Manufacturing issues which affect coating erosion performance in wind turbine blades

Cortes, Enrique Vaca; Sánchez, Fernando; Doménech, Luis; Olivares, A.; Young, Trevor; O'Carroll, Anthony; Chinesta, Francisco

doi:10.1063/1.5008010

Cited by 19 publications

(14 citation statements)

References 11 publications

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“…The appropriate development of numerical modelling of rain droplet impact can also be used to compute the stress history in the material [ 19 , 22 ]—see Figure 12 a. In [ 29 ] it is proposed to incorporate cohesive zone modelling (CZM) between layers in the numerical modelling of the droplet impact—see Figure 12 b. With both analytical and numerical approaches, it is necessary to characterise the failure resistance of the multi-layered system interface boundaries in order to use erosion lifetime prediction models such as the one described previously.…”

Section: Modelling Of a Liquid Drop Impact On Wind Turbine Bladesmentioning

confidence: 99%

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On the Material Characterisation of Wind Turbine Blade Coatings: The Effect of Interphase Coating–Laminate Adhesion on Rain Erosion Performance

Cortes¹,

Sánchez

O'Carroll

et al. 2017

Materials

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Rain erosion damage, caused by repeated droplet impact on wind turbine blades, is a major cause for concern, even more so at offshore locations with larger blades and higher tip speeds. Due to the negative economic influence of blade erosion, all wind turbine Original Equipment Manufacturers (OEMs) are actively seeking solutions. In most cases, since the surface coating plays a decisive role in the blade manufacture and overall performance, it has been identified as an area where a solution may be obtained. In this research, two main coating technologies have been considered: In-mould coatings (Gel coating) applied during moulding on the entire blade surface and the post-mould coatings specifically developed for Leading Edge Protection (LEP). The coating adhesion and erosion is affected by the shock waves created by the collapsing water droplets on impact. The stress waves are reflected and transmitted to the laminate substrate, so microstructural discontinuities in coating layers and interfaces play a key role on its degradation and may accelerate erosion by delamination. Analytical and numerical models are commonly used to relate lifetime prediction and to identify suitable coating and composite substrate combinations based on their potential stress reduction on the interface. Nevertheless, in order to use them, it is necessary to measure the contact adhesion resistance of the multi-layered system interfaces. The rain erosion performance is assessed using an accelerated testing technique, whereby the test material is repeatedly impacted at high speed with water droplets in a Whirling Arm Rain Erosion Rig (WARER). The materials, specifically the coating–laminate interphase region and acoustic properties, are further characterised by several laboratory tests, including Differential Scanning Calorimetry (DSC), pull-off testing, peeling–adhesion testing and nanoindentation testing. This body of work includes a number of case studies. The first case study compares two of the main coating technologies used in industry (i.e., gel coating and LEP); the second case investigates the effects of the in-mould gel coating curing; and the third considers the inclusion of a primer layer on a LEP configuration system. Following these case studies, the LEP is found to be a far superior coating due to its appropriate mechanical and acoustic properties and the interface between the coating and the substrate is highlighted as a key aspect, as poor adhesion can lead to delamination and, ultimately, premature failure of the coating.

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Section: Modelling Of a Liquid Drop Impact On Wind Turbine Bladesmentioning

confidence: 99%

“… ( a ) 3D FEM modelling of a water droplet impact in a thick polymer solid, from [ 22 ]; ( b ) numerical modelling of normal stress due to rain droplet impact. Interface CZM defines the failure resistance between contact layers, as in [ 29 ]. …”

Section: Figurementioning

confidence: 99%

On the Material Characterisation of Wind Turbine Blade Coatings: The Effect of Interphase Coating–Laminate Adhesion on Rain Erosion Performance

Cortes¹,

Sánchez

O'Carroll

et al. 2017

Materials

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“…Cortes et al studied polycarbonatediol ‐PU‐based coating (hybrid PU ‐urea technology) for erosion protection of wind turbines and reported good performance of these coatings. In‐mould coatings were painted or sprayed onto the mould tool.…”

