This paper addresses the issue of aerodynamic consequences of small variations in airfoil profile. A numerical comparison of flow field and cascade pressure losses for two representative repaired profiles and a reference new vane were made. Coordinates for the three airfoil profiles were obtained from the nozzle guide vanes of refurbished turboshaft engines using 3D optical scanning and digital modeling. The repaired profiles showed differences in geometry in comparison with the new vane, particularly near the leading and trailing edges. A numerical simulation was conducted using a commercial CFD code which uses the finite element approach for solving the governing equations. The computational predictions of the aerodynamic performance were validated with experimental results obtained from a transonic cascade consisting of blades with the same airfoil profiles. A CFD analysis was performed for the cascade at subsonic inlet and transonic exit conditions. Boundary layer growth, wake formation, and shock boundary layer interactions were observed in the two-dimensional computations. The flow field showed the presence of shock waves downstream of the passage throat and near the trailing edges of the blades. A conspicuous change in flow pattern due to subtle variation in airfoil profile was observed. The calculated flow field was compared with the flow pattern visualized in the experimental test rig using the Schlieren method. The total pressure calculation for the cascade exit showed an increase in pressure loss for one of the off-design profiles. The pressure loss calculations were also compared with the multi-hole total pressure probe measurement in the transonic cascade rig.

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