Download or read book Manufacturing a 9 Meter Thermoplastic Composite Wind Turbine Blade Preprint written by and published by . This book was released on 2017 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: Currently, wind turbine blades are manufactured from a combination of glass and/or carbon fiber composite materials with a thermoset resin such as epoxy, which requires energy-intensive and expensive heating processes to cure. Newly developed in-situ polymerizing thermoplastic resin systems for composite wind turbine blades polymerize at room temperature, eliminating the heating process and significantly reducing the blade manufacturing cycle time and embodied energy, which in turn reduces costs. Thermoplastic materials can also be thermally welded, eliminating the need for adhesive bonds between blade components and increasing the overall strength and reliability of the blades. As well, thermoplastic materials enable end-of-life blade recycling by reheating and decomposing the materials, which is a limitation of existing blade technology. This paper presents a manufacturing demonstration for a 9-m-long thermoplastic composite wind turbine blade. This blade was constructed in the Composites Manufacturing Education and Technology facility at the National Wind Technology Center at the National Renewable Energy Laboratory (NREL) using a vacuum-assisted resin transfer molding process. Johns Manville fiberglass and an Arkema thermoplastic resin called Elium were used. Additional materials included Armacell-recycled polyethylene terephthalate foam from Creative Foam and low-cost carbon- fiber pultruded spar caps (manufactured in collaboration with NREL, Oak Ridge National Laboratory, Huntsman, Strongwell, and Chomarat). This paper highlights the development of the thermoplastic resin formulations, including an additive designed to control the peak exothermic temperatures. Infusion and cure times of less than 3 hours are also demonstrated, highlighting the efficiency and energy savings associated with manufacturing thermoplastic composite blades.

Download or read book Design and Manufacturing of a Segmented Thermoplastic Composite Wind Turbine Blade written by Juan Bautista Garate and published by . This book was released on 2015 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt:

Download or read book Toward the Advanced Manufacturing of Land Based Wind Turbine Blades Preprint written by and published by . This book was released on 2022 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: The National Renewable Energy Laboratory (NREL) and General Electric (GE) are partners within the Additive and Modular Enabled Rotor Blades and Integrated Composites Assembly (AMERICA) project. AMERICA aims to develop advanced manufacturing solutions to reduce labor and cycle time while increasing recyclability of wind turbine blades. The project is funded by the Advanced Manufacturing Office (AMO) of the U.S. Department of Energy (DOE). This paper describes the techno-economic analysis of the novel manufacturing process applied to the tip of the blade of a representative land-based wind turbine. A comparison to a standard manufacturing process is established, highlighting challenges and opportunities. Several uncertainties affect the analysis, but with the current set of assumptions, the tip adopting advanced manufacturing is predicted to lower labor by 21%, cycle time by 39%, and total blade tip costs by 15% while simultaneously increasing production quality and adopting recyclable thermoplastic resin.

Download or read book Advances in Wind Turbine Blade Design and Materials written by Povl Brondsted and published by Elsevier. This book was released on 2013-10-31 with total page 485 pages. Available in PDF, EPUB and Kindle. Book excerpt: Wind energy is gaining critical ground in the area of renewable energy, with wind energy being predicted to provide up to 8% of the world's consumption of electricity by 2021. Advances in wind turbine blade design and materials reviews the design and functionality of wind turbine rotor blades as well as the requirements and challenges for composite materials used in both current and future designs of wind turbine blades.Part one outlines the challenges and developments in wind turbine blade design, including aerodynamic and aeroelastic design features, fatigue loads on wind turbine blades, and characteristics of wind turbine blade airfoils. Part two discusses the fatigue behavior of composite wind turbine blades, including the micromechanical modelling and fatigue life prediction of wind turbine blade composite materials, and the effects of resin and reinforcement variations on the fatigue resistance of wind turbine blades. The final part of the book describes advances in wind turbine blade materials, development and testing, including biobased composites, surface protection and coatings, structural performance testing and the design, manufacture and testing of small wind turbine blades.Advances in wind turbine blade design and materials offers a comprehensive review of the recent advances and challenges encountered in wind turbine blade materials and design, and will provide an invaluable reference for researchers and innovators in the field of wind energy production, including materials scientists and engineers, wind turbine blade manufacturers and maintenance technicians, scientists, researchers and academics. - Reviews the design and functionality of wind turbine rotor blades - Examines the requirements and challenges for composite materials used in both current and future designs of wind turbine blades - Provides an invaluable reference for researchers and innovators in the field of wind energy production

