Conjugate Heat Transfer and Flow Analysis of Double-Wall Cooling with Printable Gyroid-Type TPMS-Based Effusion

This study introduces the Gyroid structure, a type of triply periodic minimal surface (TPMS), for enhanced effusion cooling performance. Conjugate heat transfer simulations are used to compare the flow behavior, pressure loss, and overall cooling effectiveness of single- and double-wall Gyroid configurations against a baseline film hole model at blowing ratios of 0.5–2.0. Results show that the Gyroid design eliminates jet lift-off and counter-rotating vortex pairs, ensuring full coolant coverage and a thicker coolant layer than the baseline. The double-wall configuration further improves cooling with jet impingement, yielding higher average Nusselt numbers than the single-wall design. At equal pressure loss, the impingement/Gyroid model outperforms the baseline by 102.7% in cooling effectiveness. To assess manufacturability, a high-resolution CT scan is used to validate a laser powder bed fusion-printed Gyroid sample at gas turbine blade scale, confirming feasibility for industrial application. These findings highlight the superior thermal performance and manufacturability of the 3D-printed Gyroid structure, offering a promising cooling solution for next-generation turbine blades.