wind turbine blade workshop - sandia...
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Wind Turbine Blade WorkshopWind Turbine Blade Workshop
Albuquerque, New MexicoAlbuquerque, New Mexico
February 24February 24--2525thth, 2004, 2004
Wind Turbine Blade Trends & IssuesWind Turbine Blade Trends & IssuesPresenters: Marco Zvanik & Dave Hartman Presenters: Marco Zvanik & Dave Hartman -- Owens CorningOwens Corning
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Presentation Overview:• Major Wind Turbine Blade Components• Modifications Affecting Stiffness & Stability• Infusion Processing - New Materials • New Fiberglass Products Being Developed• Proposed 60+ meter Blade Assembly• Questions
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Wind Turbine Blade Components:• Traditional composite sandwich laminates are designed for out of
plane loading. However Wind Turbine Blade laminates experience in-plane loads for both the blade surfaces and shear webs.
• Inertial loads will increase as blade lengths and weights continue to grow contributing to greater shear loading.
• Decreasing overall blade weights will reduce blade loading.• Much emphasis is given to reducing weight by focusing solely on
the reinforcing fiber as a “solid laminate” rather then treating the sandwich laminate as one entity.
• More than 65% of a large wind turbine blade’s surface area is a sandwich laminate.
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External Modifications: (Macro)• Changing the overall blade profile is one way to modify stiffness & stability but may impact a blades aerodynamic performance
•
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Internal Modifications:• Modifying the internal laminate or web components is another way to enhance
stiffness & stability without changing the blades cross sectional “footprint”. This is a favorable approach since it does not impact a blade’s aerodynamic performance. Result: Decreased blade loading
New “Optimized” Blade Design
Shear Web DesignCentral Spar Design
• Increased the use of core materials• Decreased the number of webs• Eliminated the spar• Decreased blade weight
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Material Modifications: (Micro)
Shea
r St
ress
• Increase Core Thickness/Density
• Increase Reinforcing plies
• Change fiber orientation
• Change reinforcing fiber material
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Shear Buckling: (Web)
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Material Modifications: (Micro)
Shear Stress
Bending Stress
Skin
Core
Skin
Shear Stress
Critical Buckling Load- Pcr
• Increase Core Thickness/Density
• Increase Reinforcing plies
• Change fiber orientation
• Change reinforcing fiber material
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General Buckling: (Blade Surfaces)
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Fabric Compressive Test Effect and Failure Mode
0
20000
40000
60000
80000
100000
120000
60.0 65.0 70.0 75.0 80.0 85.0
Glass Fiber Content (Wt %)
Com
pres
sive
Stre
ngth
(Psi
)
CD550 ASTM D695M CD550 ASTM D695CD550 ASTM D6641CDM5502 ASTM D695CDM1250 ASTM D695MCDM1250 ASTM D695CDM1250 ASTM D6641
80 kg/mm2
60 kg/mm2
Compressive Shear
Compressive Crippling
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Effect of Manufacturing on Blade Weight:
Blade Length vs W eight
0
2000
4000
6000
8000
10000
0 10 20 30 40 50
Blade Length (m)
Bla
de W
eigh
t (kg
)
ABC
2000 Data
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New Infusion Fabrics from Knytex:
• New Flowtex© line of fabrics decrease infusion time for many closed molding processes.
• Flow channels are incorporated directly into the Knytex©
fabric eliminating the need for a disposable infusion media.
• Knytex© fabrics are available bonded to eliminate fiber crimping.
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New Fiberglass Developments:• Advantex© : New fiberglass
chemistry combining the properties of traditional E-glass with the enhanced performance characteristics of E-CR glass. Patented Technology by Owens Corning.
