Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “wind blades”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
NASA NTRS1983

Construction of low-cost, Mod-OA wood composite wind turbine blades

Two sixty-foot, low-cost, wood composite blades for service on 200 kW Mod-OA wind turbines were constructed. The blades were constructed of epoxy resin-bonded Douglas fir veneers for the leading edge sections, and paper honeycombcored, birch plywood faced panels for the afterbody sections. The blades were joined to the wind turbine hub by epoxy resin-bonded steel load take-off studs embedded into the root end of the blades. The blades were installed on the 200 kW Mod-OA wind turbine facility at Kahuku, Hawaii, The blades completed nearly 8,000 hours of operation over an 18 month period at an average power of 150 kW prior to replacement with another set of wood composite blades. The blades were replaced because of a corrosion failure of the steel shank on one stud. Inspections showed that the wood composite structure remained in excellent condition.

Lark, R. F.↗
DOE OSTI2025

VitriEdge: Repairable & Durable Vitrimer Coatings for Wind Turbine Blade Leading Edges

The primary goal of this Level 1b incubator project was to explore the use of vitrimer coatings for repair of leading-edge erosion on end-of-life wind turbine blade surfaces, beyond coating strength of adhesion which has previously been demonstrated in the Level 1a project. Uniform vitrimer coatings (thickness: 400 µm) were applied to two end-of-life wind turbine blades for flexural, fatigue, and laminate tensile testing where the addition of the coating did not produce any statistical variation in tensile properties with minor drops in flexural strength for some laminate formulations. However, a <2% variation in storage modulus was measured for laminate structures (i.e., blade samples with vitrimer coatings) across 100,000 flexural cycles and upon laminate tensile failure, the vitrimer coatings displayed no visible signs of delamination. In addition, three methods to heal vitrimer coating damage was displayed: oven heating, addition of hot water, and a forced convection heat gun. All three heating and healing mechanisms demonstrated significant healing with scratch depths decreasing between 79-91% at healing times ranging between 1-min and 10-minutes. Finally, a water jet machine was used to simulate rain erosion for both the blade surfaces and vitrimer-coated blade surfaces where the diameter and depth of the damage was recorded as a function of exposure time, water pressure, height of exposure, and angle of exposure. Of interest, while the vitrimer coating did not significantly lessen the damage experienced during rain erosion, the addition of vitrimer composite coatings(5 wt.% mica addition) did result in a crack-resistant, durable coating capable of self-healing behavior and in all cases the angle of rain exposure was the most critical parameter explored. It is crucial to continue exploring this space where vitrimer coatings are of interest for both their self-healing properties and potential use as reversible adhesives.

17 WIND ENERGY↗
DOE OSTI2023

The inclusion of uncertainty in circularity transition modeling: A case study on wind turbine blade end-of-life management

The transition to a more circular economy (CE) is complex and hard to predict, including in sustainable energy technologies. Many sources of uncertainty make it challenging to model CE scenarios and their potential benefits. As an example, the high variability in costs and revenues of different recycling options makes future wind turbine blade recycling highly uncertain. To better understand this challenge, the circular economy, life cycle assessment and visualization (CELAVI) framework - a discrete event simulation and life cycle assessment framework - is modified to incorporate uncertainty analysis capabilities. Moreover, a 3-step procedure that covers different aspects of uncertainty in CE studies and includes a Monte-Carlo analysis is proposed. The procedure is tested in a case study on wind turbine blade recycling using CELAVI. Results highlight that grinding and landfilling costs are the most influential parameters for wind power circularity. The model's output coefficients of variation (when input parameter uncertainties are propagated) are between 92% and 384% depending on the indicator. The approach developed in this study may help researchers and decision-makers who study circularity prioritize their data collection effort. Finally, our method contributes to a mounting yet critical body of research: the measurement of uncertainty in circularity transitions.

