Blade Structure Research Articles

Optimization Design and Experimental Analysis of Resistance-Reducing Anti-Fracture Rotary Blade Based on DEM Techniques

To address the significant cutting resistance and fracture susceptibility of rotary blades, an innovative blade design was conceived to minimize resistance and enhance fracture resistance. By analyzing the interaction between the blade, soil, and root systems, an optimized design for the blade structure’s breakage resistance was developed. The theory of eccentric circular side cutting edges was applied to redesign the curve of the side cutting edge, and kinematic analysis was conducted to determine the optimal edge angle (26.57°). A flexible body model of corn residues was established, and cutting resistance measurements indicated a 15.1% reduction in cutting resistance. The breakage resistance of the rotary blade was validated using a discrete element method–finite element method (DEM–FEM) coupling approach. The results demonstrated the following: neck stress (−16.85%), specific strength efficiency (+9.72%), specific stiffness efficiency (+9.78%), fatigue life (+39.08%), and ultimate fracture stress (+20.16%), thereby meeting the design objectives. The comparison between field trial results and simulation data showed an error rate (<5%), confirming the simulation test’s feasibility. These findings provide theoretical references for reducing cutting resistance and enhancing breakage resistance in rotary blades.

Parametric structure optimization of a main rotor blade as an application for FSI analysis in main rotor optimization process

Purpose Modern warfare and modern battlefield are very demanding. The recent conflicts showed that the usage of the helicopters is very limited and only the best constructions are able to provide support for the operations. The purpose of this research is to show the possibilities of new design tool for main rotor aerostructural optimization. It is a next chapter of the research that is aimed at finding new solutions for rotorcraft constructions. Design/methodology/approach This work presents a method of preliminary structure optimization of the main rotor blade using parametric modeling. It is the next step in the main rotor optimization studies. It is the next step after preparing the parametric model for the external shape CFD analysis. As a basis for parametric blade structure calculations, the analytical model is provided in this paper. The equations of rigid blade loads and, as a consequence of the strength elements, stresses are shown. The parametric blade modeling is conducted using the Graphic Integrated Programming language. The parametric design method is shown to be used for various blade planform models and different section airfoils. The structure of a blade is generated automatically after the user enters the parameters. The code-inbuilt analysis systems provide a quick inertia examination of the generated geometry, which is the basis for further optimization. The program calculates the blade loads and verifies them with the given material conditions and proposed safety factors. In the analysis, composite materials for the strength elements were proposed. Findings The results of this research showed the application of parametrization into the main rotor blade design loop. It was presented that the main rotor blade structure can be enhanced using fluid-structure interaction (FSI) methods. The time saving with the implementation the process into design loop is shown. Practical implications This work can be practically used in the main rotor blade design process. It provides the possibilities to check various blade aerodynamic configuration in a structure strength aspect. Originality/value To the best of the authors’ knowledge, there were no published research that combines the main rotor FSI analysis. The method, which is presented in the work, provides a new approach to a rotorcraft design. The application of the parametrization and combining it with the FSI method gives a novel solution for helicopters construction enhancement.

Debonding Detection of Thin-Walled Adhesive Structure by Electromagnetic Acoustic Resonance Technology.

The detection of debonding defects in thin-walled adhesive structures, such as clad-iron/rubber layers on the leading edges of helicopter blades, presents significant challenges. This paper proposes the application of electromagnetic acoustic resonance technology (EMAR) to identify these defects in thin-walled adhesive structures. Through theoretical and simulation studies, the frequency spectrum of ultrasonic vibrations in thin-walled adhesive structures with various defects was analyzed. These studies verified the feasibility of applying EMAR to identify debonding defects. The identification of debonding defects was further examined, revealing that cling-type debonding defects could be effectively detected using EMAR by exciting shear waves with the minimum defect diameter at 5 mm. Additionally, the method allows for the quantitative analysis of these defects in the test sample. Due to the limited size of the energy exchange region in the transducer, the quantitative error becomes significant when identifying debonding defects smaller than this region. The EMAR identified debonding defects in clad-iron structures of rotor blades with a maximum error of approximately 15%, confirming its effectiveness for inspecting thin-walled adhesive structures.

