Innovative Tesla turbine devices: Concept, testing and insights

This paper investigates the integration of a bladeless Tesla turbine rotor and an electric machine rotor to create a space-efficient and simplified energy conversion system. Although the Tesla turbine is a well-established concept, the proposed co-axial integration offers a novel approach that lends itself particularly well to micro-scale energy generation and heating of process gases after pressure reduction. The objective of this study is to investigate the integration of a bladeless Tesla turbine rotor with an axial flux permanent magnet (AFPM) electric machine, addressing two fundamental research questions: whether a space-efficient, power generation device (approximately 5–15 W) can be developed based on this integration, and whether the same principle can be applied to create a gas heater operating during expansion from high pressure (e.g., from 1.2 MPa to ambient pressure). The study includes simulations and experimental tests. Details of the simulation tools, modelling approach and experimental setup are presented and discussed. The results highlight the potential advantages of the integrated system in terms of its space-efficient design and practical application. This concept shows promise for use in small-scale, distributed energy systems. • Novel integration of Tesla turbine and electric machine rotors into a single unit. • Co-axial design reduces system size and complexity for micro-scale applications. • Two use cases explored: power generation (∼10 W) and process gas reheating • Simulation and experimental tests confirm system feasibility and performance. • Promising solution for compact, distributed energy and pressure reduction systems.