Assessment of Surface Roughness Effects on Micro Axial Turbines

Abstract Surface roughness significantly affects the aerodynamics and heat transfer within micro-scale turbine stages. It results in a considerable increment in the blade profile loss and leads consequently to sizeable performance reductions. The provision of low roughness surfaces in micro gas turbine stages presents challenges on account of the small (mm scale) sizes, manufacturing complexity and associated costs. The axial turbine investigated in this study is fitted to Samad Power’s TwinGen domestic micro combined heat and power unit. The micro gas turbine has a compressor pressure ratio of 3, 1200K turbine inlet temperature and a rotational speed of 170,000 rpm. This paper presents a numerical assessment of the effects of varying the surface roughness on the performance and heat transfer of the micro turbine. The surface roughness was uniformly distributed on the NGV and rotor blades. The results showed that increasing the surface roughness from 3 microns to 6, 20, and 100 microns resulted in a reduction in stage total efficiency of 0.8%, 4% and 12% respectively as well as a comparable decrease in output power (0.7%, 3.6%, and 11% respectively). The turbine temperature was also observed to be very sensitive to surface roughness and a temperature increase of some 5% at the rotor hub and over 4% increment in the blade tip surface was observed for 100 microns when compared to the 3 microns surface roughness case. The findings of this paper highlight the adverse effects of the surface roughness on the micro-turbine performance and temperature distribution as well as the importance of careful consideration of wall roughness during the design and manufacturing stages.