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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
NASA NTRS1984

Vibration and flutter of mistuned bladed-disk assemblies

An analytical model for investigating vibration and flutter of mistuned bladed disk assemblies is presented. This model accounts for elastic, inertial and aerodynamic coupling between bending and torsional motions of each individual blade, elastic and inertial couplings between the blades and the disk, and aerodynamic coupling among the blades. The disk was modeled as a circular plate with constant thickness and each blade was represented by a twisted, slender, straight, nonuniform, elastic beam with a symmetric cross section. The elastic axis, inertia axis, and the tension axis were taken to be noncoincident and the structural warping of the section was explicitly considered. The blade aerodynamic loading in the subsonic and supersonic flow regimes was obtained from two-dimensional unsteady, cascade theories. All the possible standing wave modes of the disk and traveling wave modes of the blades were included. The equations of motion were derived by using the energy method in conjunction with the assumed mode shapes for the disk and the blades. Continuities of displacement and slope at the blade-disk junction were maintained. The equations were solved to investigate the effects of blade-disk coupling and blade frequency mistuning on vibration and flutter. Results showed that the flexibility of practical disks such as those used for current generation turbufans did not have a significant influence on either the tuned or mistuned flutter characteristics. However, the disk flexibility may have a strong influence on some of the system frequencies and on forced response.

Rao, K.↗
NASA NTRS1948

Extension of Useful Operating Range of Axial-Flow Compressors by Use of Adjustable Stator Blades

A theory has been developed for resetting the blade angles of an axial-flow compressor in order to improve the performance at speeds and flows other than the design and thus extend the useful operating range of the compressor. The theory is readily applicable to the resetting of both rotor and stator blades or to the resetting of only the stator blades and is based on adjustment of the blade angles to obtain lift coefficients at which the blades will operate efficiently. Calculations were made for resetting the stator blades of the NACA eight-stage axial-flow compressor for 75 percent of design speed and a series of load coefficients ranging from 0.28 to 0.70 with rotor blades left at the design setting. The NACA compressor was investigated with three different blade settings: (1) the design blade setting, (2) the stator blades reset for 75 percent of design speed and a load coefficient of 0.48, and (3) the stator blades reset for 75 percent of design speed and a load coefficient of 0.65.

Sinnette, John T↗
NASA NTRS1993

Aeroelastic response and stability of tiltrotors with elastically-coupled composite rotor blades

There is a potential for improving the performance and aeroelastic stability of tiltrotors through the use of elastically-coupled composite rotor blades. To study the characteristics of tiltrotors with these types of rotor blades it is necessary to formulate a new analysis which has the capabilities of modeling both a tiltrotor configuration and an anisotropic rotor blade. Background for these formulations is established in two preliminary investigations. In the first, the influence of several system design parameters on tiltrotor aeroelastic stability is examined for the high-speed axial flight mode using a newly-developed rigid-blade analysis with an elastic wing finite element model. The second preliminary investigation addresses the accuracy of using a one-dimensional beam analysis to predict frequencies of elastically-coupled highly-twisted rotor blades. Important aspects of the new aeroelastic formulations are the inclusion of a large steady pylon angle which controls tilt of the rotor system with respect to the airflow, the inclusion of elastic pitch-lag coupling terms related to rotor precone, the inclusion of hub-related degrees of freedom which enable modeling of a gimballed rotor system and engine drive-train dynamics, and additional elastic coupling terms which enable modeling of the anisotropic features for both the rotor blades and the tiltrotor wing. Accuracy of the new tiltrotor analysis is demonstrated by a comparison of the results produced for a baseline case with analytical and experimental results reported in the open literature. Two investigations of elastically tailored blades on a baseline tiltrotor are then conducted. One investigation shows that elastic bending-twist coupling of the rotor blade is a very effective means for increasing the flutter velocity of a tiltrotor, and the magnitude of coupling required does not have an adverse effect on performance or blade loads. The second investigation shows that passive blade twist control via elastic extension-twist coupling of the rotor blade has the capability of significantly improving tiltrotor aerodynamic performance. This concept, however, is shown to have, in general, a negative impact on stability characteristics.

