An innovative multi hole film cooling concept for integrally woven SiC-SiC Wall Panels

1. Copyright © 2005 by ASME1
Proceedings of HT2005
2005 ASME Summer Heat Transfer Conference
July 17-22, 2005, San Francisco, California, USA
HT 2005-72037
Multi-hole Film Cooling with Integrally Woven SiC-SiC Ceramic Wall Panels
Jayesh M Mehta
TK Engineering, Cincinnati, OH.
jayesh.mehta@ae.ge.com
Garry Brown and Fengquan Zhong
Department Of Mechanical And
Aerospace Engineering,
Princeton University, Princeton
Dale Shouse and Craig Neuroth
AFRL, Dayton, OH.
Dave Marshall and Brian Cox
Rockwell Science Center
Thousand Oaks, CA
Abstract:
In the paper we have focused numerically on
coupled heat transfer for multi-hole cooling of an
integrally woven ceramic matrix composite combustor
liner numerically. In particular, through carefully
planned thought experiments we propose to expand
the current state-of-the-art design space for the
combustor liners to include shallow film injection
angles, very small diameter film holes, and a novel film
injection scheme that features opposing, staggered,
shallow film cooling jets. The numerical results
suggest that integrally woven SiC-SiC ceramic panels
featuring shallow film angles (~O (100
)), small hole
diameter (O (0.25 mm)), and opposed film jets yield
film effectivenesses that are significantly higher than
the current technology - super alloy film panels. This
has the potential for significant cooling air saving that
can be re-introduced in the combustor dome region
and result in lower NOx emissions.
Key Words:
Integrally Woven SiC-SiC CMC, Film Cooling,
Combustors, Emissions.
1.0 Introduction:
Continuous silicon carbide fiber reinforced
silicon carbide matrix (SiC-SiC) composites are
candidates for high temperature applications in the gas
turbine industry [1]. These composites offer a variety
of physical properties, such as, low coefficient of
thermal expansion, low density, and resistance to
thermal shock. Furthermore, they offer increased high
temperature stiffness, and strength properties
stemming from a variety of toughness mechanisms [2].
The high temperature potential of the integrally
woven SiC – SiC CMC also leads to several other
benefits in a combustor environment. For example,
compared to a conventional super alloy, a CMC liner
can withstand up to 1300 0
C. As a result, it requires a
significantly lower fraction of total cooling air where the
saved cooling air can now be re-introduced in the
combustor dome to affect a leaner combustion –
ensuing lower NOx emissions. In addition, the CO
emissions are lower due to reduced quenching in the
thinner film at the wall.
Figure 1 depicts the schematic of a two-skin
CMC structure that could form an annular wall of a
typical gas turbine combustor. As shown in the Figure,
the outer, colder skin is constructed of a conventional
super alloy while the inner - hotter skin and the
supporting pins are integrally woven SiC-SiC ceramic
fabrics. The integrally woven struts can also be
fabricated from super alloy. The details of the weaving
process and associated thermal and mechanical
properties can be found in Cox, Davis, Marshall, and
Yang [3], or Mehta, Shouse, Holloway, Cox, and
Marshall [4]. In Figure 2, we have schematically
described a simplified construct of an annular
combustor liner and the associated transport
processes. In this design, the outer skin is attached to

2. Copyright © 2005 by ASME2
the engine structure at the aft end, while the CMC
hotter skin is suspended from it through individually
spaced struts that are integrally woven with the CMC
skin. As the combustor temperature increases, the
outer skin grows at a rate that is different from the
inner-hotter skin whereby the mismatch in the thermal
growth of the two skins is absorbed by the compliant
pins.
From the heat transfer standpoint, the outer
skin facilitates impingement on the backside of the hot
skin while multi holes woven in the hot skin facilitate
film cooling. The hot skin could be as thin as 1 mm;
the intra-skin spacing between hot and cold liners
could be as narrow as 2 mm, while the outer skin
could be designed as a load bearing support structure
with its thickness being as high as 2 mm. A 1mm hot
skin thickness facilitates good conduction that is
enhanced by effective impingement as well as
convection in the narrow channel on the backside.