Download or read book Advanced Composite Wind Turbine Blade Design Based on Durability and Damage Tolerance written by and published by . This book was released on 2012 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt: The objective of the program was to demonstrate and verify Certification-by-Analysis (CBA) capability for wind turbine blades made from advanced lightweight composite materials. The approach integrated durability and damage tolerance analysis with robust design and virtual testing capabilities to deliver superior, durable, low weight, low cost, long life, and reliable wind blade design. The GENOA durability and life prediction software suite was be used as the primary simulation tool. First, a micromechanics-based computational approach was used to assess the durability of composite laminates with ply drop features commonly used in wind turbine applications. Ply drops occur in composite joints and closures of wind turbine blades to reduce skin thicknesses along the blade span. They increase localized stress concentration, which may cause premature delamination failure in composite and reduced fatigue service life. Durability and damage tolerance (D & DT) were evaluated utilizing a multi-scale micro-macro progressive failure analysis (PFA) technique. PFA is finite element based and is capable of detecting all stages of material damage including initiation and propagation of delamination. It assesses multiple failure criteria and includes the effects of manufacturing anomalies (i.e., void, fiber waviness). Two different approaches have been used within PFA. The first approach is Virtual Crack Closure Technique (VCCT) PFA while the second one is strength-based. Constituent stiffness and strength properties for glass and carbon based material systems were reverse engineered for use in D & DT evaluation of coupons with ply drops under static loading. Lamina and laminate properties calculated using manufacturing and composite architecture details matched closely published test data. Similarly, resin properties were determined for fatigue life calculation. The simulation not only reproduced static strength and fatigue life as observed in the test, it also showed composite damage and fracture modes that resemble those reported in the tests. The results show that computational simulation can be relied on to enhance the design of tapered composite structures such as the ones used in turbine wind blades. A computational simulation for durability, damage tolerance (D & DT) and reliability of composite wind turbine blade structures in presence of uncertainties in material properties was performed. A composite turbine blade was first assessed with finite element based multi-scale progressive failure analysis to determine failure modes and locations as well as the fracture load. D & DT analyses were then validated with static test performed at Sandia National Laboratories. The work was followed by detailed weight analysis to identify contribution of various materials to the overall weight of the blade. The methodology ensured that certain types of failure modes, such as delamination progression, are contained to reduce risk to the structure. Probabilistic analysis indicated that composite shear strength has a great influence on the blade ultimate load under static loading. Weight was reduced by 12% with robust design without loss in reliability or D & DT. Structural benefits obtained with the use of enhanced matrix properties through nanoparticles infusion were also assessed. Thin unidirectional fiberglass layers enriched with silica nanoparticles were applied to the outer surfaces of a wind blade to improve its overall structural performance and durability. The wind blade was a 9-meter prototype structure manufactured and tested subject to three saddle static loading at Sandia National Laboratory (SNL). The blade manufacturing did not include the use of any nano-material. With silica nanoparticles in glass composite applied to the exterior surfaces of the blade, the durability and damage tolerance (D & DT) results from multi-scale PFA showed an increase in ultimate load of the blade by 9.2% as compared to baseline structural performance (without nan ...

