Surface Erosion of Wind Turbine Blades:: Leon Mishnaevsky JR
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LeonSurface Erosion of Wind Turbine Blades:: Leon Mishnaevsky JR
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LeonSURFACE EROSION OF WIND
TURBINE BLADES:
IFD project Duraledge and some recent results
Leon Mishnaevsky Jr.
DTU Wind Energy
Surface erosion of wind turbine blades –
one of main reason for blade degradation
Estimation by
Westergaard Solutions,
Inc: 16,611 turbines in the
US fleet will need leading
edge repair over the next 5
year (4.5.2020).
Photos by Jakob Bech, DTU
How the erosion goes on?
Rain droplets hit
the surface in the
blade coating…
Stress waves are spread in the Microcracks develop and
material and after several hits, lead to the surface
microcracks form… roughening and cracking…
L. Mishnaevsky Jr.: Wind Energy 2019;1–18, doi.org/10.1002/we.2378
Testing of erosion of blades
Rain Erosion Tester (www.rd-as.com)
Structure of leading
edge protection
J. Bech et al, Wind Energy Sci. 3
(2) (2018)
Single point impact fatigue test (SPIFT, DTU WE)
A. Fraisse, et al, Renewable Energy 126 (2018) 1102e1112
Project DURALEDGE: Durable leading edges
for high tip speed wind turbine blades:
Project funded by Innovation
Foundation of Denmark
Start/Duration: 1.11.2018/ 36 months
Budget: 19 Mio DKK
Work packages:
WP1 Understanding the
leading edge (LE)
degradation
WP2. Multiscale computational
modelling of LEE
WP3. Optimized protective
solutions with
engineered coatings, Partners:
WP4. Validation for field
applications
www.duraledge.dk
Strategies to counteract erosion
Prediction
and repair
Protection
Prevention &
avoidance
(~erosion safe mode
control)
Banner prepared by Martin Kirchgässner, Kirchgässner Infografik
How to improve protective coatings?
Thickness of coating
Stress amplitude decays exponentially with distance; Thick
coatings are less prone to debonding
Viscoelastic damping, loss modulus
of coating material
More energy dissipation after drop impact ensures better
protection
Toughness, fatigue strength of coating material
High strength prevents damage initiation, while toughness prevents damage
growth
L. Mishnaevsky Jr.: Wind Energy 2019;1–18, doi.org/10.1002/we.2378
How to improve protective coatings?
….continuation…
Polymer structure
Example: Segmented structure of polyurethanes, with hard blocks
determining the stiffness, while flexible blocks determine the elastic
deformation.
More layers and interfaces: Wave
reflection on interfaces
If the wave from droplet impact travels through interface, the part
of energy is reflected due to the impedance mismatch.
Stress wave scattering on particles:
Reflection and refraction on the inclusions. Multiple scattering of
waves on particles lead to frequency dependent velocity and
attenuation of coherent waves.
Mechanisms of erosion
Image of severely eroded RET sample
SEM images of the three cross sections of coating system A. (a) Boarder position of
the region where the coating have been removed. (b) Section close to the eroded
region. (c) Section 2cm in front of the eroded region
Manufacturing
defects (voids,
inclusions) play
critical role in
blade erosion.
SEM images with high magnification (x1000) of
coating system A. (a) Black cracks close to the Cracks are initiated near
surface are seen to be closely connected with white
elongated particles. (b) Surface spalling are observed
largest voids in coatings.
above white elongated particles.
See Søren Fæster (DTU). X-Ray analysis of leading edge erosion mechanisms, Int. Symposium on LEEWTB, 4-6.2.2020;
L. Mishnaevsky Jr., et al Wind Energy, 2019; 1–16. https://doi.org/10.1002/we.2441
Computational modelling of surface
erosion
Estimation of loading: Rain
scenario, droplet size
distribution, flow velocity
Material characterization:
damping, viscoelastic,
strength, structure
Impact contact droplet
/particle and surface: pressure
on the surface, time, wave
distribution, Rayleigh waves
Deformation and damage
initiation: coating cracking,
debonding, fatigue, material
loss, estimation of lifetime
S.D. Rad, L. Mishnaevsky Jr, J. Bech, Leading edge erosion of wind turbine blades, Wind Energy, https://doi.org/10.1002/we.2515; S.D. Rad, L.
