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The development of a fiber Bragg grating (FBG) based distributed strain sensor system for real time structural health monitoring of a wind turbine rotor and its validation under a laboratory scale test setup is discussed in this paper. A 1 kW, 1.6 m diameter rotor, horizontal axis wind turbine with three instrumented blades is used in this study. The sensor system consists of strain sensors, surface mounted at various locations on the blade. At first the sensors are calibrated under static loading conditions to validate the FBG mounting and the proposed data collection techniques. Then, the capability of the sensor system coupled with the operational modal analysis (OMA) methods to capture natural frequencies and corresponding mode shapes in terms of distributed strains are validated under various non-rotating dynamic loading conditions. Finally, the sensor system is tested under rotating conditions using the wind flow from an open-jet wind tunnel, for both a baseline wind turbine and a wind turbine with a structurally modified blade. The blade was modified by attaching a lumped mass at the blade tip simulating structural damage or ice accretion. The dynamic characteristics of the baseline (healthy) blade and modified (altered) blade are compared to validate the sensor system’s ability for real time structural health monitoring of the rotor.

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Macroscale finite element (FE) models, with their ability to simulate additive manufacturing (AM) processes of metal parts and accurately predict residual stress distribution, are potentially powerful design tools. However, these simulations require enormous computational cost, even for a small part only a few orders larger than the melt pool size. The existing adaptive meshing techniques to reduce computational cost substantially by selectively coarsening are not well suited for AM process simulations due to the continuous modification of model geometry as material is added to the system. To address this limitation, a new FE framework is developed. The new FE framework is based on introducing updated discretized geometries at regular intervals during the simulation process, allowing greater flexibility to control the degree of mesh coarsening than a technique based on element merging recently reported in the literature. The new framework is evaluated by simulating direct metal deposition (DMD) of a thin-walled rectangular and a thin-walled cylindrical part, and comparing the computational speed and predicted results with those predicted by simulations using the conventional framework. The comparison shows excellent agreement in the predicted stress and plastic strain fields, with substantial savings in the simulation time. The method is then validated by comparing the predicted residual elastic strain with that measured experimentally by neutron diffraction of the thin-walled rectangular part. Finally, the new framework's capability to substantially reduce the simulation time for large-scale AM parts is demonstrated by simulating a one-half foot thin-walled cylindrical part.

In this paper, existing domain‐switching criteria are briefly reviewed and the predictions based on these domain‐switching criteria are compared with the available experimental data for 180° and 90° domain switchings in lead lanthanum zirconate titanate (PLZT) and lead zirconate titanate (PZT), respectively. It is found that the predictions do not match the experimental results. Motivated by this observation, a new domain‐switching criterion in terms of internal‐energy density is proposed for combined mechanical and electrical loads. Based on consideration of the atomic structure of ferroelectric materials, it is recognized that 180° and 90° domain switchings result from different mechanisms and, thus, require different critical internal‐energy densities for switching. The new criterion is found to yield very good predictions for both 180° and 90° domain switchings.