17 WIND ENERGY↗
DOE OSTI2025

High temporal frequency data from a four turbine, blade-resolved wind farm simulation with ExaWind

The data was generated with ExaWind (https://github.com/Exawind) which couples AMR-Wind (https://github.com/Exawind/amr-wind/), Nalu-Wind (https://github.com/Exawind/nalu-wind), TIOGA (https://github.com/Exawind/tioga), and OpenFAST (https://github.com/OpenFAST/openfast). This is a large-scale simulation of a blade-resolved wind farm using the ExaWind software stack. ExaWind couples together a background flow solver, AMR-Wind, and a near-body solver, Nalu-Wind, through an overset technique from the TIOGA application. Another application, OpenFAST, handles the structural dynamics of the turbine blades and towers, which informs the fluid-structure interaction of the wind turbines with the flow solvers. This particular simulation includes four blade-resolved wind turbines operating in a turbulent atmospheric boundary layer. The AMR-Wind solver uses 500 million cells and is being solved on 256 AMD GPUs of the Oakridge Leadership Computing Facility Frontier supercomputer. Each turbine is assigned its own Nalu-Wind solver with over 13 million elements per turbine and solved using 448 CPU cores, for a total of 1792 CPU cores. For each node, 56 cores contain Nalu-Wind, while 8 cores correspond to AMR-Wind operations on the GPUs. Consequently, ExaWind is entirely utilizing the CPUs and the GPUs of the nodes concurrently. The data used in the visualization is full flow field data output from the simulation. It is lossy-compressed to a specific accuracy using ZFP and written to disk every 16 time-steps to enable real-time flow visualization. The flow fields are sampled at a high temporal frequency to enable real-time, 24fps visualization. The flow fields are sampled every 12 simulation time steps (every 0.04132s).

17 WIND ENERGY↗
NASA NTRS1979

Design, fabrication, test, and evaluation of a prototype 150-foot long composite wind turbine blade

The design, fabrication, testing, and evaluation of a prototype 150 foot long composite wind turbine blade is described. The design approach and material selection, compatible with low cost fabrication methods and objectives, are highlighted. The operating characteristics of the blade during rotating and nonrotating conditions are presented. The tensile, compression, and shear properties of the blade are reported. The blade fabrication, tooling, and quality assurance are discussed.

Gewehr, H. W.↗
DOE OSTI2026

Numerical simulation of vortex-induced vibration response of a single IEA 10-MW wind turbine blade

Three-dimensional simulation of vortex-induced vibration (VIV) of a single International Energy Agency (IEA) 10-MW reference wind turbine blade with a length of 97.325 m is performed using the ExaWind stack, an open-source suite of codes. This study aims to illustrate the spanwise VIV response characteristics and cross-validate the results with an existing commercial framework. Five near-body meshes and three time steps are selected for the convergence study. To improve computational efficiency, several VIV triggering methods are also compared to shorten the VIV development period. The ExaWind-based VIV simulation strategy for a single IEA 10-MW blade is determined. First, the modal shape is validated against published results. Then, spanwise VIV responses of four blade configurations under a fixed and varied incoming flow velocity are analyzed. Results show that the VIV response is dominated by the first edgewise (second overall) mode. Little first-mode contributions appear near the second-mode node, producing a pi phase jump, and a higher harmonics response occurs near the blade root. Rotational degrees of freedom are minor compared with translational motion. The response versus reduced velocity is analyzed, showing a two-branch behavior similar to that of VIV for a bluff cylinder. Across all tested cases, the dominant frequency remains locked to the natural frequency of the second mode with no observed desynchronization. A mild deviation is observed for the case of 90-degree pitch and 310-degree azimuth rotation near a reduced velocity of 6, which will be examined with additional cases in future work. These findings indicate that severe VIV responses can arise under specific configurations and flow conditions, thereby increasing the potential for VIV fatigue damage and requiring greater attention during operation.

17 WIND ENERGY↗
NASA NTRS1987

Thermal stresses of a wind turbine blade made of orthotropic material

This study is to investigate the thermal stress of a wind turbine blade made of wood composite material. First, the governing partial differential equation on heat conduction is stated, then, a finite element procedure using a variational approach is employed for the solution of the governing equation. Thus, the temperature field throughout the blade is determined. Next, based on the temperature field, a finite element procedure using potential energy approach is applied to determine the thermal stress field. A set of results is obtained through the use of a computer, which is considered to be satisfactory.

