Leak-Rate Through Carbon Brush Seals: Experimental Tests Versus Predictions from a Porous Medium Approach

Abstract

This study presents a detailed comparative analysis between experimental leakage flow rates and numerical predictions for carbon brush seals with long bristles, utilizing a porous medium model approach. A series of tests were carried out on a static rig (without rotor rotation). The experimental setup allows tests under various interference conditions, revealing significant insights into the flow behavior through the brush seal. A numerical model based on the Darcy-Forchheimer equation is developed to interpret the complex flow dynamics within the brush seal, accounting for viscous, compressible, and inertial effects. The study evaluates the impact of brush deformation and porosity on flow resistance, leveraging experimental data to refine the numerical model parameters. This investigation not only deepens the understanding of brush seal flow physics but also improves the predictive accuracy of the numerical model in simulating operational conditions. © 2025 American Society of Mechanical Engineers (ASME). All rights reserved.