International Conference on Global Trends in Engineering, Technology and Management (ICGTETM-2016)
A Review on Research and Development in Wind Turbine
Blade Design using Composite Materials
Amol V. Deshmukh1, Sagar Sali2,Dheeraj S. Deshmukh3
12
M.E. Student, 3Professor and Head of Department
123
Department of Mechanical Engineering
SSBT’s, College Of Engineering, and Technology, Bambhori, Jalgaon. (M.S.), India
Abstract- Turbine blade design plays very
important role in overall performance enhancement of
wind turbines. Proper blade design is required to
obtain desired cross section to generate maximum
torque for driving wind turbine generator. In this
paper review of different composite materials, their
comparisons, structures, methods imparted for
reinforcement of composite materials are discussed.
This paper provides an overview of recent studies of
composite laminates for wind turbine blade design
and summarizes performance of Wind Turbine Blade
with mechanical properties of composite materials. In
this paper blade design considerations for improving
efficiency of the blade, new materials for wind turbine,
design to minimize stress concentrations are
discussed. Different material for wind turbine blade
and mechanical properties of advanced composites
are re-viewed.
Keywords-Carbon
Fiber
Composites,Failure
Criteria, Mechanisms, Fatigue Resistance, Glass
Fiber Composites.
I. INTRODUCTION
One of the primary goals for blade research is to
keep blade weight growth under control. The
efficiency of the wind turbine depends on the material
of the blade, shape of the blade and angle of the blade.
Therefore, the material of the turbine blade plays a
vital role in the wind turbines. The material of the
blade should possess high stiffness, low density and
long fatigue life features (Fig. 1) [1].
technology improves and evolves. There is a trend
toward lighter weight systems. Light weight, low cost
materials are especially important in blades. A wide
range of materials are used in wind turbines. There are
substantial differences between small and large
machines and there are projected changes in designs
that will accommodate the introduction of new
material technologies. Most composites are made up
of just two materials. One material (the matrix or
binder) binds together a cluster of fibers or the
fragments of a much stronger material and the second
material (the reinforcement) surrounds these fibers or
fragment. Researchers want to improve the
performance of the composite, such as making them
more resistant to impact [2]. Mechanical and physical
properties of fibrous composite materials are
beneficial compared to other constructional materials
of wind turbine blades. The major advantages of this
type of materials are low weight and high strength [6]
[7]. Therefore, wind turbine blades built up with
composite materials have much less weight than
traditional constructions. Composite materials
reinforced with fiberglass (Fig. 2a), carbon (Fig. 2b)
and Kevlar (Fig. 2c) fibers are considered [8].
Figure 2: Composite materials: (a)Fiber Glass (b)Carbon (c)Kevlar
[8]
Figure 1: Typical Blade profile and its cross-section [1]
The components of turbines are changing as the
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Most rotor blades in use today are built from glass
fiber-reinforced-plastic (GRP). Other materials that
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have been tried include steel, various composites and
carbon filament-reinforced-plastic (CFRP). As the
rotor size increases on larger machines, the trend will
be toward high strength, fatigue resistant materials. As
the turbine designs continually evolve, composites
involving steel, GRP, CFRP and possibly other
materials will likely come into use. Blades are
primarily made of GRP, while use of CFRP may help
to reduce weight and cost to some extent. Low cost
and reliability are the primary drivers for material
selection. Carbon fiber reinforcements are being
introduced into blades. These can be used to improve
the stiffness and tensile strength in the fiber direction,
as compared to materials containing glass, but the
gains in compressive strength are generally
significantly lower. Thus, it is often most economical
to use a mixture of glass and carbon, with carbon
being used mainly to increase the global blade
stiffness. The development of products that provide a
better combination of strength (including good
adhesion), stiffness and toughness than those available
at present would be a great step forward. However,
such materials must not degrade in service and should,
if possible, be recyclable [10].
II. BLADE DESIGN CONSIDERATIONS
Examples of the concepts that SNL is developing
include [3]:
1. More efficient blade structures (thick airfoils,
designs that fully integrate structure and
aerodynamics, and slenderized blade geometries)
2. Adaptive structures (passive bend-twist coupling
and active devices)
3. Materials, fatigue and manufacturing
4. New materials for wind turbine blades such as
carbon, carbon-hybrid, S-glass and new material
forms
5. Design details to minimize stress concentrations
in ply drop regions
6. Less expensive, embedded blade attachment
devices.