Fu, Kuan-Chen↗
NASA NTRS1981

Test evaluation of a laminated wood wind turbine blade concept

A series of tests conducted on a root end section of a laminated wood wind turbine blade are reported. The blade to hub transition of the wood blade uses steel studs cast into the wood D spar with a filled epoxy. Both individual studs and a full scale, short length, root section were tested. Results indicate that the bonded stud concept is more than adequate for both the 30 year life fatigue loads and for the high wind or hurricane gust loads.

Faddoul, J. R.↗
DOE OSTI2022

Toward the Advanced Manufacturing of Land-Based Wind Turbine Blades: Preprint

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.

3D printing↗
NASA NTRS1985

Improved stud configurations for attaching laminated wood wind turbine blades

A series of bonded stud design configurations was screened on the basis of tension-tension cyclic tests to determine the structural capability of each configuration for joining a laminated wood structure (wind turbine blade) to a steel flange (wind turbine hub). Design parameters which affected the joint strength (ultimate and fatigue) were systematically varied and evaluated through appropriate testing. Two designs showing the most promise were used to fabricate addiate testing. Two designs showing the most promise were used to fabricate additional test specimens to determine ultimate strength and fatigue curves. Test results for the bonded stud designs demonstrated that joint strengths approaching the 10,000 to 12,000 psi ultimate strength and 5000 psi high cycle fatigue strength of the wood epoxy composite could be achieved.

Fadoul, J. R.↗
DOE OSTI2021

A Methodology for Robust Load Reduction in Wind Turbine Blades Using Flow Control Devices

Decades of wind turbine research, development and installation have demonstrated reductions in levelized cost of energy (LCOE) resulting from turbines with larger rotor diameters and increased hub heights. Further reductions in LCOE by up-scaling turbine size can be challenged by practical limitations such as the square-cube law: where the power scales with the square of the blade length and the added mass scales with the volume (the cube). Active blade load control can disrupt this trend, allowing longer blades with less mass. This paper presents the details of the development of a robust load control system to reduce blade fatigue loads. The control system, which we coined sectional lift control or SLC, uses a lift actuator model to emulate an active flow control device. The main contributions of this paper are: (1) Methodology for SLC design to reduce dynamic blade root moments in a neighborhood of the rotor angular frequency (1P). (2) Analysis and numerical evidence supporting the use of a single robust SLC for all wind speeds, without the need for scheduling on wind speed or readily available measurements such as collective pitch or generator angular speed. (3) Intuition and numerical evidence to demonstrate that the SLC and the turbine controller do not interact. (4) Evaluation of the SLC using a full suite of fatigue and turbine performance metrics.

17 WIND ENERGY↗
DOE OSTI2021

Autonomous Sensor System for Wind Turbine Blade Collision Detection

This paper presents an automated blade collision detection system for use on wind turbines, toward the goal of supporting monitoring and quantitative assessment of wind energy impacts on wildlife. A wireless, multisensor module mounted at the blade root measures surface vibrations, and a blade-mounted camera provides image capture of colliding objects. Using sensor data recorded during field testing of the system on an operational wind turbine, we present the development, training, and testing of automated detection algorithms for collision detection using machine-learning approaches. In particular, we compare the use of a new two-step, anomaly-based classification algorithm with conventional adaptive boosting and amplitude-based detection techniques, where the two-step approach improves average precision for the experimental data set. This integrated sensor and classification systems demonstrates a new approach for automated, on-blade collision detection for wind turbines, with broad utility across structural health monitoring applications.

17 WIND ENERGY↗
NASA NTRS1978

The UMass wind furnace blade design

A brief description of the wind furnace concept is presented along with some preliminary performance data. Particular emphasis is placed on the design, construction, and manufacturing procedure for the 32.5 foot diameter GRP blades.