Download or read book Thermoplastic Composite Wind Turbine Blades written by Julie Jan Edouard Teuwen and published by . This book was released on 2011 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt:

Download or read book Advances in wind turbine blade design and materials written by R.P.L. Nijssen and published by Elsevier Inc. Chapters. This book was released on 2013-10-31 with total page 43 pages. Available in PDF, EPUB and Kindle. Book excerpt: Composites have been the material of choice for wind turbine blade construction for several decades. This chapter explains why. It also shows how wind turbine blade materials and our understanding of their fatigue behaviour have developed recently, and the gaps that still exist in the knowledge. The chapter discusses why fatigue is a predominant design driver for wind turbine blades. The main structural elements of the blade (load bearing components and aerodynamic shell) are considered in terms of material and design requirements, and fundamental research questions are addressed. Finally, there is a comment on current and future trends, as well as a list of recommended reading.

Download or read book Advances in wind turbine blade design and materials written by L. MISHNAEVSKY and published by Elsevier Inc. Chapters. This book was released on 2013-10-31 with total page 33 pages. Available in PDF, EPUB and Kindle. Book excerpt: An overview of the micromechanics of materials methods and approaches that can be used for the modelling of wind turbine blade composites is given in this chapter. Using the various modelling methods reviewed here, the strength, stiffness and lifetime of composite materials can be predicted and the suitability of different groups of materials for applications in wind turbine blades can be analysed. The effects of interface and matrix properties, fibre clustering and nanoreinforcement on the strength and lifetime of composites are studied in a number of simulations, and some examples of the analysis of microstructural effects on the strength and fatigue life of composites are provided.

Download or read book Methodology for Fast Iterations of Blade Designs Using Thermoplastic Composite Materials Preprint written by and published by . This book was released on 2019 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: Tidal energy is still in the early research and development phases, therefore the ability to quickly manufacture and evaluate prototype blades with new blade designs and materials is critical. This paper investigates using a Stratasys three-dimensional printer to rapidly prototype scale-model turbine blades by printing the blade tooling and using vacuum-assisted resin transfer molding (VARTM) to manufacture blades. This work outlines a methodology for cost effectively designing and manufacturing model-scale tidal turbine blades to be used in testing campaigns, and for evaluating new thermoplastic composite materials for tidal energy applications. Demonstration blades were designed in ANSYS and manufactured using an infusible thermoplastic resin system called Elium(R). The development of scale-model thermoplastic blades enables research into their fatigue performance in realistic conditions at a cost-effective scale, and manufacturing using 3-D printed tooling enables fast and low-cost blade design iterations.

Download or read book Thermoplastic Composite Wind Turbine Blades written by Simon Joncas and published by . This book was released on 2010 with total page 257 pages. Available in PDF, EPUB and Kindle. Book excerpt:

Download or read book Hybrid Anisotropic Materials for Wind Power Turbine Blades written by Yosif Golfman and published by CRC Press. This book was released on 2012-01-24 with total page 257 pages. Available in PDF, EPUB and Kindle. Book excerpt: Based on rapid technological developments in wind power, governments and energy corporations are aggressively investing in this natural resource. Illustrating some of the crucial new breakthroughs in structural design and application of wind energy generation machinery, Hybrid Anisotropic Materials for Wind Power Turbine Blades explores new automated, repeatable production techniques that expand the use of robotics and process controls. These practices are intended to ensure cheaper fabrication of less-defective anisotropic material composites used to manufacture power turbine blades. This book covers new methods of casting or pultrusion that reduce thickness in the glass- and graphite-fiber laminate prepregs used in load-bearing skin blades and web shear spars. This optimized process creates thinner, more cost-effective prepegs that still maintain strength and reliability. The book also addresses a wide range of vital technical topics, including: Selection of carbon/fiberglass materials Estimation of combination percentages Minimization and optimal placement of shear webs (spars) Advantages of resin, such as lower viscosity and curing time Strength and manufacturing criteria for selecting anisotropic materials and turbine blade materials Analysis of dynamic fatigue life and vibration factors in blade design NDE methods to predict and control deflections, stiffness, and strength Written by a prolific composite materials expert with more than 40 years of research experience, this reference is invaluable for a new generation of composite designers, graduate students, and industry professionals involved in wind power system design. Assessing significant required changes in transmission, manufacturing, and markets, this resource outlines innovative methods to help the U.S. Department of Energy meet its goal of having wind energy account for 20 percent of total generated energy by 2030.

