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This paper presents the predicted, as well as final experimental results for the design of an automatically optimized non-axisymmetric endwall and as such, attempts to close the loop between design and practice, providing additional information to other groups involved in the design of endwall contours. The contours designed in this investigation were manufactured using the direct laser sintering rapid prototyping method and installed and tested in the low-speed, 112-stage turbine at the CSIR’s test turbine facility (TTF) in Pretoria, South Africa. Steady-state 5-hole pressure probe traverses were used to characterize the performance and flow profiles upstream, immediately downstream and in a quasi-“mixed-out” sense downstream of the rotor. In addition to the datum (annular) case, both the computed as well as experimental results were compared to the corresponding results generated for a “generically” contoured rotor which was originally designed for a linear cascade test case, but one which used the same blade profile to the current case. The results show that in general both sets of contours performed well, although the added emphasis on flow correction for the contours produced in this investigation resulted in slightly worse performance in terms of loss at the rotor exit (X3) but greatly improved performance in terms of the efficiency and flow angles at the “mixed-out” (X4) measurement plane.

Non-axisymmetric endwalls in turbine stages have shown to be a robust method to improve the performance of turbines in both power generation and aero-derivative applications. Non-axisymmetric endwalls target the control of secondary flows and are designed using detailed computational fluid dynamics coupled with a variety of optimisation algorithms and utilising a number of objective functions according to the engine company or researcher's preference. These numerical predictions are often backed up by detailed measurements in linear and annular cascades and later proven in full-scale engine tests. Relatively little literature is available describing their performance in rotating test rigs or at conditions other than design, apart from that of the authors. This study comprehensively revisits the low-speed, model turbines used in the earlier study, replacing all of the 5-hole probe data with more accurate results and additional hot-film measurements. These results together with computational fluid dynamics solutions are used to show the success of the method across a large incidence range and to compare to earlier cascade results for a similar endwall and blade profile to establish the usefulness of cascade testing in this application. In addition, a comparison to two other off-design studies is made. Results indicate that the endwalls successfully improve the rotor total isentropic efficiency at all test conditions and that the improvement increases with increased turning in the blade row, from 0.5% to 1.8% across the incidence range. The results also compare well to the estimation of isentropic efficiency improvement that can be drawn from the cascade testing which stands at 1.55%.

As concern for the environment increases, so does the desire to reduce emissions and improve fuel efficiency. One avenue being investigated in the aerospace industry is the reduction in losses in a gas turbine engine through endwall contouring, which has shown some promise in improving efficiency. The current investigation was aimed at investigating the unsteady effects downstream of a rotor with a non-axisymmetric endwall contour originally designed for a cascade.Previous investigations (numerical and experimental) have shown that the endwall contour improved the turbine efficiency by reducing the cross passage secondary flows. The contour however had a detrimental effect on the tip flow. The current investigation found that there were negligible unsteady differences between the annular and contoured rotor, with the average comparing well to the steady state results. It was also found that the effects at the tip were due to the experimental blades untwisting during operation.