Numerical simulation of the creep of a turbine blade made of a monocrystalline alloy

The article is devoted to the creep model of a monocrystalline alloy and the development of a methodology for identifying material parameters based on the results of physical experiments. A finite element analysis of the creep of a gas turbine engine blade was performed. Creep is one of the most dangerous types of deformation in the operating conditions of turbine blades. In the process of studying the problems of assessing the strength of turbine blades of aircraft engines and power plants, special attention should be paid to the study of stress redistribution during creep. The characteristics of the crystallographic structures of modern turbine blades have a very significant influence on the progress of the crack development process during engine operation. To date, turbine blades are manufactured by the method of single-crystal casting. This type of blade material structure is characterized by orthotropic mechanical properties. This study considers the steady-state creep model of an anisotropic heat-resistant single-crystal alloy with cubic symmetry. The authors carried out a numerical simulation of the material parameters using the well-known literary creep properties of single crystals. An algorithm is described that allows you to determine some creep characteristics of single crystals. The parameters of the given ratios can be obtained after conducting direct experiments, or based on micromechanical analysis, using the example of composite materials. The authors calculated the creep constants of a typical heat-resistant monocrystalline alloy as a result of the approximation of its creep curves, which were obtained experimentally. Based on the Norton-Bailey equation and using the Maple Release 2021.0 calculation complex, a graph of the dependence of the rate of creep deformation on the level of load applied to the material was plotted, and the minimum rate of deformation and creep constants were also determined. The results of the calculations were used for finite-element simulation of creep on the example of a solid-state model of a high-pressure turbine blade. Several series of calculations were carried out on the basis of the ANSYS Workbench complex, in particular, the calculation of the elastic problem when the blade is loaded by centrifugal forces, as well as the accumulation of creep deformations at different exposure times. Graphs of the change in equivalent stresses and creep deformations as a function of time are plotted.

Stability impact on wind turbine blades trailing edge from bonding zone modelling methods

Abstract The trailing edge of wind turbine blade will undergo a large deformation under the action of load, resulting in a higher risk of damage and failure. The finite element analysis modeling method directly affects the simulation result, furthermore impacts the result of blade structure design. Therefore, it is necessary to find out a modeling method, which is capable to reflect the stability of bonding regions more accurately. This paper aims to discuss the influences of different finite element modeling methods on the buckling stability of blade trailing edge. The influences of shell element, tetrahedron element and hexahedron element on the blade stiffness are considered. The bonding region were simulated separately by combining shell element with bonding web, shell element with tetrahedron element and shell element with hexahedron. The influences of different bonding region modeling methods on the trailing edge buckling factor were analyzed by using the eigenvalue buckling analysis method of finite element. The simulation results provided data support for the future validation of the blade trailing edge bonding area modeling method. The results show that, the tetrahedral mesh provides a higher stiffness, followed by the hexahedral mesh, and the adhesive web form has the smallest stiffness. In order to simulate the more realistic stiffness of the adhesive area at the trailing edge of the blade, adhesive web plates can be built in the flange area of the blade root and the core material area of the trial adhesive mold; The direct bonding area can be simulated employing the hexahedron mesh; The tetrahedral mesh has high stiffness and is not suitable for modeling the adhesive area at the trailing edge. Blade simulation modeling can flexibly use different adhesive forms according to actual situations, ensuring the reliability of the simulation model.

