Quantification of process-induced effects on fatigue life of short-glass-fiber-filled adhesive used in wind turbine rotor blades

Abstract

Cracks in the adhesive joints of wind turbine blades can often cause severe structural blade damage. Effects induced by the manufacturing process can have a significant impact on the cycle number toward crack initiation in the bonding material. This research compared two experimental series of neat adhesive, dog-bone-shaped specimens with different degrees of cure, fiber orientation, and porosity content, which were subjected to static and cyclic tension-tension loading. To enhance the comparability of the two coupon series, the experimental data was normalized. Normalization factors were introduced to compensate for the different properties of the two series. These factors were derived from correction models. After normalization, the S-N values of the two data series were in good agreement in the high-cycle fatigue regime. In the very-low-cycle fatigue regime, however, there was still a lack of agreement in some cases, including the static strength. Moreover, the failure mechanisms were investigated by analyzing images from the fracture surfaces and dedicated samples using X-ray microscopy. The correction models presented can be applied to estimate the design strength of adhesives. This knowledge can then be used to make rotor blade structures more resistant to crack initiation.