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A Review of Recent Research on Flow and Heat Transfer Analysis in Additively Manufactured Transpiration Cooling for Gas Turbines

Author

Listed:
  • Kirttayoth Yeranee

    (Institute of Turbomachinery, School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 200240, China)

  • Yu Rao

    (Institute of Turbomachinery, School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 200240, China
    Shenzhen Research Institute, Shanghai Jiao Tong University, Shenzhen 518000, China)

Abstract

Advanced gas turbine cooling technologies are required to bridge the gap between turbine inlet temperatures and component thermal limits. Transpiration cooling has emerged as a promising method, leveraging porous structures to enhance cooling effectiveness. Recent advancements in additive manufacturing (AM) enable precise fabrication of complex transpiration cooling architectures, such as triply periodic minimal surface (TPMS) and biomimetic designs. This review analyzes AM-enabled transpiration cooling for gas turbines, elucidating key parameters, heat transfer mechanisms, and flow characteristics of AM-fabricated designs through experimental and numerical studies. Previous research has concluded that well-designed transpiration cooling achieves cooling effectiveness up to five times higher than the traditional film cooling methods, minimizes jet lift-off, improves temperature uniformity, and reduces coolant requirements. Optimized coolant controls, graded porosity designs, complex topologies, and hybrid cooling architectures further enhance the flow uniformity and cooling effectiveness in AM transpiration cooling. However, challenges remain, including 4–77% porosity shrinkage in perforated transpiration cooling for 0.5–0.06 mm holes, 15% permeability loss from defects, and 10% strength reduction in AM models. Emerging solutions include experimental validations using advanced diagnostics, high-fidelity multiphysics simulations, AI-driven and topology optimizations, and novel AM techniques, which aim at revolutionizing transpiration cooling for next-generation gas turbines operating under extreme conditions.

Suggested Citation

  • Kirttayoth Yeranee & Yu Rao, 2025. "A Review of Recent Research on Flow and Heat Transfer Analysis in Additively Manufactured Transpiration Cooling for Gas Turbines," Energies, MDPI, vol. 18(13), pages 1-42, June.
    • Handle: RePEc:gam:jeners:v:18:y:2025:i:13:p:3282-:d:1685550
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    References listed on IDEAS

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    1. Sandip Dutta & Inderjot Kaur & Prashant Singh, 2022. "Review of Film Cooling in Gas Turbines with an Emphasis on Additive Manufacturing-Based Design Evolutions," Energies, MDPI, vol. 15(19), pages 1-35, September.
    2. Wen Wang & Yan Yan & Yeqi Zhou & Jiahuan Cui, 2022. "Review of Advanced Effusive Cooling for Gas Turbine Blades," Energies, MDPI, vol. 15(22), pages 1-28, November.
    3. Joon Ahn, 2022. "Large Eddy Simulation of Film Cooling: A Review," Energies, MDPI, vol. 15(23), pages 1-21, November.
    4. Kirttayoth Yeranee & Yu Rao, 2022. "A Review of Recent Investigations on Flow and Heat Transfer Enhancement in Cooling Channels Embedded with Triply Periodic Minimal Surfaces (TPMS)," Energies, MDPI, vol. 15(23), pages 1-29, November.
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