• New SE 1200 polyester & SE 1500 epoxy Single End Rovings for weaving and infusion processing of Wind Turbine Blades.– Enhanced Fatigue Characteristics
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Environmental Advantages of Advantex© Fiberglass:• About 100,000,000 lbs of glass are used
each year to build wind turbines blades• Advantex© fiberglass production reduces
emissions:– Boron 85% reduction - NOx 80% reduction– Fluorine 90% reduction
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0
10
20
30
40
50After 24h After 168h
Advantex ECRGLAS TraditionalE-glass
OC1
TraditionalE-glass
OC2
TraditionalE-glass
Competitor2
TraditionalE-glass
Competitor1
TraditionalE-glass
Competitor3
TraditionalE-glass
Competitor4
0
10
20
30
40
50After 24h After 168h
Advantex ECRGLAS TraditionalE-glass
OC1
TraditionalE-glass
OC2
TraditionalE-glass
Competitor2
TraditionalE-glass
Competitor1
TraditionalE-glass
Competitor3
TraditionalE-glass
Competitor4
Advantex ECRGLAS TraditionalE-glass
OC1
TraditionalE-glass
OC2
TraditionalE-glass
Competitor2
TraditionalE-glass
Competitor1
TraditionalE-glass
Competitor3
TraditionalE-glass
Competitor4
Advantex® Corrosion Resistance:% Weight Loss
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Creep-Rupture of Composite Rodsin 1 Normal Acids (HCl - H2SO4)
1
10
100
1 10 100 1000 10000 100000 1000000Time to Failure (hours)
Load
(% u
ltim
ate)
50 years
Advantex Glass
Traditional E-Glass
12.1%
0.9%
r2 = 0.97 - Advr2 = 0.96 Trad E
.
73 hrs
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Creep-Rupture of Composite Rodsin Cement Extract (pH 12.6)
10
100
1 10 100 1000 10000 100000 1000000
Time to Failure (hours)
Load
(% u
ltim
ate)
50 years
Advantex Glass
Traditional E-glass24.8%
14.8%r2 = 0.91 - Advr2 = 0.84 - Trad 6700 hrs
9 months
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Creep-Rupture of Composite Rodsin 5% Saltwater
10
100
1 10 100 1000 10000 100000 1000000Time to Failure (hours)
Load
(%ul
timat
e)
50 years
r2 = 0.75 - Advr2 = 0.94 - Trad E
Traditional E-Glass
Advantex Glass
37.1%
27.4%
8000 hrs11 months
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Strain-Corrosion of GRP pipe ringsin 5% H2SO4
log
(Stra
in)
log
(Stra
in)
log (Time)log (Time)
50 years11 days
Advantex® glass
traditional E-glass
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New SE 1500 Single End Roving:
7123New SE1500 7113Previous E-glass
Glass content (%)Extrapolated Stress at 106
cycles(MPa)
Product
Fatigue Properties Laminate Comparison: +/- 450
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11,37
14,90
11,30
13,02
15,00
10
100
1 10 100 1000 10000 100000 1000000Cycles
MPa
Previous E-glass Covariant Regression Single Data 95% CL Line 95% CL
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20,12
26,27
19,27
22,99
27,43
10
100
1 10 100 1000 10000 100000 1000000Cycles
MP
a
SE 1500 Covariant Regression Single Data 95% CL Line 95% CL
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New SE 1500 Single End Roving:
7117.913,766149New SE 1500
7111.3414,13286.8Previous E-glass
Glass content (%)
Elongation %Modulus(MPa)
Strength (MPa)
Product
Tensile Properties: +/- 450 Laminate
711.834,512111New SE 1500
712.343,72998Previous E-glass
Glass content (%)
Elongation %Modulus(MPa)
Strength (MPa)
Product
Compressive Properties: +/- 450 Laminate
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New Ideas For 60+ m Blade Assembly
OC is looking to develop new ways to produce larger blades in order to achieve the following goals:
• Cost effective ransportability of 60+ meter blades on 1 truck
• On-site assembly of either 2 or 3 piece blades
• Ability to design stiffness and torsional response into blade
• Eliminate the need for length wise joining of blade halves
• Could these joints be transition points between different materials to reduce deflection, dampen vibrations & allow flap twist coupling?
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Blade Buckling Information Supplied by:
Peter Norlin - DIAB
Fabric Test Data Supplied by:
David Hartman – Owens Corning
Advantex & SE 1500 Test Data Supplied by:
Byrd Hennessee – Owens Corning
Thank you to the following suppliers for their assistance &
technical support: