Comparative Thermal Analysis of Turbine Blades with and Without Internal Cooling Passages

Karan Nalugade — 2026-03-16

This study investigates the thermal performance of gas turbine blades operating under extreme temperature conditions where the working temperatures often exceed the melting limits of conventional materials. To address this challenge, advanced cooling strategies are essential for maintaining blade integrity and operational efficiency. In this research, a comprehensive computational fluid dynamics (CFD) analysis was performed to evaluate the thermal behavior of turbine blades with and without internal cooling passages. The simulations were conducted using ANSYS Fluent, based on a turbine blade geometry derived from the patent WO2014042720A2. The baseline blade material selected for the study was Inconel 792 due to its high-temperature strength and oxidation resistance. The results indicate that the incorporation of internal cooling passages significantly enhances thermal management by reducing the average blade wall temperature from 1439.5 to 1357.4 K, corresponding to a reduction of approximately 82 K (5.7%). Furthermore, a parametric analysis involving eight high-temperature materials was conducted to assess the influence of thermophysical properties on blade temperature distribution. The study reveals that materials with higher thermal conductivity and specific heat capacity contribute to improved heat dissipation and more uniform temperature profiles. Overall, the findings highlight the critical role of internal cooling mechanisms and appropriate material selection in improving turbine blade durability and preventing thermal failure in high-temperature gas turbine applications.

Design and Development of Guide Fixture for Precision Pin Assembly in Hydraulic Valve Bodies

Mahesh Kale — 2026-01-23

Hydraulic valve assemblies demand micron-level precision during pin insertion to ensure reliability, prevent leakage, and extend service life. Conventional manual pressing methods often fail to achieve the required transition fit of 20–30 µm, leading to misalignment, eccentric fits, and high rejection rates. This study presents the design and development of a precision guide fixture tailored for hydraulic valve pin assembly. The fixture integrates a slotted base, a locating pin mechanism, a pressing interface, and anti-rotation supports to achieve concentric alignment. Computer-aided design (CAD) tools were used for modeling, while finite element analysis (FEA) validated stress distribution and tolerance control. Fabrication employed hardened steel and EN-series alloys, followed by experimental validation using micrometers and dial gauges. Results demonstrated concentricity accuracy improvement from ±80 µm to ±20–30 µm, error rate reduction from 10–12% to 2–3%, and enhanced operator safety. The fixture reduced setup time and proved scalable for different valve sizes. This research contributes to fixture design literature by addressing micron-level press-fit tolerances in hydraulic assemblies and establishes a foundation for future semi-automated assembly systems.

Journal of Recent Trends in Mechanics

Comparative Thermal Analysis of Turbine Blades with and Without Internal Cooling Passages

Design and Development of Guide Fixture for Precision Pin Assembly in Hydraulic Valve Bodies