Design and Thermal Optimization of Gas Turbine Blade Cooling Using Coupled CFD–CFX Simulation and Film Cooling Methods

Abstract

Turbine blades in gas turbines are exposed to extremely high temperatures, often exceeding the material limits, which can lead to thermal failure, reduced efficiency, and shortened service life. To overcome these challenges, film cooling techniques are widely used to protect turbine blades by creating a thin insulating layer of coolant over the blade surface. This study focuses on the Computational Fluid Dynamics (CFD) analysis of turbine blade cooling using film cooling techniques in ANSYS Fluent, incorporating both fluid flow and thermal considerations. The work aims to analyze temperature distribution, cooling effectiveness, and flow behavior over turbine blade surfaces. Various film cooling configurations such as hole geometry, injection angle, blowing ratio, and hole spacing are evaluated to enhance cooling performance. The interaction between hot mainstream gases and coolant air is studied to understand heat transfer mechanisms and film effectiveness. Additionally, the study explores advanced materials and Thermal Barrier Coatings (TBC) to improve thermal resistance and durability of turbine blades under high-temperature conditions. Design optimization of cooling hole arrangement and blade geometry is carried out to achieve maximum cooling efficiency with minimal coolant usage. The results contribute to improved turbine blade performance, enhanced thermal protection, and increased operational life by integrating cooling techniques, material enhancement, and CFD-based optimization.