The design of a new transonic wind tunnel to reproduce bypass aero-engine flow conditions is described. This study has been driven by the interest to investigate and optimize the aero-thermal effects of an air/oil integrated surface heat exchanger placed at the inner wall of the secondary duct of a turbofan. The test section of the intermittent wind tunnel consists of a complex three-dimensional (3D) geometry. The flow evolves over the splitter, duplicated at real scale, as it does in the engine, guided by helicoidally shaped lateral walls. Numerical flow analyses have been used to guide the design of the complete wind tunnel. Zero-dimensional models have been developed to recreate the wind tunnel behaviour. Two- and three-dimensional computations have been performed to optimize the test section and the inlet guide vanes that duplicate the flow downstream of the engine fan. The reproduction of the bypass flow structure has been numerically analysed. Flow computations with and without the presence of instrumentation in the test section have been contrasted. Additionally, the influence of an aerodynamic probe on the flow has been studied numerically. This study should lead to improvements in the thermal management of future aircraft power plants, particularly by taking benefit of the cold bypass air to refrigerate the lubrication oil, without penalizing the propulsive efficiency.
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