Scalloped Tesla Disc Turbines with Supercritical CO2: A New Approach to Drag Reduction and Efficiency

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Scalloped Tesla Disc Turbines with Supercritical CO2: A New Approach to Drag Reduction and Efficiency

Could a simple scallop pattern make Tesla disc turbines more efficient? By combining supercritical CO2 and bio-inspired blade design, a new frontier in turbine optimization is taking shape.

Scalloped Tesla Disc Turbines with Supercritical CO2: A New Approach to Drag Reduction and Efficiency

The Tesla disc turbine, known for its simplicity and low-cost construction, uses smooth, parallel discs to transfer energy from a working fluid via boundary layer adhesion and viscosity. While elegant in theory, real-world efficiency can be hindered by turbulence, inefficient flow paths, and drag at high velocities. Enter the concept of biomimetic tubercles—specifically, scalloped patterns on the edges of the turbine discs—and the high-density properties of supercritical CO2 (sCO2) as a working fluid.

Leveraging Supercritical CO2

Supercritical CO2 is a dense, low-viscosity fluid that operates above its critical point of 31°C and 7.38 MPa. Unlike conventional steam or refrigerants, sCO2 offers high energy density, rapid thermal exchange, and a compact footprint for power systems. These properties make it ideal for use in closed-loop Organic Rankine Cycle (ORC) or Brayton-like turbine systems, including Tesla turbines where flow control is paramount.

Why Scallops on a Tesla Disc?

Inspired by tubercles on humpback whale fins, scallop-shaped protrusions or indentations on the edge of each disc could stabilize and direct the flow of sCO2 more efficiently through the narrow boundary layers between discs. These features are thought to:

Reduce flow separation and turbulence

Maintain smoother vortices and streamline flow paths

Improve torque transfer to the rotor shaft

Unlike traditional airfoil blades, Tesla discs are flat, and edge shaping is much easier to implement through stamping or laser cutting. The scallop geometry offers a simple, repeatable manufacturing method that does not disrupt the core architecture of the turbine.

Design and Manufacturing Simplicity

Standard Tesla turbines rely on stacking multiple flat discs on a central shaft. By pre-stamping each disc with a sinusoidal or scalloped edge, the entire turbine can be produced with minimal added complexity. Manufacturing can be done using CNC stamping, waterjet cutting, or die-forming techniques, particularly in high-temperature steels or titanium alloys suitable for sCO2 environments.

Key Advantages

Enhanced Efficiency: Flow conditioning reduces energy losses and increases rotational force.

Compact Design: Scalloping may allow fewer discs to achieve the same power output.

Low-Cost Fabrication: No precision blades or castings are required.

Compatibility with sCO2: High fluid density improves boundary layer adhesion.

Applications

This concept holds promise for:

Waste heat recovery systems in data centers and industry

Compact geothermal or solar thermal power units

Decentralized or modular energy systems using closed-loop CO2 cycles

Conclusion

By combining the high density and favorable thermodynamics of supercritical CO2 with a biomimetic approach to Tesla disc edge geometry, a new evolution in turbine performance is possible. Scalloped disc edges offer a low-cost, manufacturable improvement that could significantly enhance energy recovery and efficiency in next-generation turbine systems.