Until this time, such a database was not available within the gas turbine industry. Accordingly, the study focuses on determination of the local heat flux for the airfoil and endwall surfaces of the vane row of a fully-cooled turbine stage. The measurements were performed at the Ohio State University Gas Turbine Laboratory using the Turbine Test Facility. The full-scale rotating 1 and 1/2 turbine stage is operated at the proper corrected engine design conditions: Flow Function (FF), corrected speed, stage Pressure Ratio (PR), and temperature ratios of gas to wall and gas to coolant. The primary measurements of temperature, pressure, and heat flux are repeated for different vane inlet temperature profiles and different vane cooling flows to establish an understanding of the influence of film cooling on local heat transfer. Double-sided Kapton heat-flux gauges are used for heat-flux measurements at different span locations along the airfoil surfaces and along the inner endwall. The cooling scheme consists of numerous cooling holes located on the endwalls, at the airfoil leading edge, on the airfoil pressure and suction surfaces, and at the trailing edge, resulting in a fully cooled first stage vane. The unique film-cooled endwall heat transfer data demonstrated in contour plots reveals insight to the complex flow behavior that is dominant in this region, which becomes even more complicated with the addition of coolant.
Varying profile shapes resulted in significant heat transfer variations in a growing fashion towards the trailing edge region, which increased in magnitude when there is no coolant supply. The largest cooling effect is observed on 5% span pressure surface and at the inner endwall region. Heat transfer decreases from tip towards hub with addition of cooling. However, a similar decrease is not observed at the inner endwall region by doing so, which suggests excess coolant once beyond an optimum blowing ratio. Cooling flow rate and temperature profile shape affect the distributions on the airfoil surface very similarly, the latter observed more clearly at the endwall region. The vane outer cooling effect is comparable to the combined coolant effect at all surfaces, while no impact of purge flow is observed. Aligning the hot streaks with the vane leading edge lowered heat transfer compared to mid-passage alignment at the mid-span suction surface and through the endwall passage, and increased it at the endwall exit, while the pressure surface is found to be insensitive to this switch. Comparison with a previous research program with the un-cooled version of the vane gave good agreement on the pressure surface and at the endwall, but significantly lower heat transfer on the suction surface due to ingestion of the hot flow through the cooling holes when there is no cooling.