III. MATERIALS FOR WIND TURBINE BLADES
The material selection of the wind turbine blades
plays an important role in the wind turbine designs. In
selecting materials for an application, technological
considerations
of
material
properties
and
characteristics are important. The economic aspects of
material selection, such as availability, cost of raw
materials and cost of manufacturing, are equally
important [12], [13]. One of the most important
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factors affecting selection of materials for engineering
design is the properties of the materials. The important
properties of the materials are mechanical, thermal,
chemical properties, etc.The material of which a part
is composed must be capable of performing part’s
function (always it must be possible or not) without
failure. A material in a given application must also be
reliable. A material must safely perform its function.
Also cost of the materials and cost of processing the
material plays role.
In any material selection, the following requirements
should be focused, they are:
High material stiffness is needed to maintain
optimal shape of performance.
Low density is needed to reduce gravity
forces.
Long-fatigue life is needed to reduce material
degradation [12] [14]
Figure 3: Ashby material selection diagram [1], [16], [17]
Wind energy is harvested by the rotation of the wind
turbine’s rotor blades. Rotor blades have historically
been made of wood; but because of its sensitivity to
moisture and processing costs, modern materials such
as glass fiber-reinforced-plastic (GFRP), carbon fiberreinforced-plastic (CFRP), steel and aluminium are
replacing the traditional wooden units. Composite
materials are becoming more important in the
construction of wind turbine blade structures. The
primary advantages of composite materials are their
high strength, relatively low weight and corrosion
resistance. It was recognized that structures are
hybrids of different engineering materials and that to
achieve true benefits from advanced composites,
developments in this area must include the integrated
structural system as well. It is important to create
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critical mass for this technology if it is to be
successful in a commercial exploitation. [17]
Composites are classifiedaccording to their matrix
phase. There are polymer matrix composites (PMCs),
ceramic matrix composites (CMCs) and metal matrix
composites (MMCs). Materials within these categories
are often called “advanced” if they combine the
properties of high strength and high stiffness, low
weight, corrosion resistance, and in some cases special
electrical properties. This combination of properties
makes advanced composites very attractive for
aircraft, aerospace structural parts and wind turbine
blades [18]. A matrix supports the fibers and bonds
them together in the composite material. The matrix
transfers any applied loads to the fibers, keeps the
fibers in their position and chosen orientation, gives
the composite environmental resistance and
determines the maximum service temperature of a
composite.
IV. MECHANICAL PROPERTIES OF
ADVANCED COMPOSITES
If composites combine the properties of high
strength values and high stiffness values, with low
weight and corrosion resistance, these materials are
often called as advanced composite materials (ACMs).
Advanced composite materials are also known as
advanced polymer matrix composites [19]. These are
generally characterized or determined by unusually
high strength fibers with unusually high stiffness, or
modulus of elasticity characteristics, compared to
other materials, while bound together by weaker
matrices (Fig. 4). These are termed advanced
composite materials (ACM) in comparison to the
composite materials commonly in use such as
reinforced concrete, or even concrete itself. The high
strength fibers are also low density while occupying a
large fraction of the volume [28].
1) Fiber Orientation:This range of values is
determined by the orientation of the plies to the
applied load. Proper selection of ply orientation in
advanced composite materials is necessary to provide
a structurally efficient design. The part might require
00 plies to react to axial loads, 450 plies to react to
shear loads and 900 plies to react to side loads. The
fibers in a unidirectional material run in one direction
and the strength and stiffness is only in the direction
of the fiber. Pre-impregnated tape is an example of a
unidirectional ply orientation. The fibers in a
bidirectional material run in two directions, typically
900 apart. A plain weave fabric is an example of a
bidirectional ply orientation. These ply orientations
have strength in both directions but not necessarily the
same strength (Fig. 5) [29].
Figure 5: Bidirectional and unidirectional material properties [29]
The plies of a quasi-isotropic layup are stacked in a
00,
–450, 450and 900sequence or in a 00, –600 and 600
sequence. (Fig. 6) These types of ply orientation
simulate the properties of an isotropic material. Many
wind turbine blades composite structures are made of
quasi-isotropic materials.
Figure 6: Quasi-isotropic material lay-up [20]
Figure 4: Advanced composites general characteristics [28]
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Warp indicates the longitudinal fibers of a fabric.
The warp is the high strength direction due to the
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straightness of the fibers. A warp clock is used to
describe direction of fibers on a diagram, spec sheet,
or manufacturer’s sheets. If the warp clock is not
available on the fabric, the orientation is defaulted to
zero as the fabric comes off the roll. Therefore, 900 to
0º is the width of the fabric across (Fig.7).
mechanical interference coupled with surface
treatment and chemical bonding between the fiber and
the matrix. Typically they are defined as standard,
intermediate and high modulus fibers. Carbon fiber
properties are given in Table 1 [18].