Study on pressure fluctuation characteristics of the mixed-flow pump with the tandem misaligned blade structure

Abstract As supporting equipment for deep-sea oil and gas resource exploitation, how to improve the transmission performance and stability of the impeller of the mixed-flow pump (MFP) has become a key technical problem. This paper focuses on studying the impeller blade of the MFP. Based on the blade optimization technology, four different tandem misaligned blade (TMB) angle schemes of α=0°,15°,45°,75° are proposed. The SST k-ω turbulence model is used to simulate the different blade angles under the pure liquid condition. The pressure pulsation of the MFP and the blade load distribution are studied. This result show that the TMB structure increases the pressure fluctuation inside the MFP. The pressure coefficient inside the impeller exhibits a more consistent pattern at an angle of α=45° compared to other angles, and the internal flow field of the MFP exhibits most stable. From this analysis of blade load distribution, TMBs have a greater effect on the pressure surface of the front blade of the MFP. When α=15°, the best pressurization performance of the MFP. This study may serve as a benchmark for subsequent iterations of optimizing the MFP’s model and hydraulic design.

The material relating to the anatomy of Rhaponticum serratuloides leaf blades according to age conditions

In the article the features of the morphological and anatomical structure of leaf blades in the process of ontogenesis of Rhaponticum serratuloides Georgi (Bobr.) during juvenile, immature, virginal, generative and senile age states were presented. It was noted that as the plant matures, the degree of dissection and linear dimensions of the leaf blades, as well as their vascular bundles and trichomes, increase. It was established that in the juvenile and immature periods of development whole and elliptical leaves predominate. In the virginal state, in addition to the typical entire leaves, leaves with an unpaired pinnate leaf blade appear. The generative state of Rh. serratuloides is characterized by having upper leaves as entire, sessile; the lower ones are petiolate, pinnately lobed with a large apical lobe. In the senile state, leaves of immature and virginal types are found. General patterns of leaf internal structure of Rh. serratuloides and another representative of the same genus Rh.carthamoides Willd (Iljin) were revealed as following: the plants are of dorsal-ventral type of leaf blade structure, with collateral vascular bundles of a closed type with a sclerenchyma covering and leaf pubescence. Along with this, characteristic diagnostic features for leaves of Rh. serratuloides were described as the following: the absence of capitate glands and long cord-like hairs during all age states, the presence of air-bearing cavities in the parenchyma of virginal and senile plants, associated with the habitat of the plant under study, because it grows in flooded meadows, along the shores of lakes and swamps.

Effect of process parameters on the mechanical performance of fusion-joined additively manufactured segments

Purpose Herein, the authors report the effects of printing parameters, joining method, and annealing conditions on the structural performance of fusion-joined short-beam sections produced by additive manufacturing. Design/methodology/approach The authors first identified appropriate printing parameters for joining segmented short beams and then used those parameters to print and fusion-join segments with different configurations of stiffeners to form a longer section of a wing or small wind turbine blade structure. Findings It was found that the beams with three lateral and three base stiffening ribs give the highest flexural strength among the three beams investigated. Results on joined beams annealed at different conditions showed that annealing at 70 °C for 0.5 h yields higher performance than annealing at the same temperature for longer times. It is also found that in the case of the hot-plate-welded three-dimensional (3D)-printed structures, no annealing is needed for reaching a high strength-to-weight ratio, but annealing is helpful for maximizing the modulus-to-weight ratio. Both thermal buckling and edge wrapping were observed under annealing at 70°C for 0.5 h for 3D-printed beams comprising two lateral and four base stiffening plates. Originality/value Fusion-joining of additively manufactured segments is needed owing to the constraint in building volume of a typical commercial 3D-printer. However, study of the effect of process parameters is needed to quantify their effect on mechanical performance. This investigation has therefore identified key printing parameters and annealing conditions for fusion-joining short segments to form larger structures, from multiple 3D-printed sections, such as wind blade structures.