Download or read book Advances in wind turbine blade design and materials written by P.D. Clausen and published by Elsevier Inc. Chapters. This book was released on 2013-10-31 with total page 28 pages. Available in PDF, EPUB and Kindle. Book excerpt: Small wind turbine blades share a number of features with large blades, but have some important differences. The two main differences are their much higher rotational speed, which causes more fatigue cycles and higher yaw moments, and their operation at low Reynolds number, which means that thick aerofoil sections cannot be used near the root. This chapter discusses the design challenges arising from these differences, the materials commonly used for blade manufacture, and the fatigue testing of small blades. The use of timber is highlighted for very small blades, and fibre-reinforced composite manufacture of larger ones is discussed in terms of sustainability, conformity of manufactured shape, and fatigue behaviour.

Download or read book Advances in wind turbine blade design and materials written by B. Madsen and published by Elsevier Inc. Chapters. This book was released on 2013-10-31 with total page 33 pages. Available in PDF, EPUB and Kindle. Book excerpt: This chapter about biobased composites starts by presenting the most promising types of cellulose fibres; their properties, processing and preforms for composites, together with an introduction to biobased matrix materials. The chapter then presents the typical mechanical properties of biobased composites, based on examples of composites with different fibre/matrix combinations, followed by a case study of the stiffness and specific stiffness of cellulose fibre composites vs glass fibre composites using micromechanical model calculations. Finally, the chapter presents some of the special considerations to be addressed in the development and application of biobased composites.

Download or read book Structural Testing of 9 M Carbon Fiber Wind Turbine Research Blades written by Joshua Paquette and published by . This book was released on 2007 with total page 11 pages. Available in PDF, EPUB and Kindle. Book excerpt: This paper outlines the results of tests conducted on three 9-m carbon fiber wind turbine blades designed through a research program initiated by Sandia National Laboratories.

Download or read book Wind Turbine Composite Blade Manufacturing written by and published by . This book was released on 2011 with total page 25 pages. Available in PDF, EPUB and Kindle. Book excerpt: Renewable energy is an important element in the US strategy for mitigating our dependence on non-domestic oil. Wind energy has emerged as a viable and commercially successful renewable energy source. This is the impetus for the 20% wind energy by 2030 initiative in the US. Furthermore, wind energy is important on to enable a global economy. This is the impetus for such rapid, recent growth. Wind turbine blades are a major structural element of a wind turbine blade. Wind turbine blades have near aerospace quality demands at commodity prices; often two orders of magnitude less cost than a comparable aerospace structure. Blade failures are currently as the second most critical concern for wind turbine reliability. Early blade failures typically occur at manufacturing defects. There is a need to understand how to quantify, disposition, and mitigate manufacturing defects to protect the current wind turbine fleet, and for the future. This report is an overview of the needs, approaches, and strategies for addressing the effect of defects in wind turbine blades. The overall goal is to provide the wind turbine industry with a hierarchical procedure for addressing blade manufacturing defects relative to wind turbine reliability.

Download or read book Thermoplastic Composite Wind Turbine Blades written by Kjelt van Rijswijk and published by . This book was released on 2007 with total page 249 pages. Available in PDF, EPUB and Kindle. Book excerpt:

Download or read book Design of 9 meter Carbon fiberglass Prototype Blades written by and published by . This book was released on 2007 with total page 46 pages. Available in PDF, EPUB and Kindle. Book excerpt: TPI Composites, Inc. (TPI), Global Energy Concepts, LLC (GEC), and MDZ Consulting (MDZ) have collaborated on a project to design, manufacture, and test prototype carbon-fiberglass hybrid wind turbine blades of 9-m length. The project, funded by Sandia National Laboratories, involves prototype blades in both conventional (unidirectional spar fibers running along the blade span) and ''adaptive'' (carbon fibers in off-axis orientation to achieve bend-twist-coupling) configurations. After manufacture, laboratory testing is being conducted to determine the static and fatigue strength of the prototypes, in conjunction with field testing to evaluate the performance under operational conditions.