Mehta et al [5] have investigated transport
mechanisms associated with woven ceramics.
However, recently studies have appeared in the open
literature that focus on film cooling of these structures
[6]. In particular, an ability to weave multi-hole panels
with a large number of holes, shallow flow angles, and
smaller hole-to-hole spacing offers several
opportunities for developing innovative multi-hole film
cooling schemes that are only specific to ceramic
structures.
As a result, in the study we have focused on
assessing novel multi-hole cooling schemes for
integrally woven ceramics. In particular, we view this
paper as a collection of numerical thought
experiments that expand the current film cooling
design space to include integrally woven ceramic
structures.
L
h d
w
Combustion
gas
air
h
d
w
Hot Ceramic Liner
Cold metallic
impingement baffle
Metallic Pins
Figure 1 Schematic Of A Potential CMC
Combustor Liner Scheme
Film Cooling
Holes
air
Impingement Holes
L
h d
w
Combustion
gas
air
h
d
w
Hot Ceramic Liner
Cold metallic
impingement baffle
Metallic Pins
Figure 1 Schematic Of A Potential CMC
Combustor Liner Scheme
Film Cooling
Holes
air
Impingement Holes
Conduction
Combustor casing Fixed At One End
Cold Impingement Baffle And Holes
Hot CMC Combustor Liner
with Metallic pins And Normal Holes
Film Cooling Holes
Impingement Holes
Thermal Growth Mismatch
Between Impingement baffle
And Liner absorbed by
compliant metallic pins
T film, h gas,
η
Impingement,
Convection, and
Radiation
Figure 2 Detailed Configuration And basic HT mechanisms For a CMC Combustor Liner
Conduction
Combustor casing Fixed At One End
Cold Impingement Baffle And Holes
Hot CMC Combustor Liner
with Metallic pins And Normal Holes
Film Cooling Holes
Impingement Holes
Thermal Growth Mismatch
Between Impingement baffle
And Liner absorbed by
compliant metallic pins
T film, h gas,
η
Impingement,
Convection, and
Radiation
Conduction
Combustor casing Fixed At One End
Cold Impingement Baffle And Holes
Hot CMC Combustor Liner
with Metallic pins And Normal Holes
Film Cooling Holes
Impingement Holes
Thermal Growth Mismatch
Between Impingement baffle
And Liner absorbed by
compliant metallic pins
T film, h gas,
η
Impingement,
Convection, and
Radiation
Figure 2 Detailed Configuration And basic HT mechanisms For a CMC Combustor Liner

3. Copyright © 2005 by ASME3
Main Flow
Film Cooling Flow
Film Cooling Holes
CMC Plate
2.0 Film Cooling Research:
Lin et al [7] have presented a summary of
recent experimental studies in the area of adiabatic
film effectiveness. Most relevant among them refer to
investigations by Mayle and Camarata [8], and Sasaki
et al [9] who studied angled film cooling for a turbine
leading edge application. Both of them evaluated the
adiabatic film effectiveness for square as well as for
the staggered cooling pattern. Leger, Miron, and
Emido [10], recently investigated multi-hole film
cooling for a combustor liner. They concluded that hole
angle inclination and hole diameter have strong
influences on cooling effectiveness and cooling air
consumption. In particular, they demonstrated the
detrimental influence of too high a film hole angle and
the film hole diameter. The film hole angle controlled
the jet penetration into the boundary layer with the
higher angle causing the jet to mix more readily with
the hot gases. On the other hand, the larger hole
diameter with the same percentage open area results
in less effective film coverage.