The Influence of Structural Parameters on the Ultimate Strength Capacity of a Designed Vertical Axis Turbine Blade for Ocean Current Power Generators

An ocean current power generator is a power plant that uses kinetic energy from ocean currents to generate electricity. Considering that the blade is the component that receives the biggest load from seawater currents, its structural design should be strong enough to sustain the applied load. Therefore, this research seeks a suitable design and material for turbine blades using the finite element method (FEM). A NACA 0021 blade with a total length of 3600 mm is used for the base geometry. A parametric study was conducted by varying the spacing between the supports, the pitch angle, the material, and the frame model. Considering a high load, the suitable amount of space between the stiffeners was 2200 mm. It was found that a pitch angle variation between −20° and +20° did not significantly affect the strength of the blade structure. The frame geometry variation caused the rigidity and cross-section area of the blade to differ. Therefore, web-shaped or bar-shaped frames are preferable because they have optimal maximum load-to-weight ratios. The material variation analysis resulted in CFRP material being chosen because it had a high maximum load/weight ratio and a high maximum stress.

Coupling vibration mechanism of rotating shaft–disc–blade system with blade crack—A systematical investigation on the effect of crack, condition, and structure parameters

Rotating shaft–disc–blade (RSDB) system is one of the most important parts of turbomachinery, such as aero-engine, gas turbine, and power plant. Understating and revealing the coupling vibration mechanism of RSDB system is significant for blade health monitoring and blade crack detection. However, the multi-structure, multi-vibration source, and multi-stress coupling makes it a very tough task. This study aims to reveal the coupling vibration mechanism of RSDB system by systematically investigating the steady-state vibration responses under the influences of different blade crack, operation condition, and structure parameters. First and foremost, a coupling vibration model of RSDB system that comprehensively considers the multi-structure, multi-vibration source, and multi-stress coupling effects is presented. And then, a novel condition indicator for blade health monitoring, called blade–blade distance, is proposed to better characterize and analyse the coupling vibration of RSDB system with blade crack. At last, the comprehensive effects of blade crack, operating condition, and structure parameters on the coupling vibration mechanism of the RSDB system with blade crack are systematically studied. The comparative results demonstrate the effectiveness of blade–blade distance and super-harmonic components of shaft torsional vibration and blade bending vibration for indicating the presence of blade crack and tracking the crack severity. Another observation should be noted is that the vibration behaviour including the blade–blade distance, super-harmonic components of shaft torsional vibration and blade bending vibration, the combination frequency components of shaft bending vibration are co-affected by blade crack, operating condition, and structure parameters. It is indicated that the blade health monitoring and crack detection of rotating blade should comprehensively consider different indicators to obtain a more robust and accurate results.

Experimental and numerical study on the effect mechanism of geometric parameters on jet impingement cooling in a limited space

In order to meet the development needs of the internal cooling structure of gas turbine blades, this paper researches the jet impingement cooling in a limited space. Numerical simulation method is employed to obtain the flow field details and analyze the flow and heat transfer mechanism. The heat transfer coefficient distribution of the target surface is obtained by the transient liquid crystal, which verifies the accuracy of the CFD results. The effects of inlet mass flow rate m˙in, rows of jet holes N, jet hole diameter Dj, jet-to-target distance H/Dj and transverse distance between jet holes S/W are considered. The results show that: The flow and heat transfer characteristics at different m˙in are qualitatively similar. N has a significant effect on the heat transfer coefficient and total pressure difference. With the increase of N, the heat transfer coefficient and the total pressure difference decrease. Dj has obvious effect on heat transfer coefficient and total pressure difference. As Dj increases, both the heat transfer coefficient and the total pressure difference decrease. H/Dj has only a slight effect on the heat transfer coefficient and total pressure difference. When H/Dj increases from 1.2 to 2.2, the heat transfer coefficient increases and the total pressure difference decreases. When H/Dj increases from 2.2 to 3.2, the heat transfer coefficient decreases and the total pressure difference is almost unchanged. The effect of S/W on the heat transfer coefficient and total pressure difference is more obvious than that of H/Dj. The heat transfer coefficient and total pressure difference are the largest when S/W = 0.5. The structure with N = 8，Dj = 24 mm，H/Dj = 2.2，S/W = 0.5 has the best comprehensive heat transfer performance under the range of the boundary condition.