Standard
Intermediate
High
modulus
modulus
modulus
3450-4830
3450-6200
3450-5520
Tensile
MPa
MPa
MPa
Strength
Young’s
220-241
290-297
345-448
Modulus
GPa
GPa
GPa
Elongation
1.5-2.2%
1.3-2.0%
0.7-1.0%
at break
Table 1: Carbon fiber properties [18]
Figure 7: A warp clock [20]
Knitted or stitched fabrics can offer many of the
mechanical advantages of unidirectional tapes. Fiber
placement can be straight or unidirectional without the
over/under turns of woven fabrics. The fibers are held
in place by stitching with fine yarns or threads after
preselected orientations of one or more layers of dry
plies. These types of fabrics offer a wide range of
multi-ply orientations. Although there may be some
added weight penalties or loss of some ultimate
reinforcement fiber properties, some gain of interlaminar shear and toughness properties may be
realized. Some common stitching yarns are polyester,
aramid or thermoplastics. (Fig. 8) [20].
Aramid fibers have the highest strength to weight
ratio compared to other commercially available fibers.
Kevlar manufactured by DuPont is a familiar brand
name. Aramid fiber exhibits similar tensile strength to
glass fiber, but can have modulus at least two times as
great
Aramid is very tough allowing significant energy
absorption but, compared to carbon, it is lower in
compressive strength and has poorer adhesion to the
matrix. It is also susceptible to moisture absorption.
Aramid fiber properties depend on the structure used
and can be tailored for high toughness or high
modulus. Aramid (Kevlar) fiber properties are given
in Table 2 [18].
Tensile
Strength
Young’s
Modulus
Elongation
at break
Kevlar 29
Hightoughnes
s
3.6 GPa
Kevlar 49
High
modulus
3.6-4.1 GPa
Kevlar 149
Ultrahigh
modulus
3.6 GPa
83 GPa
131 GPa
179 GPa
4%
2.8%
2.0%
Table 2: Aramid (Kevlar) fiber properties [18]
2) Resins
Figure 8: Nonwoven material (stitched) [20]
Carbon fiber is the reinforcement material of
choice for “advanced” composites, Carbon fiber
exhibits excellent fatigue resistance which does not
suffer from stress rupture compared with glass or
aramid fibers. Carbon fibers are supplied in tows and
may vary from 1000 fibers per tow to hundreds of
thousands per tow. Untreated carbon fibers do not wet
easily, so adhesion to the matrix must be achieved by
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The resin systems used to manufacture
advanced composites are of two basic types:
thermosetting and thermoplastic. Thermosetting
resins predominate today, while thermoplastics
have only a minor role in manufacturing advanced
composites. Thermoset resins require addition of a
curing agent or hardener and impregnation onto a
reinforcing material, followed by a curing step to
produce a cured or finished part. Once cured, the
part cannot be changed or reformed, except for
finishing [21]. Some of the more common
thermosets include: epoxies polyurethanes phenolic
and amino resins bismaleimides (BMI, polyimides)
polyamides of these, epoxies are the most
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commonly used in today’s PMC industry. These
resins range from low-viscosity liquids to highmolecular weight solids. Typically they are highviscosity liquids. Fiber reinforcement materials are
added to the resin system to provide strength to the
finished part [18].
V. COMPOSITE TESTING
SNL has had an ongoing effort to characterize
composite materials for wind turbine use. Much of the
related fatigue testing of composite materials has been
and continues to be performed by Montana State
University (MSU), which first published the
DOE/MSU Composite Material Fatigue database in
1997 [3,4]. This document, which is updated yearly,
contains the results of static and fatigue coupon testing
of commercially-available composite materials.
1)Effects of Fiber Type
The effects of fiber type on tension and
compression fatigue resistance are shown in Fig 9.
Where the stress and strain based fatigue resistance in
tension (R = 0.1) and compression (R = 10) are
compared [4] [5].
The four laminates, representing three main fiber
types all with epoxy resins, are:
E-glass
(or
AdvantexTM), QQ1 ELT- 5500-EP
WindStrandTM, WS1
Carbon hybrid (Grafil 34-600, 48k tow), P2B
The laminates have differing contents of 00 plies
relative to 450 plies, slightly different fiber contents,
and different processing. Notable differences in
fatigue performance are that the carbon hybrid is
superior in terms of stress, and shows a much higher
fatigue exponent as com-pared to the glass fiber
materials tested at R = 0.1 (tension-tension fatigue).
The same can be said of the performance of carbon at
R = 10 (compression-compression fatigue). Of the
glass laminates, QQ1 is notably less fatigue resistant
than E-LT-5500-EP in tension while the converse is
true in compression. WindStrandTM is generally
similar to the best of the E-glass laminates in each
case, but slightly stronger in terms of stress, in
tension. The aligned strand structure of the
WindStrandTM WS1 laminates may be advantageous
as compared with the stitched fabrics used for QQ1
and E-LT-5500 [25].