Nixon, Mark W.↗
NASA NTRS1992

Computational fluid dynamics study of the variable-pitch split-blade fan concept

A computational fluid dynamics study was conducted to evaluate the feasibility of the variable-pitch split-blade supersonic fan concept. This fan configuration was conceived as a means to enable a supersonic fan to switch from the supersonic through-flow type of operation at high speeds to a conventional fan with subsonic inflow and outflow at low speeds. During this off-design, low-speed mode of operation, the fan would operate with a substantial static pressure rise across the blade row like a conventional transonic fan; the front (variable-pitch) blade would be aligned with the incoming flow, and the aft blade would remain fixed in the position set by the supersonic design conditions. Because of these geometrical features, this low speed configuration would inherently have a large amount of turning and, thereby, would have the potential for a large total pressure increase in a single stage. Such a high-turning blade configuration is prone to flow separation; it was hoped that the channeling of the flow between the blades would act like a slotted wing and help alleviate this problem. A total of 20 blade configurations representing various supersonic and transonic configurations were evaluated using a Navier Stokes CFD program called ADAPTNS because of its adaptive grid features. The flow fields generated by this computational procedure were processed by another data reduction program which calculated average flow properties and simulated fan performance. These results were employed to make quantitative comparisons and evaluations of blade performance. The supersonic split-blade configurations generated performance comparable to a single-blade supersonic, through-flow fan configuration. Simulated rotor total pressure ratios of the order of 2.5 or better were achieved for Mach 2.0 inflow conditions. The corresponding fan efficiencies were approximately 75 percent or better. The transonic split-blade configurations having large amounts of turning were able to generate large amounts of total turning and achieve simulated total pressure ratios of 3.0 or better with subsonic inflow conditions. These configurations had large losses and low fan efficiencies in the 70's percent. They had large separated regions and low velocity wakes. Additional turning and diffusion of this flow in a subsequent stator row would probably be very inefficient. The high total pressure ratios indicated by the rotor performance would be substantially reduced by the stators, and the stage efficiency would be substantially lower. Such performance leaves this dual-mode fan concept less attractive than originally postulated.

Kepler, C. E.↗
NASA NTRS1949

Performance of Single-Stage Turbine of Mark 25 Torpedo Power Plant with Two Nozzles and Three Rotor-Blade Designs

A single-stage modification of the turbine from a Mark 25 torpedo power plant was investigated to determine the performance with two nozzles and three rotor-blade designs. The performance was evaluated in terms of brake, rotor, and blade efficiencies at pressure ratios of 8, 15 (design), and 20. The blade efficiencies with the two nozzles are compared with those obtained with four other nozzles previously investigated with the same three rotor-blade designs. Blade efficiency with the cast nozzle of rectangular cross section (J) was higher than that with the circular reamed nozzle (K) at all speeds and pressure ratios with a rotor having a 0.45-inch 17 degree-inlet-angle blades. The efficiencies for both these nozzles were generally low compared with those of the four other nozzles previously investigated in combination with this rotor. At pressure ratios of 15 and 20, the blade efficiencies with nozzle K and the two rotors with 0.40-inch blades having different inlet angles were higher than with the four other nozzles, but the efficiency with nozzle J was generally low. Increasing the blade inlet angle from 17 degrees to 20 degrees had little effect on turbine performance, whereas changing the blade length from 0.40 to 0.45 inch had a marked effect. Although a slight correlation of efficiency with nozzle size was noted for the rotor with 0.45-inch 17 degree-inlet-angle blades, no such effect was discernible ,for the two rotors with 0.40-inch blades.Losses in the supersonic air stream resulting from the complex flow path in the small air passages are probably a large percentage of the total losses, and apparently the effects of changing nozzle size and shape within the limits investigated are of secondary importance.

