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28-10-2009
Challenge the future
DelftUniversity ofTechnology
Vacuum infused thermoplasticcomposites for wind turbine blades
Julie Teuwen, Design and Production of Composites Structures
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Introduction
WIND ENERGY:
Promising renewable energysource
Fast growing market share inenergy supply
WIND TURBINE BLADES:
Length > 50 m Life expectancy 20 years
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Large Wind Turbine Blades
Dedicated Offshore Wind Power Systems:
Stronger and more constant wind Increasingly large blades to increase power output per turbine and
reduce cost per kWh
No noise-pollution and aesthetical issues
Larger blades require: Materials with higher specific properties (E/, /):
Carbon fibre based composites
More efficient structural design
mblade (Rblade)3
2.35
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Current blade manufacturing technology
Material:
Glass fibres (NCFs) Thermoset resin
Process: Vacuum infusion
Prepregging Design:
2 skins and 1 spar
Structural bonding
Design
Material
Process
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Alternative structural design Re-introduction of ribs:
Higher structural efficiency (E/)
Reduces buckling of the spar Provides attachment points and load paths for smart actuators,
control surfaces and sensors
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Why thermoplastics?
Processing:
Forming Assembly by welding
Properties: Good impact properties
High toughness, also at low temperatures Abrasion resistant
Chemical resistant
Life cycle: Unlimited shelf-life of raw materials
Short production cycle time
Fully recyclable
Pre-cut laminatesheet material
Infra redheating panels
Rubber die
Metal die
Rubber press
Final thermoplasticcomposite part
Heating element
Clampconnection
Weldedparts
Voltmeter
Ampmeter
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What still stands in the way? Costs:
Technology costs:
New technologies and expensive equipment
Material costs:
Need for intermediates
Processing:
High processing temperatures (>200C): High costs, thermal stresses
Melt pressing technology:
Limits part size and thickness
Properties: Fatigue performance:
Weak fiber-to-matrix bond
Monomer
Polymer
PowderGranules
Film Solution
Laminate Prepreg
Finalproduct
Traditi
onal
Pro
cessin
gof
Thermopla
stic
Com
posite
s
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Vacuum infusion of thermoplasticcomposites
Reactive processing:
Processing:
From the monomer directly to the polymer
Large, thick, integrated parts
Commonly used technology
Below melting temperature of polymer
Properties: Improved fibre-to-matrix bond
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Vacuum infusion of thermoplasticcomposites
Selection of resin: Low processing
temperature (150-180C)
Low viscosity (10 mPa.s)
Low price/performance(2-3/kg)
Anionic Polyamide-6: AP-Nylon
World wide availability
0,001
0,01
0,1
1
10
100
1000
10000
100000
0 50 100 150 200 250 300 350 400 450
Processing temperature [C]
Meltviscosity
[Pas]
epoxyvinylester
polyester
PMMA
PA-6
PBT
PA-12
PEK
ETPUPC
PMMA
PA-12
PA-6
PBTPPS
PES
PEI
PEEK
PEKK
Reactive processingof thermoset resins
Reactive processing ofthermoplastic resins
Melt processing ofthermoplastic polymers
0,001
0,01
0,1
1
10
100
1000
10000
100000
0 50 100 150 200 250 300 350 400 450
Processing temperature [C]
Meltviscosity
[Pas]
epoxyvinylester
polyester
PMMA
PA-6
PBT
PA-12
PEK
ETPUPC
PMMA
PA-12
PA-6
PBTPPS
PES
PEI
PEEK
PEKK
Reactive processingof thermoset resins
Reactive processing ofthermoplastic resins
Melt processing ofthermoplastic polymers
Selection of resin: Low processing
temperature
Low viscosity
Low price/performance
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Alternative blade manufacturingtechnology
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What is done on material development? Polymer chemistry and physics
Resin infusion process
Composite properties
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Polymer chemistry and physics
Resin composition
0
20
40
60
80
100
0 5 10 15 20 25 30 35 40
time [min]
Degreeofc
onversion[%].
Fast system
Slow systeminfusion
cure CAPROLACTAM
ACTIVATOR C20 INITIATOR C1
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Polymer chemistry and physics
Resin constitution Identify important parameters Understand & simulate the reaction
Polymerisation at different temperatures and comparison with pure -caprolactame,
inner temperature record, same beginning
0
50
100
150
200
250
0 200 400 600 800 1000 1200 1400 1600 1800 2000
time [s]
temperature[C]
pue CL, 140C, 1.measur.
