Experimental and CFD analysis based design of additively manufactured stepped spillway for open channel flow experiments

Additive Manufacturing (AM) is emerging as a cost-effective alternative to conventional manufacturing techniques for applications requiring components with complex geometries. Cost savings are achieved through reduced raw material usage, shorter manufacturing times, and the elimination of expensive tooling. AM serves as a valuable tool for designing and developing complex shapes in fluid flow research. Stepped spillways are widely recognized for their effectiveness in dissipating energy and are implemented globally. Their optimal design is critical for reducing downstream erosion and improving the economic efficiency of stilling basin configurations. Building on previous studies employing AM in open-channel flow applications, this paper presents a comparative analysis of two stepped spillway configurations incorporating preceding weir designs. The comparison evaluates fluid velocity profiles, discharge rates, upstream and down stream water depths, associated hydraulic parameters, and experimental observations. To validate and extend the findings, this paper employs computational fluid dynamics(CFD) modelling, which demonstrates strong agreement with experimental results. Additional tests investigate sealed and unsealed models, the latter allowing significant side flow. This paper highlights how AM enables economical small-scale model fabrication, which can enhance largescale design processes and contribute to the advancement of experimental fluid flow research.