Mishnaevsky Jr. Rain erosion of wind turbine blades, Meccanica, doi:10.1007/s11012-019-01089-x
Some Observations
Rain drop hitting blade surface at an Large rain drop change shapes: due
angle: normal impact creates higher to air resistance, and that changes the
stresses in the coating than incident impact deformation mechanisms
Voids in coatings: even presence of
Surface roughness leads to higher 100 µm voids/air bubbles leads to 10 %
stresses in coatings and more shorter lifetime of the coatings.
localized stress field.
S.D. Rad, L. Mishnaevsky Jr, Wind Energy, https://doi.org/10.1002/we.2515; Meccanica, doi:10.1007/s11012-019-01089-x
Some Observations– continuation
Wet surface of blades: water film reduces Multiple layers, soft/stiff bilayer
the peak stress effectively and can increase coatings: Soft coating layer on top of
lifetime by 25%. stiff layer ensures lower stresses in the
coating
Polyurethane structure: lifetime of Effect of viscoelasticity of coating:
coatings increases with increasing
Stresses are lower for purely elastic
difference between damping properties
coatings, but are localized in vicinity of
of soft & hard phases of PU.
drop impact area. Viscoelasticity leads
high stress region beneath the surface.
Arena et al,
10.3144/expresspo
lymlett.2015.18
Kolařík, J Polymer Research 7
(1), 2000, 7-14
S.D. Rad, L. Mishnaevsky Jr, Wind Energy, https://doi.org/10.1002/we.2515; Meccanica, doi:10.1007/s11012-019-01089-x
International Symposium on Leading
Edge Erosion of Wind Turbine Blades
February 4-6, 2020,
Roskilde, DTU,
Denmark
120 participants
www.conferencemanager.
dk/leewtb
Energy Insight 2020,
lnkd.in/esisQax, pp.
50-53,
Acknowledgements
Financial support of the Innovation Foundation of Denmark in the
framework of the Grand Solutions project DURALEDGE, Durable
leading edges for high tip speed wind turbine blades, File nr.:
8055-00012A, is gratefully acknowledged.
Bent. F. Sørensen, Charlotte Bay Hasager, Jakob I. Bech, Saeed
Doagou-Rad, Søren Fæster, Yukihiro Kusano and other colleagues
at DTU, Department of Wind Energy contributed to this work.
Some References
A. Fraisse et al., Impact fatigue damage of coated glass fibre reinforced polymer
laminate, Renewable Energy 126 (2018) 1102e1112
J. Bech et al, Extending the life of wind turbine blade leading edges, Wind Energy
Sci. 3 (2) (2018)
L. Mishnaevsky Jr.: Repair of wind turbine blades, Renewable Energy, 2019
L. Mishnaevsky Jr., et al Micromechanisms of leading edge erosion of wind turbine
blades, Wind Energy, 2019; 1–16.
L. Mishnaevsky Jr.: Toolbox for optimizing anti-erosion protective coatings, Wind
Energy 2019;1–18
S.D. Rad, L. Mishnaevsky Jr, J. Bech, Leading edge erosion of wind turbine blades,
Wind Energy, https://doi.org/10.1002/we.2515
S.D. Rad, L. Mishnaevsky Jr. Rain erosion of wind turbine blades, Meccanica,
doi:10.1007/s11012-019-01089-x
L. Mishnaevsky Jr., J. Sütterlin, Micromechanical model of surface erosion,
Polymer Degradation and Stability 166, 2019
Thank you very much