Energy performance improvement for a mixed flow pump based on advanced inlet guide vanes

The sharp decrease in the efficiency of a mixed flow pump within over-load flow rates presents a challenge for coastal drainage pumping stations. To address this issue, two different structures of advanced inlet guide vanes (AIGV), full-adjustable (FA) and half-adjustable (HA) structures, are designed to approach a better energy performance improvement strategy. Entropy production theory is applied into transient flow field to reveal their influence mechanism on the spatial distribution of energy dissipation. The primary findings are as follows: (1) AIGVs effectively solve the sharp decrease in the energy performance of mixed-flow pumps within the over-load flow rate range, broadening its efficient operation range. (2) The decrease in the axial velocity under the effect of AIGV explains the primary fluid physics of the increased efficiency. (3) The improvement in the match between the impeller inflow angle distribution and the impeller blades structure suppresses the generation and transmission of the flow separation on the pressure side, and reduce the near-wall energy dissipation. The novel HA-AIGV obtains a better flow control effect.

Vibration control of the straight bladed vertical axis wind turbine structure using the leading-edge protuberanced blades

This study investigates the impact of structural responses resulting from alterations in aerodynamic characteristics caused by incorporating leading-edge protuberance (LEP) blades in vertical-axis wind turbines (VAWTs) under various wind speeds. The current experimental investigation was conducted on a scaled-down straight-blade VAWT with multiple wind speeds at a fixed pitch angle and uniform blade configuration. The unsteady structural excitation caused by the decay of vortices due to the different aerodynamic loads and its effect on the VAWT structure is examined in great detail. The presence of counter-rotating vortices from the LEP profile, however, enhances the aerodynamics of the blades at higher angles of attack. It is crucial to understand the structural characteristics resulting from changes in aerodynamics. The paper presents the effects of the LEP on the structural excitation of the VAWT by analyzing the acceleration and displacement data obtained from the static structure of VAWT for various operational wind speeds. The results showed decreased acceleration and displacement amplitudes for the VAWT with LEP at medium and higher wind speeds. Significant aerodynamic and structural damping was observed in the VAWT with LEP blades. The results obtained were in close agreement with the time and frequency domains of the measured displacement and acceleration from the structure. The bidirectional vibration control was observed for the VAWT with LEP, which was found to have a reduction ratio of 70 %.

Strength and Vibration Analysis of Axial Flow Compressor Blades Based on the CFD-CSD Coupling Method

During the operational process of an axial-flow compressor, the blade structure is simultaneously subjected to both aerodynamic loads and centrifugal loads, posing significant challenges to the safe and reliable operation of the blades. Considering both centrifugal loads and aerodynamic loads comprehensively, a bidirectional CFD-CSD coupling analysis method for blade structure was established. The Navier–Stokes governing equations were utilized to solve the internal flow field of the axial-flow compressor. The conservative interpolation method was utilized to couple and solve the blade’s static equilibrium equation, and the deformation, stress distribution, and prestress modal behavior of compressor blades were mainly analyzed. The research results indicate that the maximum deformation of the blades occurred at the lead edge tip, while stress predominantly concentrated approximately 33% upward from the blade root, exhibiting a radial distribution that gradually decreased. As the rotational speed increased, the maximum deformation of the blades continuously increased. Furthermore, at a constant rotational speed, the maximum deformation of the blade exhibited a trend of first increasing and then decreasing with the increase in mass flow. In contrast, the maximum stress showed a trend of first increasing, then decreasing, and finally increasing again as the rotational speed continuously increased. Centrifugal loads are the primary factor influencing blade stress and natural frequency. During operation, the blades exhibited two resonance points, approximately occurring at 62% and 98% of the design rotational speed.