Schum, Harold J.↗
NASA NTRS2003

Active Blade Vibration Control Being Developed and Tested

Gas turbine engines are currently being designed to have increased performance, lower weight and manufacturing costs, and higher reliability. Consequently, turbomachinery components, such as turbine and compressor blades, have designs that are susceptible to new vibration problems and eventual in-service failure due to high-cycle fatigue. To address this problem, researchers at the NASA Glenn Research Center are developing and testing innovative active blade vibration control concepts. Preliminary results of using an active blade vibration control system, involving a rotor supported by an active magnetic bearing in Glenn's Dynamic Spin Rig, indicate promising results (see the photograph). Active blade vibration control was achieved using feedback of blade strain gauge signals within the magnetic bearing control loop. The vibration amplitude was reduced substantially (see the graphs). Also, vibration amplitude amplification was demonstrated; this could be used to enhance structural mode identification, if desired. These results were for a nonrotating two-bladed disk. Tests for rotating blades are planned. Current and future active blade vibration control research is planned to use a fully magnetically suspended rotor and smart materials. For the fully magnetically suspended rotor work, three magnetic bearings (two radial and one axial) will be used as actuators instead of one magnetic bearing. This will allow additional degrees of freedom to be used for control. For the smart materials work, control effectors located on and off the blade will be considered. Piezoelectric materials will be considered for on-the-blade actuation, and actuator placement on a stator vane, or other nearby structure, will be investigated for off-the-blade actuation. Initial work will focus on determining the feasibility of these methods by performing basic analysis and simple experiments involving feedback control.

Johnson, Dexter↗
NASA NTRS2012

Determination of Turbine Blade Life from Engine Field Data

It is probable that no two engine companies determine the life of their engines or their components in the same way or apply the same experience and safety factors to their designs. Knowing the failure mode that is most likely to occur minimizes the amount of uncertainty and simplifies failure and life analysis. Available data regarding failure mode for aircraft engine blades, while favoring low-cycle, thermal mechanical fatigue as the controlling mode of failure, are not definitive. Sixteen high-pressure turbine (HPT) T-1 blade sets were removed from commercial aircraft engines that had been commercially flown by a single airline and inspected for damage. Each set contained 82 blades. The damage was cataloged into three categories related to their mode of failure: (1) Thermal-mechanical fatigue, (2) Oxidation/Erosion, and (3) "Other." From these field data, the turbine blade life was determined as well as the lives related to individual blade failure modes using Johnson-Weibull analysis. A simplified formula for calculating turbine blade life and reliability was formulated. The L(sub 10) blade life was calculated to be 2427 cycles (11 077 hr). The resulting blade life attributed to oxidation/erosion equaled that attributed to thermal-mechanical fatigue. The category that contributed most to blade failure was Other. If there were there no blade failures attributed to oxidation/erosion and thermal-mechanical fatigue, the overall blade L(sub 10) life would increase approximately 11 to 17 percent.

Zaretsky, Erwin V.↗
NASA NTRS2012

Characterization of Deficiencies in the Frequency Domain Forced Response Analysis Technique for Supersonic Turbine Bladed Disks

Turbine blades in rocket and jet engine turbomachinery experience enormous harmonic loading conditions. These loads result from the integer number of upstream and downstream stator vanes as well as the other turbine stages. Assessing the blade structural integrity is a complex task requiring an initial characterization of whether resonance is possible and then performing a forced response analysis if that condition is met. The standard technique for forced response analysis in rocket engine turbines is to decompose a computational fluid dynamics (CFD).generated flow field into its harmonic components, and to then perform a frequency response analysis at the problematic natural frequencies using cyclically symmetric structural dynamic models. Recent CFD analysis and water-flow testing at NASA/MSFC, though, indicates that this technique may miss substantial harmonic and non ]harmonic excitation sources that become present in complex flows. This complex content can only be captured by a CFD flow field encompassing at least an entire revolution. A substantial development effort to create a series of software programs to enable application of the 360 degree forcing function in a frequency response analysis on cyclic symmetric models has been completed (to be described in a future paper), but the question still remains whether the frequency response analysis itself is capable of capturing the excitation content sufficiently. Two studies comparing frequency response analysis with transient response analysis, therefore, of bladed-disks undergoing this complex flow environment have been performed. The first is of a bladed disk with each blade modeled by simple beam elements and the disk modeled with plates (using the finite element code MSC/NASTRAN). The focus of this model is to be representative of response of realistic bladed disks, and so the dimensions are roughly equivalent to the new J2X rocket engine 1st stage fuel pump turbine. The simplicity of the model allows the CFD load to be able to be readily applied, along with analytical and experimental variations in both the temporal and spatial fourier components of the excitation. In addition, this model is a first step in identifying response differences between transient and frequency forced response analysis techniques. The second phase assesses this difference for a much more realistic solid model of a bladed-disk in order to evaluate the effect of the spatial variation in loading on blade dominated modes. Neither research on the accuracy of the frequency response method when used in this context or a comprehensive study of the effect of test-observed variation on blade forced response have been found in the literature, so this research is a new contribution to practical structural dynamic analysis of gas turbines. The primary excitation of the upstream nozzles interacts with the blades on fuel pump of the J2X causes the 5th Nodal diameter modes to be excited, as explained by Tyler and Sofrin1, so a modal analysis was first performed on the beam/plate model and the 5ND bladed-disk mode at 40167 hz was identified and chosen to be the one excited at resonance (see figure 1). The first forced response analysis with this model focuses on identifying differences between frequency and transient response analyses. A hypothesis going into the analysis was that perhaps the frequency response was enforcing a temporal periodicity that did not really exist, and so therefore it would overestimate the response. As high dynamic response was a considerable source of stress in the J2X, examining this concept could potentially be beneficial for the program.

