An investigation into the exploratory use of additive manufacturing in stepped spillway model testing in open channel flow

Department of Science and Engineering, Solent University, Southampton, Hampshire, SO14 0YN

Abstract

Stepped spillways provide an excellent form of energy dissipation and are used in many locations around the world. Effective designs are crucial in improving protection to downstream erosion and providing economic benefits to the stilling basin design. Additive manufacturing (AM) provides a wide range of possibilities of testing complex and varied geometries in fluid flow research at relatively low cost. This research builds upon previous studies in utilising AM in open channel flow applications. This paper presents a comparative analysis between two types of stepped spillway using preceding weir designs in terms of fluid velocity profile, flow rate, water height upstream and downstream; associated fluid flow parameters and experimental observations. For validation and further analysis, computational fluid dynamics (CFD) modelling is conducted to show close comparisons to the experimental results. Conditions are varied to compare the differences between models being sealed and unsealed, allowing for significant side flow. AM technology allows for cost-effective small models to be created, that can significantly improve the design process for larger scale testing and enhances the field of study for experimental fluid flow research.