Wind Turbine Blade Fault Diagnosis: Approximate Entropy as a Tool to Detect Erosion and Mass Imbalance

Wind energy is a clean, sustainable, and renewable source. It is receiving a large amount of attention from governments and energy companies worldwide as it plays a significant role as an alternative source of energy in reducing carbon emissions. However, due to long-term operation in reduced and difficult weather conditions, wind turbine blades are always seriously damaged. Hence, damage detection in blade structure is essential to evaluate its operational condition and ensure its structural integrity and safety. We aim to use fractal, entropy, and chaos concepts as descriptors for the diagnosis of wind turbine blade condition. They are, respectively, estimated by the correlation dimension, approximate entropy, and the Lyapunov exponent. Formal statistical tests are performed to check how they are different across wind turbine blade conditions. The experimental results follow. First, the correlation dimension is not able to distinguish between all conditions of wind turbine blades. Second, approximate entropy is suitable to distinguish between healthy and erosion conditions and between healthy and mass imbalance conditions. Third, chaos is not a discriminative feature to distinguish between wind turbine blade conditions. Fourth, wind turbine blades with either erosion or mass imbalance exhibit less irregularity in their respective signals than healthy wind turbine blades.

A developed fatigue analysis approach for composite wind turbine blade adhesive joints using finite-element submodeling technique

The intricate shapes and complex structures of composite wind turbine blades pose significant challenges in conducting local-fatigue simulation analyses. Moreover, adhesive joints, commonly found in composite wind turbine blades, are often neglected in current finite-element methods, leading to a dearth of empirical evidence to substantiate design enhancements for these blades. To tackle these issues, this study introduces a fatigue analysis methodology based on a finite-element submodeling approach to investigate the local fatigue behavior of composite wind turbine blades, with particular emphasis on the adhesive joints. The research begins with a comprehensive fatigue simulation analysis of composite wind turbine blades to establish boundary conditions for subsequent submodeling. A specialized submodel focusing on the trailing edge, a common adhesive joint, is constructed with the inclusion of extra adhesive regions for a more accurate depiction of their actual configuration. This submodel is subsequently utilized to investigate the localized fatigue characteristics unique to the trailing edge. Moreover, an exploration into the influence of the submodeling technique and its parameters on the predicted outcomes is carried out to enhance the applicability of the proposed methodology. These results significantly advance the understanding of local static and fatigue properties in large-scale structures through finite element analysis.

Numerical Investigation of Flow Evolution in Centrifugal Compressors During Surge

Abstract Surge can lead to violent flow fluctuations in the compression system and damage to the blade structures. In this article, a fully three-dimensional numerical model of the centrifugal compressor surge is developed, and the accurate transient flow evolutions in different components during the surge are studied in detail. The results show that in the surge initiation, the pressure distortion caused by the asymmetric geometry of the volute at the diffuser outlet transfers along blade passages to the impeller inlet, which induces two types of stall cells with different rotating speeds and sizes developing independently in two isolated circumferential positions at the impeller inlet. With the surge development, the two types of stall cells come into contact and are mixed, which causes the asymmetric local reverse flow near the casing of the impeller leading edge. Subsequently, the reverse flow extends to the full annuls at the impeller inlet, and the compressor pressure ratio falls abruptly. At the same time, several expansion waves arise in the impeller and travel downstream along the volute and the outlet pipe. As reflected by the nozzle, these expansion waves travel back upstream into the impeller. The findings of this research have great implications for the asymmetric flow control methods, which develop novel asymmetric geometries to counteract the influence of the volute and extend the compressor stable operation range.