Brown, Andrew M.↗
NASA NTRS2012

Evaluation of Rotor Structural and Aerodynamic Loads using Measured Blade Properties

The structural properties of Higher harmonic Aeroacoustic Rotor Test (HART I) blades have been measured using the original set of blades tested in the wind tunnel in 1994. A comprehensive rotor dynamics analysis is performed to address the effect of the measured blade properties on airloads, blade motions, and structural loads of the rotor. The measurements include bending and torsion stiffness, geometric offsets, and mass and inertia properties of the blade. The measured properties are correlated against the estimated values obtained initially by the manufacturer of the blades. The previously estimated blade properties showed consistently higher stiffnesses, up to 30% for the flap bending in the blade inboard root section. The measured offset between the center of gravity and the elastic axis is larger by about 5% chord length, as compared with the estimated value. The comprehensive rotor dynamics analysis was carried out using the measured blade property set for HART I rotor with and without HHC (Higher Harmonic Control) pitch inputs. A significant improvement on blade motions and structural loads is obtained with the measured blade properties.

Jung, Sung N.↗
NASA NTRS2013

Determination of Turbine Blade Life from Engine Field Data

It is probable that no two engine companies determine the life of their engines or their components in the same way or apply the same experience and safety factors to their designs. Knowing the failure mode that is most likely to occur minimizes the amount of uncertainty and simplifies failure and life analysis. Available data regarding failure mode for aircraft engine blades, while favoring low-cycle, thermal-mechanical fatigue (TMF) as the controlling mode of failure, are not definitive. Sixteen high-pressure turbine (HPT) T-1 blade sets were removed from commercial aircraft engines that had been commercially flown by a single airline and inspected for damage. Each set contained 82 blades. The damage was cataloged into three categories related to their mode of failure: (1) TMF, (2) Oxidation/erosion (O/E), and (3) Other. From these field data, the turbine blade life was determined as well as the lives related to individual blade failure modes using Johnson-Weibull analysis. A simplified formula for calculating turbine blade life and reliability was formulated. The L10 blade life was calculated to be 2427 cycles (11 077 hr). The resulting blade life attributed to O/E equaled that attributed to TMF. The category that contributed most to blade failure was Other. If there were no blade failures attributed to O/E and TMF, the overall blade L(sub 10) life would increase approximately 11 to 17 percent.

Zaretsky, Erwin V.↗
NASA NTRS2013

Jet Engine Bird Ingestion Simulations: Comparison of Rotating to Non-Rotating Fan Blades

