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Composite Materials for Wind Turbine Blades Povl Brndsted Materials Research Division Ris National Laboratory for Sustainable Energy Technical University of Denmark Application Windmills Wind turbines Entertaining and Larger Larger

  1. Composite Materials for Wind Turbine Blades Povl Brøndsted Materials Research Division Risø National Laboratory for Sustainable Energy Technical University of Denmark

  2. Application Windmills – Wind turbines Entertaining and Larger Larger Challenging Small 2 Risø DTU, Technical University of Denmark Risø DTU, Technical University of Denmark MatWind, Keynote 2011-05-15

  3. 5M Wind Power Turbine, Brunsbüttel, Germany, 61.5 m blades (Courtesy of LM Glasfiber A/S) 3 Risø DTU, Technical University of Denmark Risø DTU, Technical University of Denmark MatWind, Keynote 2011-05-15

  4. Growth 4 Risø DTU, Technical University of Denmark Risø DTU, Technical University of Denmark MatWind, Keynote 2011-05-15

  5. The Wind Turbine Blade LM 61.5 m (17.7 tons) 30 Trendline blades < 40 m 25 Blade Weight (metric ton) y = 0.0005x 2.6589 20 15 10 5 0 0 10 20 30 40 50 60 70 Blade Length (m) 5 Risø DTU, Technical University of Denmark Risø DTU, Technical University of Denmark MatWind, Keynote 2011-05-15

  6. Blade construction - an aerodynamic shell and a load-carrying beam 6 Risø DTU, Technical University of Denmark Risø DTU, Technical University of Denmark MatWind, Keynote 2011-05-15

  7. Blade construction 7 Risø DTU, Technical University of Denmark Risø DTU, Technical University of Denmark MatWind, Keynote 2011-05-15

  8. Load Type 8 Risø DTU, Technical University of Denmark Risø DTU, Technical University of Denmark MatWind, Keynote 2011-05-15

  9. Blade construction - an aerodynamic shell and a load-carrying beam 9 Risø DTU, Technical University of Denmark Risø DTU, Technical University of Denmark MatWind, Keynote 2011-05-15

  10. 10 Risø DTU, Technical University of Denmark Risø DTU, Technical University of Denmark MatWind, Keynote 2011-05-15

  11. Adhesive Joints 11 Risø DTU, Technical University of Denmark Risø DTU, Technical University of Denmark MatWind, Keynote 2011-05-15

  12. Material Selection for Blades • Optimise against Stiffness • Optimise against fatigue • Optimise agaist Weight • Life time 20 Years => >100.000.000 load cycles 12 Risø DTU, Technical University of Denmark Risø DTU, Technical University of Denmark MatWind, Keynote 2011-05-15

  13. Selection Tool - Stiffness 13 Risø DTU, Technical University of Denmark Risø DTU, Technical University of Denmark MatWind, Keynote 2011-05-15

  14. Composite Parameters Fibre orientation Fibre properties Porosity Mechanical performance Matrix properties of composites Fibre content Fibre length Fibre packing ability Fibre/matrix interface properties 14 Risø DTU, Technical University of Denmark Risø DTU, Technical University of Denmark MatWind, Keynote 2011-05-15

  15. Typical properties of fibres and composites Fibres Composites Type Stiffness Tensile Density, Vol. Orientati Stiffness Tensile Density, Merit on   f  c 1/2 /  c Strength Fraction Strength E f E c E c  f MPa  c MPa V f GPa g/cm3 GPa g/cm3 Glass-E 72 3500 2.54 0.5 0º 38.0 1800 1.87 3.3 0.3 Random 9.3 420 1.60 1.9 Carbon 350 4000 1.77 0.5 0º 176.0 2050 1.49 8.9 0.3 Random 37.0 470 1.37 4.4 Aramid 120 3600 1.45 0.5 0º 61.0 1850 1.33 5.9 0.3 Random 14.1 430 1.27 2.9 Polyethylene 117 2600 0.97 0.5 0º 60.0 1350 1.09 7.1 0.3 Random 13.8 330 1.13 3.3 Cellulose 80 1000 1.50 0.5 0º 41.0 550 1.35 4.7 0.3 Random 10.1 170 1.29 2.5 15 Risø DTU, Technical University of Denmark Risø DTU, Technical University of Denmark MatWind, Keynote 2011-05-15

  16. Composite Materials Fibres: Matrix: Composite materials • Glass fibres • Thermosetting polymers • Carbon fibres • Thermoplastic polymers + = • Aramid fibres • Metals • Cellulose • Ceramics fibres • and more …. Spider silk fibres 16 Risø DTU, Technical University of Denmark Risø DTU, Technical University of Denmark MatWind, Keynote 2011-05-15