Study of design methods and heat transfer characteristics of combined cooling structure for turbine blades with turbine inter-vane burner

The turbine inter-vane burner can greatly increase the engine thrust but brings about a harsh thermal environment to the turbine blades. Fuel-air combined cooling structure is an effective way to solve the thermal protection problem of the blades. There is a lack of research on the thermal protection of turbine blades with turbine inter-vane burner, especially systematic research on the fuel–air combined cooling structure. In this paper, the design methods of the fuel–air combined cooling structure of turbine blades with turbine inter-vane burner are proposed, and one-dimensional empirical formulas are used to design specific parameters. The heat transfer characteristics of the designed combined cooling structure are numerically investigated and analyzed without turbine inter-vane combustion, where the mainstream temperature varies from 818 K to 1414 K, the cold air temperature ranges from 500 K to 700 K, and the mass flow rate of cold air changes from 0.005 kg/s to 0.02 kg/s. The results show that in the combined cooling structure with embedded fuel channels, the heat absorbed by fuel is mostly influenced by cold air temperature compared to mainstream temperature and mass flow rate of cold air. The proportion of fuel heat absorption to overall heat absorption decreases from 0.25 to 0.13 when mainstream temperature increases from 818 K to 1418 K, as the increase of mainstream temperature has a minimal effect on the heat flux of the fuel channels, but can significantly increase the overall heat absorption. The proportion of fuel heat absorption to the overall heat absorption changes from 0.15 to 0.31 when cold air temperature increases from 500 K to 700 K, as the increase of cold air temperature enhances the heat exchange between the fuel channels and the cold air but decreases the heat exchange between the mainstream and the cold air. Besides, the flow and heat transfer performance of the combined cooling structure of turbine blades with turbine inter-vane combustion is numerically studied. The results show that the temperature of blade and fuel channels are maintained within the safe range with turbine inter-vane combustion, providing research support for subsequent studies on the fuel–air combined cooling structure of turbine blades with turbine inter-vane burner.

Powder movement rules of laser powder bed fusion additive manufacturing aluminum alloy based on discrete element method

Laser Powder Bed Fusion (LPBF) is a promising metal additive manufacturing technology based on layer by layer powder spreading, and powder bed uniformity has a great influence on the forming quality. By Discrete Element Method and powder spreading experiment, the interaction and movement between powder were studied during powder spreading, including powder jamming, rebound, splash, eddy, and empty powder area. Additionally, five kinds of powder spreading schemes were explored, and the new process of one-way reciprocating with tri-splint blade was designed to change the motion state of powder spreading from “blade pushing powder” to “blade holding powder.” By increasing the distance between the blade and the working platform form 0 to 20 µm with the distance between the upper surface of the substrate and the working platform 50 µm, defects such as powder splash and empty powder decreased. And the uniform powder bed of aluminum alloy powder was achieved with the new process of one-way reciprocating with tri-splint blade structure.

Feasibility of Natural Fibre Usage for Wind Turbine Blade Components: A Structural and Environmental Assessment

There are two key areas of development across wind turbine blade lifecycles with the potential to reduce the impact of wind energy generation: (1) deploying lower-impact materials in blade structures and (2) developing low-impact blade recycling solution(s). This work evaluates the feasibility of using natural fibres to replace traditional glass and carbon fibres within state-of-the-art offshore blades. The structural design of blades was performed using Aeroelastic Turbine Optimisation Methods and lifecycle assessment was conducted to evaluate the environmental impact of designs. This enabled the matching of blade designs with preferred waste treatment strategies for the lowest impact across the blade lifecycle. Flax and hemp fibres were the most promising solutions; however, they should be restricted to use in stiffness-driven, bi-axial plies. It was found that flax, hemp, and basalt deployment could reduce Cradle-to-Gate Global Warming Potential (GWP) by around 6%, 7%, and 8%, respectively. Cement kiln co-processing and mechanical recycling strategies were found to significantly reduce Cradle-to-Grave GWP and should be the prioritised strategies for scrap blades. Irrespective of design, carbon fibre production was found to be the largest contributor to the blade GWP. Lower-impact alternatives to current carbon fibre production could therefore provide a significant reduction in wind energy impact and should be a priority for wind decarbonisation.