Cromack, D. E.↗
NASA NTRS2019

Automated Fiber Placement of Composite Wind Tunnel Blades: Process Planning and Manufacturing

The ability to accurately manufacture large complex shapes in a consistent and repeatable manner has led to Automated Fiber Placement (AFP) being the predominant mode of manufacturing for large composite aerospace structures today. Currently, AFP is being considered for medium- and small-scale parts. Composite wind tunnel blades have traditionally been fabricated by hand layup for pre-impregnated or dry fabrics with resin infusion. Though well proven, the traditional fabrication method is laborious and tedious, and hence expensive. The project described in this paper used the Integral Structural Assembly of Advanced Composites (ISAAC) facility at the NASA Langley Research Center to build a manufacturing demonstration unit (MDU) with a shape representative of a wind tunnel blade. This MDU is used to discuss tooling, process planning, and fabrication. Additionally, details of the generic manufacturing workflow are presented.

Harik, Ramy↗
DOE OSTI2020

Design for Recycling Principles Applicable to Selected Clean Energy Technologies: Crystalline-Silicon Photovoltaic Modules, Electric Vehicle Batteries, and Wind Turbine Blades

Abstract The global growth of clean energy technology deployment will be followed by parallel growth in end-of-life (EOL) products, bringing both challenges and opportunities. Cumulatively, by 2050, estimates project 78 million tonnes of raw materials embodied in the mass of EOL photovoltaic (PV) modules, 12 billion tonnes of wind turbine blades, and by 2030, 11 million tonnes of lithium-ion batteries. Owing partly to concern that the projected growth of these technologies could become constrained by raw material availability, processes for recycling them at EOL continue to be developed. However, none of these technologies are typically designed with recycling in mind, and all of them present challenges to efficient recycling. This article synthesizes and extends design for recycling (DfR) principles based on a review of published industrial and academic best practices as well as consultation with experts in the field. Specific principles developed herein apply to crystalline-silicon PV modules, batteries like those used in electric vehicles, and wind turbine blades, while a set of broader principles applies to all three of these technologies and potentially others. These principles are meant to be useful for stakeholders—such as research and development managers, analysts, and policymakers—in informing and promoting decisions that facilitate DfR and, ultimately, increase recycling rates as a way to enhance the circularity of the clean energy economy. The article also discusses some commercial implications of DfR. Graphical Abstract

36 MATERIALS SCIENCE↗
DOE OSTI2023

Toward the Advanced Manufacturing of Land-Based Wind Turbine Blades

The National Renewable Energy Laboratory 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 U.S. Department of Energy's Advanced Manufacturing Office. This paper describes the techno-economic and life cycle analysis of the novel manufacturing process applied to the 15-meter long tip of the blade of a representative 3.4 MW land-based wind turbine. We establish a comparison to a standard manufacturing process, highlighting challenges and opportunities. Several uncertainties affect the analysis, but we highlight an opportunity space. 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. A life cycle analysis returns comparable metrics for climate change impact and embodied energy between the two processes.

3D printing↗
DOE OSTI2023

Aero‐servo‐elastic co‐optimization of large wind turbine blades with distributed aerodynamic control devices

Abstract This work introduces automated wind turbine optimization techniques based on full aero‐servo‐elastic models and investigates the potential of trailing edge flaps to reduce the levelized cost of energy (LCOE) of wind turbines. The Wind Energy with Integrated Servo‐control (WEIS) framework is improved to conduct the presented research. Novel methods for the generic implementation and tuning of trailing edge flap devices and their controller are also introduced. Primary flap and controller parameters are optimized to demonstrate potential maximum blade tip deflection reductions of 21 % . Concurrent design optimization (i.e., co‐design) of a novel segmented wind turbine blade with trailing edge flaps and its controller is then conducted to demonstrate blade cost savings of 5 % . Additionally, rotor diameter co‐design optimization is demonstrated to reduce the LCOE by 1.3 % without significant load increases to the tower. These results demonstrate the efficacy of control co‐design optimization using trailing edge flaps, and the entirety of this work provides a foundation for numerous control co‐design‐oriented studies for distributed aerodynamic control devices.

17 WIND ENERGY↗