Section: Multilayer Coatings and Interfacesmentioning

confidence: 99%

Toolbox for optimizing anti‐erosion protective coatings of wind turbine blades: Overview of mechanisms and technical solutions

Mishnaevsky

2019

Wind Energy

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Factors and structural parameters of coatings influencing the efficiency of protective coating systems against rain erosion of wind turbine blades are reviewed. The possibilities to enhance the attenuation of wave energy from droplet impact, increase damping and varying stiffness, creating interfaces for wave reflection, adding reinforcement for wave scattering, and creating additional layers or skeleton‐like reinforcing or wave absorbing structures, are discussed in the paper. Formulas for quantitative estimation of these effects as well as qualitative relationships between the structural parameters of coatings and their performance are presented. Recommendations and promising directions for the improvement of the protective coating systems for rain erosion protection of wind turbine blades are presented.

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“…This primarily results in short computational time. In addition, Cortés et al [148] proposed the A recent attempt to model the life of leading-edge coatings that are subjected to rain erosion was made by Slot et al [93]. Like Springer's, this model is based on the linear cumulative damage rule of Palmgren-Miner [141].…”

Section: Numerical Modelling Of Leading Edge Erosionmentioning

confidence: 99%

“…This primarily results in short computational time. In addition, Cortés et al [148] proposed the incorporation of cohesive zone modelling (CZM) for coatings and multilayered systems to consider the role of interfaces in the impact of erosion failure.…”

Section: Numerical Modelling Of Leading Edge Erosionmentioning

confidence: 99%

Water Droplet Erosion of Wind Turbine Blades: Mechanics, Testing, Modeling and Future Perspectives

Ibrahim

Medraj

2019

Materials

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The problem of erosion due to water droplet impact has been a major concern for several industries for a very long time and it keeps reinventing itself wherever a component rotates or moves at high speed in a hydrometer environment. Recently, and as larger wind turbine blades are used, erosion of the leading edge due to rain droplets impact has become a serious issue. Leading-edge erosion causes a significant loss in aerodynamics efficiency of turbine blades leading to a considerable reduction in annual energy production. This paper reviews the topic of water droplet impact erosion as it emerges in wind turbine blades. A brief background on water droplet erosion and its industrial applications is first presented. Leading-edge erosion of wind turbine is briefly described in terms of materials involved and erosion conditions encountered in the blade. Emphases are then placed on the status quo of understanding the mechanics of water droplet erosion, experimental testing, and erosion prediction models. The main conclusions of this review are as follow. So far, experimental testing efforts have led to establishing a useful but incomplete understanding of the water droplet erosion phenomenon, the effect of different erosion parameters, and a general ranking of materials based on their ability to resist erosion. Techniques for experimentally measuring an objective erosion resistance (or erosion strength) of materials have, however, not yet been developed. In terms of modelling, speculations about the physical processes underlying water droplet erosion and consequently treating the problem from first principles have never reached a state of maturity. Efforts have, therefore, focused on formulating erosion prediction equations depending on a statistical analysis of large erosion tests data and often with a combination of presumed erosion mechanisms such as fatigue. Such prediction models have not reached the stage of generalization. Experimental testing and erosion prediction efforts need to be improved such that a coherent water droplet erosion theory can be established. The need for standardized testing and data representation practices as well as correlations between test data and real in-service erosion also remains urgent.

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Manufacturing issues which affect coating erosion performance in wind turbine blades

Cited by 19 publications

References 11 publications

On the Material Characterisation of Wind Turbine Blade Coatings: The Effect of Interphase Coating–Laminate Adhesion on Rain Erosion Performance

On the Material Characterisation of Wind Turbine Blade Coatings: The Effect of Interphase Coating–Laminate Adhesion on Rain Erosion Performance

Toolbox for optimizing anti‐erosion protective coatings of wind turbine blades: Overview of mechanisms and technical solutions

Water Droplet Erosion of Wind Turbine Blades: Mechanics, Testing, Modeling and Future Perspectives

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