In addition to the experimental studies, various
investigators have carried out numerous
Computational Heat Transfer studies over the past
several years. In one of the earlier studies on film,
cooling Mehta and Burrus [11], and Mehta [12] had
developed a simplified 2-D parabolic scheme,
featuring a Low-Re Turbulence model [13]. Evidently,
due to its parabolic 2-D nature, it could not handle
flows with increasingly adverse pressure gradients and
results featured limited accuracy. More recently,
Demuren, Rodi, and Schonung [14], have performed
3-D computations with injection from a single row of
holes. They considered non-isotropic turbulent
viscosities and diffusivities for closure and reached
good agreement with experimental data. However, Lin
and Shih [15] have reported results that are more
accurate. They used k-ω/SST turbulence model for the
closure of the ensemble-averaged governing
equations. Kumar and Mongia [16] recently evaluated
two turbulence models for multi-hole cooling on gas
turbine combustor liners. The first model by Sarkar
and So [17], seemed to match experimental data well
and the second model by Yang and Shih [18] provided
less accurate comparison.
With the advent of powerful microprocessors,
the Direct Numerical Simulation (DNS) of the
compressible Navier-Stokes equations is becoming a
reality for at least low Reynolds number (Reθ < 1000)
cooling systems. In one such study, Zhong and Brown
[6] have investigated a film cooling system operating at
a relatively low Reθ of 620. They also coupled the heat
transfer on both sides of multi-hole liner. In their
coupled numerical study, turbulent mixing was
modeled accurately with the DNS formulation. The
mean velocity and temperature profiles matched
reasonably well with their experimental data.
3.0 Uniqueness of the Present Study:
The current film cooling design space is
limited to either effusion cooling [18] in porous
materials or film cooling with large diameter holes (>
0.5 mm), large film injection angles (>200
), staggered
pattern, large mass blowing ratios (with an associated
large cooling flow requirement), and film injection in
the downstream direction. In general, manufacturing
processes, aerodynamic considerations or
complexities associated with laser drilling of these
holes impose these constraints on the current design
space.
With the advent of integrally woven film cooled
liners we propose to expand this design space to
include: smaller diameter holes (< 0.3 mm), shallower
film injection angles (< 200
), lower film jet velocities
(with associated lower cooling flow requirement), and
film injection that is in the upstream as well as in the
downstream directions.
Therefore, the thought experiments of this
study present a solution space that is particularly
applicable to thin, multi holed, woven ceramic liners of
future advanced gas turbine combustors.
Figure 3 Computational Domains for the
Numerical Model

4. Copyright © 2005 by ASME4
4.0 Numerical Studies:
Figure 3 depicts the domain of the numerical
simulations that includes the main flow channel, five
rows of film cooling holes, and a plenum that feeds
these holes. The inlet plane for the main flow was
located 20 hole diameters upstream of the first row of
holes, while the exit plane was positioned 50 hole
diameters downstream from the last row of holes. The
inlet and exit planes were assumed adiabatic, while
periodic boundaries were assumed for the planes in
the transverse directions. The Reynolds-Averaged
Navier Stokes (RANS), and energy equations were
discretized using a second-order upwind scheme, and
they were solved using CFX - 5[19]. The pertinent
turbulence model was the SMC-ω the Reynolds stress-
ω model, while the low-Re scalable wall-function [19]
provided the near-wall treatment.
4.1 Film Cooling Model Anchoring:
With the objective of anchoring the above
model for inlet velocity, turbulence, and grid
parameters, we had carried out numerical studies for
the test conditions of Leger, Miron, and Emidio [10]. In
particular, the following test conditions were simulated
for anchoring:
Mjet = 0.52,1.26,2.10; Th/Tc = 1.04, 1.10, and 1.25 [1].
In the above, Mjet is the mass blowing ratio,
while Th and Tc are the free stream temperatures of the
hot and cold streams, respectively. In addition, the
cooling hole diameter was 0.508 mm while the film
angle was varied from 30 degrees to 150 degrees from
horizontal. The film-cooling pattern featured a
staggered arrangement with hole-to-hole spacing
(axial as well as transverse) of six diameters.
In Figure 4, we have compared the film
effectiveness for three angles of injection; 300
, 900
(normal), and 1500
(upstream). As shown in the Figure,
the numerical predictions not only compare well with
the measured effectiveness, but replicate the trends
reasonably well too. For 300
, and 900
injections, the
effectiveness shows very little difference, if any, in the
intra-multi hole zone. However, downstream of the
multi-hole zone the film effectiveness drops
Figure 4 Model Comparisons with Experimental
Data of Ref [10].
sharply for normal injection, compared to 300
.
