Manufacturing and Flexural Characterization of Infusion-Reacted Thermoplastic Wind Turbine Blade Subcomponents
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Manufacturing and Flexural Characterization of Infusion-Reacted Thermoplastic Wind Turbine Blade Subcomponents Robynne E. Murray 1 & Dayakar Penumadu 2 & Dylan Cousins 3 & Ryan Beach 1 & David Snowberg 1 & Derek Berry 1 & Yasuhito Suzuki 3,4 & Aaron Stebner 3 Received: 28 December 2018 / Accepted: 14 January 2019/ # Springer Nature B.V. 2019
Abstract Reactive thermoplastics are advantageous for wind turbine blades because they are recyclable at end of life, have reduced manufacturing costs, and enable thermal joining and shaping. However, there are challenges with manufacturing wind components from these new materials. This work outlines the development of manufacturing processes for a thick glass fiber–reinforced acrylic thermoplastic resin wind turbine blade spar cap, with consideration given to effects of the exothermic curing reaction on thick composite parts. Comparative elastic properties of these infusible thermoplastic materials with epoxy thermoset materials, as well as thermoplastic coupon components, are also included. Based on the results of this study it is concluded that the thermoplastic resin system is a viable candidate for the manufacturing of wind turbine blades using vacuum-assisted resin transfer molding. Significant gains in energy savings are realized avoiding heated molds, ability for recycling, and providing an opportunity for utilizing thermal welding. Keywords Thermoplastic resin . Elasticity . Mechanical testing . Vacuum infusion
* Robynne E. Murray [email protected] Yasuhito Suzuki [email protected]
1
National Renewable Energy Laboratory, 15013 Denver West Parkway, Golden, CO 80401, USA
2
University of Tennessee, 851 Neyland Drive, Knoxville, TN 37996-2010, USA
3
Colorado School of Mines, 1500 Illinois Street, Golden, CO 80401, USA
4
Department of Applied Chemistry, Graduate School of Engineering, Osaka Prefecture University, 1-1 Gakuen-cho, Naka-ku, Sakai, Osaka 599-8531, Japan
Applied Composite Materials
1 Introduction The development of longer turbine blades to increase power generation is motivated by the United States’ goal of 20% wind power integration by 2030 [1]. However, an increase in blade size presents manufacturing challenges with respect to the time, cost, and energy requirements for blade production. A move toward manufacturing methods and materials that reduce cycle times and energy consumption can lead to overall blade cost reductions and enable larger blades [2]. Advances in blade manufacturing such as increased automation have reduced inmold cycle times [3]; however, the in-mold heating process and additional oven heating for post-cure of thermoset-matrix composites such as epoxy are energy-, labor-, and time-intensive, which makes these composites expensive with long cycle time. Recent advances in the development of novel chemistry based thermoplastic resin systems can now allow for polymerization at room temperature [4], eliminating the need for heated blade tooling and ovens for post-cure. This technology can significantly reduce the ma
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