Bird strike events in commercial airliners are a fairly common occurrence. According to data collected by the US Department of Agriculture, over 80,000 bird strikes were reported in the period 1990-2007 in the US alone [1]. As a result, bird ingestion is an important factor in aero engine design and FAA certification. When it comes to bird impacts on engine fan blades, the FAA requires full-scale bird ingestion tests on an engine running at full speed to pass certification requirements. These rotating tests are complex and very expensive. To reduce development costs associated with new materials for fan blades, it is desirable to develop more cost effective testing procedures than full-scale rotating engine tests for material evaluation. An impact test on a non-rotating single blade that captures most of the salient physics of the rotating test would go a long way towards enabling large numbers of evaluative material screening tests. NASA Glenn Research Center has been working to identify a static blade test procedure that would be effective at reproducing similar results as seen in rotating tests. The current effort compares analytical simulations of a bird strike on various nonrotating blades to a bird strike simulation on a rotating blade as a baseline case. Several different concepts for simulating the rotating loads on a non-rotating blade were analyzed with little success in duplicating the deformation results seen in the rotating case. The rotating blade behaves as if it were stiffer than the non-rotating blade resulting in less plastic deformation from a given bird impact. The key factor limiting the success of the non-rotating blade simulations is thought to be the effect of gyroscopics. Prior to this effort, it was anticipated the difficulty would be in matching the pre-stress in the blade due to centrifugal forces Additional work is needed to verify this assertion, and to determine if a static test procedure can simulate the gyroscopic effects in a suitable manner. This paper describes the various non-rotating concepts analyzed, and demonstrates the effect believed to be gyroscopic in nature on the results.

Howard, Samuel A.↗
NASA NTRS2013

Jet Engine Bird Ingestion Simulations: Comparison of Rotating to Non-Rotating Fan Blades

Bird strike events in commercial airliners are a fairly common occurrence. According to data collected by the US Department of Agriculture, over 80,000 bird strikes were reported in the period 1990 to 2007 in the US alone (Ref. 1). As a result, bird ingestion is an important factor in aero engine design and FAA certification. When it comes to bird impacts on engine fan blades, the FAA requires full-scale bird ingestion tests on an engine running at full speed to pass certification requirements. These rotating tests are complex and very expensive. To reduce development costs associated with new materials for fan blades, it is desirable to develop more cost effective testing procedures than full-scale rotating engine tests for material evaluation. An impact test on a nonrotating single blade that captures most of the salient physics of the rotating test would go a long way towards enabling large numbers of evaluative material screening tests. NASA Glenn Research Center has been working to identify a static blade test procedure that would be effective at reproducing similar results as seen in rotating tests. The current effort compares analytical simulations of a bird strike on various non-rotating blades to a bird strike simulation on a rotating blade as a baseline case. Several different concepts for simulating the rotating loads on a non-rotating blade were analyzed with little success in duplicating the deformation results seen in the rotating case. The rotating blade behaves as if it were stiffer than the non-rotating blade resulting in less plastic deformation from a given bird impact. The key factor limiting the success of the non-rotating blade simulations is thought to be the effect of gyroscopics. Prior to this effort, it was anticipated the difficulty would be in matching the prestress in the blade due to centrifugal forces Additional work is needed to verify this assertion, and to determine if a static test procedure can simulate the gyroscopic effects in a suitable manner. This paper describes the various non-rotating concepts analyzed, and demonstrates the effect believed to be gyroscopic in nature on the results

Howard, Samuel A.↗
NASA NTRS2013

Weight Assessment for Fuselage Shielding on Aircraft With Open-Rotor Engines and Composite Blade Loss

The Federal Aviation Administration (FAA) has been engaged in discussions with airframe and engine manufacturers concerning regulations that would apply to new technology fuel efficient "openrotor" engines. Existing regulations for the engines and airframe did not envision features of these engines that include eliminating the fan blade containment systems and including two rows of counter-rotating blades. Damage to the airframe from a failed blade could potentially be catastrophic. Therefore the feasibility of using aircraft fuselage shielding was investigated. In order to establish the feasibility of this shielding, a study was conducted to provide an estimate for the fuselage shielding weight required to provide protection from an open-rotor blade loss. This estimate was generated using a two-step procedure. First, a trajectory analysis was performed to determine the blade orientation and velocity at the point of impact with the fuselage. The trajectory analysis also showed that a blade dispersion angle of 3deg bounded the probable dispersion pattern and so was used for the weight estimate. Next, a finite element impact analysis was performed to determine the required shielding thickness to prevent fuselage penetration. The impact analysis was conducted using an FAA-provided composite blade geometry. The fuselage geometry was based on a medium-sized passenger composite airframe. In the analysis, both the blade and fuselage were assumed to be constructed from a T700S/PR520 triaxially-braided composite architecture. Sufficient test data on T700S/PR520 is available to enable reliable analysis, and also demonstrate its good impact resistance properties. This system was also used in modeling the surrogate blade. The estimated additional weight required for fuselage shielding for a wing- mounted counterrotating open-rotor blade is 236 lb per aircraft. This estimate is based on the shielding material serving the dual use of shielding and fuselage structure. If the shielding material is not used for dual purpose, and is only used for shielding, then the additional weight per aircraft is estimated to be 428 lb. This weight estimate is based upon a number of assumptions that would need to be revised when applying this concept to an actual airplane design. For example, the weight savings that will result when there is no fan blade containment system, manufacturing limitations which may increase the weight where variable thicknesses was assumed, engine placement on the wing versus aft fuselage, etc.

