Session: 13-01 Heat Transfer in Turbines

Submission Number: 174298

Exploration of Simulation Strategies for Modelling Conjugate Heat Transfer Across Thermal Barrier Coatings on Gas Turbine Blades 

Thermal Barrier Coatings (TBCs) are essential ceramic layers that insulate the underlying metal components from extreme hot combustion gases in gas turbines. This protection prevents thermal degradation, extends component lifespan, and critically, allows the engine to operate at higher temperatures for improved efficiency and power output.

Accurate simulation of TBCs on gas turbine blades is crucial for performance prediction and design optimization. While conventional Conjugate Heat Transfer (CHT) simulations for gas turbines have widely employed simplified contact resistance models for TBCs, these often lead to inaccuracies in heat transfer and unreliable temperature predictions on the underlying substrate metal. Higher fidelity TBC models are essential to more accurately predict blade temperatures for optimizing blade design and ultimately reducing costly physical testing.

In this paper, various simulation strategies for modelling conjugate heat transfer across TBCs on gas turbine blades are explored. The Siemens Energy Gas Turbine Demo Blade 5000FX is simulated in Simcenter STAR-CCM+ using three distinct TBC modelling strategies: (1) Contact Resistance Modelling, (2) 2D Shell Modelling, and (3) 3D Thin Mesh Modelling. A brief summary of the Simcenter STAR-CCM+ workflow for each strategy, including specific workflow optimizations is first presented. The three TBC modelling strategies are then compared and contrasted on their resulting solution accuracy and computational performance.

Finally, it is concluded that while 3D Thin Mesh Modelling offers the highest fidelity for detailed design evaluation, 2D Shell Modelling provides an optimal balance of accuracy and computational efficiency, significantly accelerating run times in Simcenter STAR-CCM+. These findings provide valuable guidance for TBC simulation methodology selection, streamlining design optimization and accelerating the development of more durable and efficient gas turbine engines.

Presenting Author: Siddhartha Gautham A V Siemens Digital Industry Software

Presenting Author Biography: Siddhartha Gautham A V, or Sid, is an Advanced Engineer within the Technology Application Group (TAG) at Siemens Digital Industries Software, India. He collaborates closely with development and project management teams to enhance the industrial applicability and suitability of the Siemens Simcenter software portfolio. His core focus areas within TAG include heat transfer applications, GPU-accelerated simulations, and whole engine modelling.
Prior to joining Siemens in 2022, Sid spent six years at Rolls-Royce Civil Aerospace, specializing in the thermo-fluid modelling of aviation gas turbine engines across various responsibilities. He holds a Master's degree in Thermal Engineering from the Indian Institute of Technology, Madras, and a Bachelor’s degree in Mechanical Engineering from GRIET, Hyderabad.
Outside of work, Sid cherishes time with his two-year-old daughter. When his schedule allows, he enjoys working out at the gym and console gaming.

Authors:

Siddhartha Gautham A V Siemens Digital Industry Software
Cassandra Carpenter Siemens Digital Industry Software
Charles Burnett Siemens Energy