10. Carbon fiber reinforced laminates for wind blades
are most limited by compressive strength and ultimate
strain [22] [23]. Additionally, the presence of even
minor amounts of fiber misalignment has been shown
to reduce static and fatigue properties significantly
[24]. Maximum compressive properties are obtained
with laminates which have the straightest fiber
alignment, generally unidirectional prepreg 0 0 plies;
poorest properties have been found with woven
fabrics, particularly with large tows. Figure 11
compares the compressive static and fatigue properties
for three carbon fiber materials: P2B, relatively thick
(0.3 mm) prepreg with unidirectional carbon fiber 0 0
plies; MMWK C/G-EP, infused tri-axial fabric with
+450 and -450 E-glass plies sandwiching 00 carbon
strands; and CGD4, VARTM processed 00 stitched
carbon fabric with E-glass 450 plies. The P2B laminate
gives properties typical of other large tow prepregs.
The CGD4 laminate is among the best stitched or
bonded carbon fabrics tested [22], but not as good as
the prepreg, apparently due to slight misalignment in
the fabric strands. The MMWK-C/G- EP laminate
properties were at least equivalent to various prepregs
tested in this program, with very straight strands held
in place by the glass 45’s. This fabric contains about
25% off-axis material by volume which reduces the
strength and modulus values relative to 100%
unidirectional carbon laminates [25].
Figure 10: Comparison of compressive fatigue resistance of hybrid
laminates with carbon 00 plies and E-glass 450 plies: materials P2B
(prepreg); MMWK C/G-EP (infused stitched hybrid tri-axial
fabric); and CGD4E (VARTM stitched fabrics) at R = 10.
2)Effect of Carbon Reinforcement
Carbon hybrid laminates are compared in Figure
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Figure 9: Fatigue comparison of multidirectional laminates based on E-glass (QQ1 and E-LT-5500), WindStrandTM (WS1) and carbon
(P2B) fibers at similar fiber contents, in terms of stress (top) and strain (bottom), epoxy resins, R = 0.1 (left side) and R = 10 (right side).
Major issues have been identified which can produce
severe fatigue damage or failure in good quality
coupons at maximum absolute strains in the range of
0.2 to 0.4%:
1. Glass fiber laminates with less fatigue resistant
fabric architectures at higher fiber contents, loaded
in tensile fatigue with R-values in the -0.5 to 0.1
range.
2. Delaminations at ply drops and ply joints, for plies
greater than 1.0 mm thickness for glass fibers, or
0.6 mm for carbon fibers (most R-values).
3. Matrix cracking in off-axis plies, for R-values with
a significant tensile component (glass and carbon
fiber laminates, various resins).
4. Carbon fiber laminates compressive strength and
its sensitivity to fabric or other fiber waviness.
5. Delamination and adhesive failure in complex
details under both static and fatigue loading.
6. Hot/wet conditions can exacerbate these issues
(with the exception of the first).
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VI. FINDINGS FROM REVIEW
Following important points are found during
review of literature:
The relatively new
WindStrandTM based laminates, in addition to
moderately higher modulus, show very good fatigue
resistance under both tension and compression loading,
compared to E-glass. Carbon, either prepreg or the
infused triax hybrid fabric, is very fatigue resistant
under all loading conditions; other infused fabrics
have shown reduced compression resistance. The
increased volume has resulted in an expected
reduction in cost.Delamination resistance under pure
and mixed modes is strongly matrix dependent, with
epoxies generally providing the most resistance. Ply
drop delamination at high fatigue cycles occurs at low
strains regardless of R-value, position through the
thickness or overall laminate thickness. The thickness
of material dropped at a single position is an important
geometric parameter; improvements have been
demonstrated for treatments of the ply drop edge,
including chamfering and pinking.
CONCLUSIONS
Stiffness helps for preventing buckling of parts of the
blade against compressive stresses. Structural
arrangement and dimensions in accordance with
materials selection helps in making the Blade
lightweight thus minimizing the cost. As per study
composites are unique in their ability to be tailored for
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different properties using various reinforcement
configurations and matrix materials. Advanced
composites like fiber-reinforced composites of the
type used in wind turbine blades are laminates that can
be very strong and stiff when loaded in their own
plane, but are much weaker when loaded out-of-plane
because the layers, or plies, can more readily be pulled
apart. Increasingly enabled by the introduction of
newer polymer resin matrix materials and high
performance reinforcement fibers of glass, carbon and
aramid, the penetration of these advanced materials
has witnessed a steady expansion in uses and volume.
As per the review it is concluded that new polymer
resins and reinforcement fibers of glass, carbon and
aramid are most effective performance enhanced
materials.
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