Moreover, for 1500
injection, the film effectiveness
accumulates rapidly in the intra-multi hole zone, but
then it drops off rather sharply in the downstream
direction.
Figure 5 depicts the variation of the film
effectiveness with blowing ratio. As shown in the
Figure, the numerical model replicates the
effectiveness values as well as the trends reasonably
well.
We must point out that that the above
anchoring of the model was achieved with about 1.1
million nodes. This has resulted in grid resolution (in
the boundary layer) as follows: ∆x+
= 9.2, and ∆z+
=
8.7, while in the normal direction there were 16 grid
lines below y+
= 15. Furthermore, for these study the
inlet turbulence intensity was fixed at 6%, while the
turbulence length scale was fixed at 12% of the main
flow channel height.
Influence Of Hole Angle
Model Anchoring with Ref. 10
0.62
0.66
0.7
0.74
0.78
0.82
0.86
0.9
-40 0 40 80 120 160
x (mm) - Distance From First Row Of Holes
FilmEffectiveness
30 (Ref 10)
90(Ref 10)
150(Ref 10)
30(CF-X)
90(CF-X)
150(CF-X)

5. Copyright © 2005 by ASME5
Figure 5 Model Comparisons with Experimental
Data of Ref [10].
4.2 Film Cooling for Woven Ceramics:
Most of the work cited above have reported
film cooling effectiveness for film cooling parameter
ranges as outlined in Table 1. For a woven ceramic
liner these boundaries can now be relaxed to include
an extended range as shown in the Table.
As the Table shows the woven ceramic
fabrics, extend the current design space dramatically
with attendant benefits in film cooling effectiveness. In
addition, the last item, the film injection direction also
deserves a special mention here. As Figure 4 depicts,
the upstream injection (α = 1500
) results in rapid
accumulation of the film effectiveness in the multi-hole
zone, but then it drops off sharply in the downstream
region. On the contrary, for the 300
downstream
injections, the film accumulation is slow but then it
drops off more gradually also. With the woven ceramic
CMC, it is now possible to devise a film-cooling
scheme
Figure 6 A Schematic of the CMC Weave with
Opposed Jets
that leverages on the above experience. As shown in
Figure 6, the integral weaving now allows one to place
two staggered rows of holes such that the emerging
jets oppose each other in the film sub-layer. This
arrangement offers the following advantages over the
conventional film injected in the stream wise direction.
1. For the same mass-blowing ratio, two
opposing jets result in lower momentum.
Consequently, the jet penetration into the
boundary layer is limited.
2. In its limit of the resultant near-normal
injection into the main flow and smaller hole-
to-hole spacing, this arrangement resembles
more closely transpiration cooling, and
2. Bore cooling is more effective due to shorter
conduction path between two adjacent rows of
holes.
Table 1 Range Of Film Cooling Parameters
Parameter Conventional Woven
cooling Ceramic
scheme Liner
1 Injection Hole: diameter - mm > 0.50 0.20 to 0.50
2 Injection Hole: Angle - Degrees 20 to 90 10 to 20
3 Injection Hole: Length - mm 2 to 6 6 to 12
4 Injection Hole: length/Diameter 4 to 12 24 to 30
5 Hole - to - Hole Spacing 6 to 8 4 to 6
(Multiple of Diameter)
6 Film Injection Direction Downstream Opposed jets
Influence Of Mass Blowing Ratio
0.52
0.62
0.72
0.82
0.92
-40 0 40 80 120
Distance From First Row Of Holes
x (mm)
Effectiveness
Mjet = 0.42 (ref 10)
Mjet = 0.42 (CF-X)
Mjet = 3.14 (Ref 10)
Mjet = 3.14 (CF-X)

6. Copyright © 2005 by ASME6
(b) Alpha = 90 deg
(c) Alpha = 170 deg
(a) Alpha = 10 deg
305 K 280 K 245 K
(b) Alpha = 90 deg
(c) Alpha = 170 deg
(a) Alpha = 10 deg
305 K 280 K 245 K
Influence Of Hole Angle
0.1
0.3
0.5
0.7
-40 -20 0 20 40 60 80 100
x (mm) - Distance From First Row Of Holes
FilmEffectiveness
10 deg
90deg
adiabatic
170 deg
4.3 Influence of Hole Angle Inclination:
For the same aero-thermal combustor
operating conditions, and same cooling flow, the hole
angle influences the cooling effectiveness through the
following interactive mechanisms:
1. The shallower angle results in longer
cooling passages through the liner
resulting in enhanced bore cooling, and
2. The shallower angle allows the cooling
flow to develop fully before it exits into the
hot gas path. Its subsequent mixing with
hot boundary layer occurs without much
penetration in the boundary layer.