aircraft safety↗
NASA NTRS2022

Optimization Approach for Wind Tunnel Fan Blade Strain Gage Correlation with Test Fixture Unknowns

NASA has a significant maintenance challenge with the aging wind tunnel infrastructure across the Agency. Some wind tunnel fan blades, such as those in the National Transonic Facility at NASA Langley Research Center, have been in use for far longer than their planned 10-year lifetime. No detailed analytical models of the fan blades from their initial fabrication were created. To support the fabrication of either new, nominally identical fan blades or newly designed fan blades, accurate analytical models of the existing fan blades are necessary to demonstrate an understanding of the capabilities of the existing fan blades. Additionally, the existing documentation of the testing of the existing fan blades has gaps. In this report, a process for improving test-analysis correlation for these wind tunnel fan blades is discussed. This process involved a detailed study of unknown parameters in test fixture parameters from the old and incomplete test documentation. To improve correlation, these unknown parameters were used as design variables in an optimization study to minimize the error between test data and computed structural responses. Legacy strain gage data from tests conducted in 1981 were compared with results from a finite element model created in 2019. The use of test data from 1981 was necessary because none of the existing fan blades could be spared for use in destructive structural testing. While this process was demonstrated for wind tunnel fan blades, this process could be utilized for evaluating unknowns in test fixtures for other structural test configurations.

wind tunnel↗
NASA NTRSDate not supplied

Effect of Rotor Blade Elasticity on UAM Quadrotor Acoustics

The 6-passenger quadrotor concept vehicle designed under the NASA Revolutionary Vertical Lift Technology (RVLT) Project is considered for acoustic analysis. The tip speed is 550 ft/sec, with three blades per rotor (550/3). Originally, the blades were rigid, uniform spanwise, and with flap and pitch degrees of freedom. The blade model has since been updated: a lag hinge was added, and nonuniformities and elastic properties were introduced. Four blade models are considered: 1) original model, rigid uniform flap-pitch; 2) rigid uniform flap-lag-pitch; 3) rigid nonuniform flap-lag-pitch; and 4) elastic nonuniform flap-lag-torsion. Predictions are made for three flight conditions (approach, flyover, and takeoff) using the four blade models. The RVLT Toolchain is exercised using CAMRAD II and pyaaron/AARON/ANOPP2. Quadrotor trim and performance, 0.75R vertical blade loading for all four rotors, and noise sources are analyzed. Also, the contributions of the front and rear rotor pairs to noise are studied. In approach and flyover, a 2 dBA loading noise difference (delta) is predicted between blade models 1 and 4 (delta for takeoff is smaller, 1 dBA). Most of this noise delta is due to the lag hinge and nonuniformities, which is consistent with the results of a 2022 study that had considered only the approach condition; the current results extend this conclusion to flyover and takeoff also. The insensitivity of quadrotor noise to blade elasticity is currently attributed to the high blade torsional stiffness (frequency 6.41 per rev) and the small blade radius (9 ft) of the 550/3 design. Suggestions for potential follow-on work are given.

