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Stall mechanisms in multi-stage axial compressors at different rotational speeds and identification of initial stall locations

Published online by Cambridge University Press:  14 November 2025

X. Yang
Affiliation:
National Elite Institute of Engineering, Northwestern Polytechnical University, Xi’an, China
W. Chu*
Affiliation:
National Elite Institute of Engineering, Northwestern Polytechnical University, Xi’an, China School of Power and Energy, Northwestern Polytechnical University, Xi’an, China
H. Zhang
Affiliation:
National Elite Institute of Engineering, Northwestern Polytechnical University, Xi’an, China School of Power and Energy, Northwestern Polytechnical University, Xi’an, China
L. Huang
Affiliation:
School of Power and Energy, Northwestern Polytechnical University, Xi’an, China AECC Sichuan Gas Turbine Establishment, Chengdu, China
Q. Li
Affiliation:
School of Power and Energy, Northwestern Polytechnical University, Xi’an, China
H. Wang
Affiliation:
School of Power and Energy, Northwestern Polytechnical University, Xi’an, China
*
Corresponding author: Wuli Chu; Email: wlchu@nwpu.edu.cn
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Abstract

To investigate the stall mechanisms of a multi-stage axial compressor under different rotational speeds and identify the initial stall stages, this study focuses on a high-load nine-stage axial compressor, validated through experimental data. The results reveal that at 100% corrected rotational speed, flow instability is primarily triggered by corner separation in the front four stators (S1–S4). At 80% corrected rotational speed, the instability stems from the interaction between the first rotor (R1) tip leakage vortex and the main flow, coupled with the front four stators’ corner separation. Precise identification of initial stall locations in multi-stage axial compressors is imperative. The study first employs qualitative flow-field analysis to identify initial stall locations by comparing meridional mass flux variation contour maps and axial velocity iso-surfaces. The results show that the stall inception occurs at the S2 root under 100% corrected rotational speed, while at 80% corrected rotational speed, stall initiates simultaneously at both the S2 root and the R1 tip. Furthermore, an innovative three-dimensional flow blockage quantification method was established to systematically evaluate blockage severity within multi-stage blade passages. This approach utilises relative blockage variation metrics to quantitatively identify regions of rapid flow deterioration, achieving remarkable consistency with qualitative flow-field analysis. The qualitative and quantitative analysis results have been mutually corroborated. The proposed blockage quantification approach enables precise evaluation across stages without complex flow fields comparisons, allowing rapid identification of stall-initiating locations and supporting subsequent stability enhancement optimization.

Information

Type
Research Article
Copyright
© The Author(s), 2025. Published by Cambridge University Press on behalf of Royal Aeronautical Society
Figure 0

Figure 1. Schematic illustration of compressor stall mechanism: (a) tip stall (b) corner stall.

Figure 1

Figure 2. Schematic diagram of a multi-stage axial-flow compressor: (a) partial-stage geometric model (b) meridional plane.

Figure 2

Figure 3. Adjustable stator vane geometric configuration schematic.

Figure 3

Table 1. Control law of adjustable stator vanes

Figure 4

Table 2. Partial clearance values at 100% corrected rotational speed

Figure 5

Table 3. Partial clearance values at 70% corrected rotational speed

Figure 6

Figure 4. Mesh visualisation of the computational domain.

Figure 7

Figure 5. Partial clearance view of adjustable stator vanes.

Figure 8

Table 4. Turbulence model comparison of experiment and CFD at 100% corrected rotational speed under NS condition

Figure 9

Table 5. Turbulence model comparison of experiment and CFD at 100% corrected rotational speed under maximum flow condition

Figure 10

Figure 6. Pressure ratio characteristics comparison of CFD and experiment at 74.1% corrected rotational speed with bleeding configuration.

Figure 11

Figure 7. Performance curves at different rotational speeds for comparison: (a) pressure ratio characteristic (b) adiabatic efficiency characteristic.

Figure 12

Figure 8. B2B relative Mach number distribution contour map at 100% corrected rotational speed: (a) PE 98% span (b) NS 98% span (c) PE 2% span (d) NS 2% span.

Figure 13

Figure 9. B2B relative Mach number distribution contour map at 80% corrected rotational speed: (a) PE 98% span (b) NS 98% span (c) PE 2% span (d) NS 2% span.

Figure 14

Figure 10. Tip clearance leakage flow streamline diagram of R1 at NS condition: (a) 100% corrected rotational speed (b) 80% corrected rotational speed.

Figure 15

Figure 11. Relative velocity diagram of 98% span at 80% corrected rotational speed under NS condition.

Figure 16

Figure 12. Streamline diagrams of hub partial clearance leakage flow of S1, S2, S3 and S4: (a) 100% corrected rotational speed (b) 80% corrected rotational speed.

Figure 17

Figure 13. Limiting streamline and VZ = −0.1m/s iso-surface at the roots of S1 and S2: (a) 100% corrected rotational speed S1 (b) 100% corrected rotational speed S2 (c) 80% corrected rotational speed S1 (d) 80% corrected rotational speed S2.

Figure 18

Figure 14. Contour map of meridional mass flux variation (ΔρVZ): (a) 100% corrected rotational speed (b) 80% corrected rotational speed.

Figure 19

Figure 15. VZ = −0.1m/s iso-surface of the first 4 stages: (a) 100% corrected rotational speed PE (b) 100% corrected rotational speed NS (c) 80% corrected rotational speed PE (d) 80% corrected rotational speed NS.

Figure 20

Figure 16. Different blockage quantitative calculation domain distinction: (a) based on single 2D plane (b) based on 3D flow channel.

Figure 21

Figure 17. ρVZ axial slice contour map with blockage region identification: (a) axial slice contour map of mass flux (b) identification of velocity deficit zone.

Figure 22

Table 6. Blockage coefficients and its relative changes

Figure 23

Figure 18. Prospects for stability-enhancing measures.