Figure 7 depicts the computed span-wise
averaged variation of film effectiveness for different
film angles. Within the multi-hole region the film angle
(In the downstream direction) has little effect, if any.
However, downstream of the last row of cooling holes,
the film associated with 100
angles persists over a
longer distance, and provides significantly better
cooling compared to 900
.
Figure 7 Influence of Film Angle on Film
Effectiveness
In fact, for upstream injection (film angle 1700
), the film
builds up rapidly in the multi-hole region and then it
drops downstream. In addition, Figure 7 also depicts
the adiabatic film effectiveness, corresponding to 100
film injection for comparison. As shown, the conductive
film effectiveness is significantly higher for a highly
conductive thin ceramic wall than that for an adiabatic
wall. As we view this in the context of a thin ceramic
liner versus a thicker super alloy liner, the results
clearly suggest that the ability to use highly
conductive, thinner ceramic liner is one of the key
benefits of these liners.
Figure 8 shows temperature contours near the
liner surface for three film injection angles: 100
, 900
,
and 1700
. These contours are in a plane that is three
grid lines above the plate, and represent temperature
variations at y+
~ 5. As shown in Figure 8(a), the cold
film remains attached nearly to the wall (For 100
injection) where the film jet penetration is minimal
yielding better film effectiveness. On the other hand, at
900
, Figure 8(b), and at 1700
, Figure 8(c), the film jet
penetrates into the boundary layer and disrupts it -
causing lower film effectiveness. In addition, a rapid
drop of film effectiveness downstream of the film-
cooled zone for 1700
film injection is quite evident.
Figure 8 Temperature Contours for Three Film
Angles
4.4 Influence of the Hole Geometry and Pattern:
These influences for a metallic liner are well
established. A staggered hole pattern yields better-
averaged film effectiveness compared to the square
array [11]. In addition, a larger hole diameter as well
as closely spaced holes (i.e. Increased Open Area)
yield better film effectivenesses for a given blowing
ratio. However, implicit in the last two observations is
the fact that for the same blowing ratio, a larger hole
diameter or smaller hole-to-hole spacing would require
more cooling flow for the same cooling surface area. In
contrast, an ability to weave cooling holes with
diameters as small as 0.25 mm (Compared to the
current practice of holes 0.50 mm or greater) provides
an opportunity to develop film-cooling designs that are
at least as robust if not more effective than the current
practice. In the following numerical experiment, we
have compared film effectiveness for the smaller hole
(0.25 mm); with the larger hole (0.50 mm) for the same
percentage open area and the same cooling flow.

7. Copyright © 2005 by ASME7
For a non-adiabatic, ceramic liner - the
cumulative result is better film cooling effectiveness
which is caused by: the larger blowing ratio, and
improved bore cooling. A potential drawback of such a
scheme is the attendant higher-pressure drop across
the liner due to high film efflux velocities, and the
larger number of holes.