140C, 1.measurement
150C, 1.measurement160C, 1.measurement
pure CL, 150C, 1.measur.
pure CL, 160C, 1.measur.
160C150C
140C
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Polymer chemistry and physics
Resin constitution Identify important parameters Understand & simulate the reaction Characterise the properties
Comparison with currently used material
2
1
0.1
0.2
f
m
Compared to injection molded PA-6
Condition Youngs modulus[GPa]
Maximum strength[MPa]
Strain at failure[%]
23C, dry 4.2 (+ 41%) 96 (+ 14%) 9 (-)23C, 50% RH 2.1 (+ 59%) 61 (+ 4%) 28 (-)
80C, dry 1.6 (+ 65%) 51 (+ 32%) 29 (-)
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Resin infusion process
Development of resin infusion process:
Fabric (fine and coarse weave) Glass
UD
Glass
110C
110C
160-180C
60 minutes
250 mbar
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Resin infusion process
Development of resin infusion process Homogeneous properties: In flow direction
Through thickness
135
140
145
150
155
160
165
170
175
0 5 10 15 20 25
Time [min]
Tem
perature[C]
Tmould = 160C (inlet)
Tmould = 160C (center)
Tmould = 160C (outlet)
Outlet Inlet
-5
0
5
10
15
20
25
30
35
40
45
135 140 145 150 155 160 165 170 175 180 185
Temperature (C)
Layer Thermofoil+Carbon
CarbonResistiveThermofoilPlated press
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Resin infusion process
Development of vacuum infusion process
Homogeneous properties Identify important parameters Optimise infusion process Good mechanical properties
Good fibre-to-matrix bond
10
20
30
40
50
60
70
80
140 150 160 170 180 190 200
Mould temperature [C]
Interlaminarsh
earstrength[MPa]
APA-6 composite (unsized/outlet)
APA-6 composite (sized/outlet)
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Composite Properties
Static properties
(Dry conditioned)
0
100
200
300
400
500
600
Compressive strength Tensi le strength Shear strength
[MPa]
APA-6 Epoxy PA-6
0
5
10
15
20
25
30
Compressive modulus Tensile modulus Shear modulus
[GPa]
APA-6 Epoxy PA-6In dry state, APA-6 outperforms
all other reference material
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Composite Properties
Static properties(moisture conditioned):
0
50
100
150
200
250
300
350
400
450
500
Compressive strength Tensile strength Shear strength
[MPa]
APA-6 Epoxy PA-6
0
5
10
15
20
25
30
Compressive modulus Tensile modulus Shear modulus
[GPa]
APA-6 Epoxy PA-6
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Composite Properties
Dynamic properties: APA-6 compositemanufactured at 180C has
better fatigue properties
than the melt processed PA-
6 composite:
Same toughness
Higher interfacial bond
strength0
50
100
150
200
250
300
350400
1.0E
+02
1.0E
+03
1.0E
+04
1.0E
+05
1.0E
+06
1.0E
+07
n
S[MPa]
APA-6 (180C)PA-6Epoxy
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Conclusions
For rib/spar/skin-structures, thermoplastic composites arefavoured over thermoset composites. Parts can be rapidly meltprocessed and assembled through welding. Blades will be fullyrecyclable.
Vacuum infusion of thermoplastic composites is introduced to
overcome the classical drawbacks of these materials.
The cure of a semi-crystalline thermoplastic resin is morecomplicated than of a thermoset resin.
AP Nylon has a low viscosity (10 mPa.s), good availability, alow price (2-3 /kg), and a relatively low processing temperature(150-180C).
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Conclusions Homogeneous composites were obtained after optimisation of
infusion process. Temperature, pressure and time are the key
parameters.
Reactively processed PA-6 outperforms melt processed PA-6 inall temperatures and humidities tested.
Static properties of APA-6 composites are better than of theirHPA-6 and epoxy counterparts in dry conditions. When moistureconditioned, the performance of APA-6 composites drops rapidly.
Reactive processing of thermoplastic composites results in astrong interfacial bond strength and leads consequently tobetter fatigue performance compared to melt processing.
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Vacuum infused thermoplastic
composites for wind turbine blades
Questions?
Julie Teuwen
Delft University of TechnologyFaculty of Aerospace Engineering
Design and Production of Composite Structures