  17. Composite Architectures  Fibre-orientation  unidirectional  weaves/patterns  random orientation  Boundary fibre/matrix:  interface  interphase (zone) 17 Risø DTU, Technical University of Denmark Risø DTU, Technical University of Denmark MatWind, Keynote 2011-05-15

  18. Manufacturing • Hand layup • Vacuum Assisted Resin Transfer Moulduíng 18 Risø DTU, Technical University of Denmark Risø DTU, Technical University of Denmark MatWind, Keynote 2011-05-15

  19. 19 Risø DTU, Technical University of Denmark Risø DTU, Technical University of Denmark MatWind, Keynote 2011-05-15

  20. Tvind Møllen 20 Risø DTU, Technical University of Denmark Risø DTU, Technical University of Denmark MatWind, Keynote 2011-05-15

  21. 21 Risø DTU, Technical University of Denmark Risø DTU, Technical University of Denmark MatWind, Keynote 2011-05-15

  22. 22 Risø DTU, Technical University of Denmark Risø DTU, Technical University of Denmark MatWind, Keynote 2011-05-15

  23. 23 Risø DTU, Technical University of Denmark Risø DTU, Technical University of Denmark MatWind, Keynote 2011-05-15

  24. 24 Risø DTU, Technical University of Denmark Risø DTU, Technical University of Denmark MatWind, Keynote 2011-05-15

  25. Root End 25 Risø DTU, Technical University of Denmark Risø DTU, Technical University of Denmark MatWind, Keynote 2011-05-15

  26. Composite Length Scales 26 MatWind, Keynote

  27. Properties • Measurements of Mechanical Properties on Different Scales • Full scale structures • Wind turbines • Components • Blades • Subcomponents • construction details from blades, adhesive joints • Materials performance • Standards, recommendations, experimental models • Microstructures • Single fibre tests, ESEM tests 27 Risø DTU, Technical University of Denmark Risø DTU, Technical University of Denmark MatWind, Keynote 2011-05-15

  28. 28 Risø DTU, Technical University of Denmark Risø DTU, Technical University of Denmark MatWind, Keynote 2011-05-15

  29. Blade test - quality control LM 61.5 m 29 Risø DTU, Technical University of Denmark Risø DTU, Technical University of Denmark MatWind, Keynote 2011-05-15

  30. Blade tested to failure – static loading (well above design load) 30 Risø DTU, Technical University of Denmark Risø DTU, Technical University of Denmark MatWind, Keynote 2011-05-15

  31. Complicated failure - many failure modes 31 Risø DTU, Technical University of Denmark Risø DTU, Technical University of Denmark MatWind, Keynote 2011-05-15

  32. Fracture modes Cracks in gelcoat (chanal cracks) Adhesive joint failure Skin/adhesive Delamination debonding  (+/-45 ) Adhesive joint failure Splitting along 32 Risø DTU, Technical University of Denmark Risø DTU, Technical University of Denmark fibres MatWind, Keynote 2011-05-15

  33. Fracture modes - example: a wind turbine blade Delamination Split cracks Sandwich Laminate debonding Foam 33 Risø DTU, Technical University of Denmark Risø DTU, Technical University of Denmark MatWind, Keynote 2011-05-15

  34. Fracture modes - example: a wind turbine blade Compression Delamination failure Sandwich debonding Split cracks 34 Risø DTU, Technical University of Denmark Risø DTU, Technical University of Denmark MatWind, Keynote 2011-05-15

  35. Fracture modes - example: a wind turbine blade Multiple Splitting delaminations Compression failure Buckling-driven delamination Delamination Splitting Split cracks in surface layer Delamination 35 Risø DTU, Technical University of Denmark Risø DTU, Technical University of Denmark MatWind, Keynote 2011-05-15

  36. Multiscale modelling Combine a coarse 3D model with a fine model of each damage mode z 36 Risø DTU, Technical University of Denmark Risø DTU, Technical University of Denmark MatWind, Keynote 2011-05-15

  37. Subcomponent Test – Girder Section 37 Risø DTU, Technical University of Denmark Risø DTU, Technical University of Denmark MatWind, Keynote 2011-05-15

  38. Mechanical testing – Test Coupons Measurement of mechanical properties used in • qualification of materials • constitutive models based on material structures and micromechanical behaviour • design, reliability and lifetime estimation • models describing elastic-plastic behaviour and for use in solid mechanics modelling 38 Risø DTU, Technical University of Denmark Risø DTU, Technical University of Denmark MatWind, Keynote 2011-05-15

  39. Material Qualification • Characterisation of Laminates • Characterisation of Core material and structure • Characterisation of interface between skin and core • Characterisation of sandwich The materials are to be tested in static loading and in fatigue loading 40 Risø DTU, Technical University of Denmark Risø DTU, Technical University of Denmark MatWind, Keynote 2011-05-15

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