Figure 9 Benefit of a Ceramic liner over a
conventional liner for the same cooling flow
The resulting film cooling effectiveness for a
woven ceramic is compared with that for the current
technology metallic liner in Figure 9. As shown, a
metallic liner (with its current design parameter space,
Table 1), results in film cooling effectiveness
accumulating at a faster pace in the in the multi-hole
region compared to the scheme with smaller holes for
the ceramic liner.
4.5 Cooling with Opposed jets:
The above results demonstrate that the use of
integrally woven ceramics leads to a film cooling
design that replicates transpiration cooling, while
maintaining the benefits associated with conventional
metallic film cooling. The transpiration cooling with its
low hole-to-hole spacing, high blowing ratio with lower
cooling flow, and high bore cooling effectiveness is
probably the most effective scheme. However, it
suffers from high-pressure losses for a given cooling
flow. In addition, laser drilling of thousands of tiny
holes in a liner is prohibitive from a cost standpoint.
On the other hand, the integrally woven
ceramic liners allow one to achieve some of the
aerodynamic features of transpiration cooling without
associated pressure and cost penalties. One such
scheme is illustrated in Figure 6. As shown in the
Figure, two adjacent rows are configured in a
staggered manner with each row featuring jets that are
opposed. Recall from Figure 7 that an upstream facing
jet helps accumulate film effectiveness in the multi-
hole zone better than the downstream facing jet. In
contrast, the downstream facing film persists for longer
distances on the surface. In addition, the staggered
nature of the scheme, the smaller diameter holes, and
more effective bore cooling associated with thin,
shallow angled film holes result in better cooling
effectiveness.
Figure 10 Benefits Of opposed jets
Figure 10 depicts the variation of film
effectiveness for a ceramic liner with opposed film
cooling compared to that for the film injected into the
downstream as well as upstream direction only.
Figure 11 Temperature Contours for
Downstream, Upstream, and Opposed Jets
The opposed jet configuration results in the
rapid accumulation of the film in the film cooled zone
with very little, if any, deterioration of the film in the
downstream region.
A ceramic Liner Benefit Over A Conventional metallic Liner
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
-40 0 40 80
x (mm) - Distance From First Row Of Holes
FilmEffectiveness
Ceramic Liner
Metallic Liner
Influence Of Opposed Jets
0.1
0.3
0.5
0.7
-40 0 40 80
x (mm) - Distance From First Row Of Holes
FilmEffectiveness
10 deg
Opposed
170 deg
(b) Alpha = 170 deg
(c) Alpha = 10 and 170 deg
Opposed
(a) Alpha = 10 deg
305 K 280 K 245 K
(b) Alpha = 170 deg
(c) Alpha = 10 and 170 deg
Opposed
(a) Alpha = 10 deg
305 K 280 K 245 K

8. Copyright © 2005 by ASME8
Figure 11 shows the corresponding
temperature contours on the liner surface for
downstream injection (Figure 11(a)), for upstream
direction (Figure 11(b)), and opposed film injection,
Figure 11(c). As shown in the figure, two opposed jets
help to build up the film boundary layer rapidly in the
initial film-cooling region, followed by a more gradual
reduction in the effectiveness downstream.
5.0 Concluding Remarks:
In this paper, we present preliminary results of
numerical thought experiments that delineate the
behavior of film cooling parameters for an integrally
woven SiC-SiC ceramic combustor liner. The major
observations can be summarized as follows.
Woven ceramic liners with smaller hole
diameter and shallow film angles have the potential to
provide a film cooling effectiveness that is better than
the current metallic liner. In particular, small diameter
film cooling with opposed jets, in the limit, behave like
transpiration cooling though with reduced pressure
drop across the liner. In addition, the thin ceramic
liners with their higher effective conductance result in a
uniform temperature through the liner – which
potentially may result in significantly reduced thermal
stresses.
6.0 Acknowledgement:
This work was carried out under AFRL sponsored
SBIR (Small Business Innovative Research) grant:
AFRL – F33615-03-C-2342. The authors wish to thank
Drs. Dale Shouse and Mel Roquemore for their
support and continuing interest in the development of
the ceramic technology for combustors.
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9. Copyright © 2005 by ASME9
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