Rotor Blade↗
DOE OSTI2024

Large-eddy simulations of turbulent wake flows behind helical- and straight-bladed vertical axis wind turbines rotating at low tip speed ratios

Turbulent wake flows behind helical- and straight-bladed vertical axis wind turbines (VAWTs) rotating at low tip speed ratios (TSRs) are studied numerically. The turbulent flows are simulated using the large-eddy simulation (LES) model, and the rotating turbine blades are modeled using the actuator line method. The helical VAWT has identical key parameters as the straight VAWT except for the 135° helical twist of the blades over the 0.3m vertical span. A set of LES runs are performed for two TSRs, 0.6 and 0.4, and the results are reported and analyzed. At these low TSRs, the wake behind the straight-bladed VAWT exhibits two-dimensional dominant flow motions (in the horizontal plane perpendicular to the straight blades) in the near-wake region that cause considerable spanwise expansion of the wake as it extends downstream. In contrast, the helical-bladed VAWT generates highly three-dimensional (3D) wake flow structures and upward/downward mean flow motions within the wake that cause the wake to expand mainly in the vertical direction. Turbulence statistical analyses also show that the 3D wake flow features induced by the helical blades accelerate the wake transition to turbulence and enhance the small-scale turbulent dissipation (as shown by the subgrid-scale turbulent dissipation in the LES), which leads to a more rapid decay of the wake turbulence intensity than that in the straight-bladed VAWT case at the same TSR. Finally, compared with the straight-bladed VAWT, the helical-bladed VAWT also exhibits much smaller temporal variations for the torque and power coefficients during the rotation cycle, which can be beneficial for wind power generation.

17 WIND ENERGY↗
DOE OSTI2025

Robot-based Additive Manufacturing of Lego-type Modular Molds for Wind Blades

The objective of this project is to reduce the cost and lead time of horizontal wind turbine blade mold tooling and blade transportation, while maintaining the highest standards of blade quality. The solution involves a smart-design family of modular molds that are easily transportable to fabrication sites near the place of service. Key innovations include the use of additive manufacturing (AM) to integrate conformal thermal management channels, offering enhanced control over the thermal profiles tailored to specific blade materials. This approach enables in-situ quality assurance during mold fabrication, significantly improves mold life, and allows for reuse across multiple production cycles. Ultimately, the solution aims to optimize both tooling and transportation costs, contributing to the scalability of wind turbine blade production. A significant barrier to scaling up the production of large wind turbine blades lies in the high costs associated with tooling and the transportation of blades. Traditional molds are expensive, bulky, and difficult to transport, adding considerable lead time and cost to the overall manufacturing process. Additionally, transporting blades to distant locations for final assembly further exacerbates these challenges. The project aims to address these inefficiencies by demonstrating a modularized, additive-manufactured mold that meets all necessary blade specification requirements, specifically for blade lengths between 120m and 150m.

17 WIND ENERGY↗
DOE OSTI2025

Spatiotemporal Variability in Wind Turbine Blade Leading Edge Erosion

Wind turbine blade leading edge erosion (LEE) reduces energy production and increases wind energy operation and maintenance costs. Degradation of the blade coating and ultimately damage to the underlying blade structure are caused by collisions of falling hydrometeors with rotating blades. The selection of optimal methods to mitigate/reduce LEE are critically dependent on the rates of coating fatigue accumulation at a given location and the time variance in the accumulation of material stresses. However, no such assessment currently exists for the United States of America (USA). To address this research gap, blade coating lifetimes at 883 sites across the USA are generated based on high-frequency (5-min) estimates of material fatigue derived using a mechanistic model and robust meteorological measurements. Results indicate blade coating failure at some sites in as few as 4 years, and that the frequency and intensity of material stresses are both highly episodic and spatially varying. Time series analyses indicate that up to one-third of blade coating lifetime is exhausted in just 360 5-min periods in the Southern Great Plains (SGP). Conversely, sites in the Pacific Northwest (PNW) exhibit the same level of coating lifetime depletion in over three times as many time periods. Thus, it may be more cost-effective to use wind turbine deregulation (erosion-safe mode) for damage reduction and blade lifetime extension in the SGP, while the application of blade leading edge protective measures may be more appropriate in the PNW. Annual total precipitation and mean wind speed are shown to be poor predictors of blade coating lifetime, re-emphasizing the need for detailed modeling studies such as that presented herein.

Pryor, Sara C. (ORCID:0000000348473440)↗