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At least 91 records · Page 5

Effects of Trailing Edge Thickness and Blade Loading Distribution on the Aerodynamic Performance of Simulated CMC Turbine Blades

The aerodynamic performance of three blade sets that represent the geometric manufacturing constraints of Ceramic Matrix Composite (CMC) blades was measured experimentally in a large-scale transonic turbine blade cascade. The trailing edge thicknesses of CMC blades are anticipated to be significantly larger than those of current state-of-the-art metallic blades. The blades tested in the current study had trailing edge thicknesses of 5%, 7%, and 9% relative to the blade axial chord. The three blade sets were designed with matching throat dimensions, so the blade loading distributions were varied to retain similar overall loading levels. Data were acquired at four Reynolds numbers, covering a factor of six range. All data were acquired at the design isentropic exit Mach number of 0.74. Measurements include blade loading and five-hole probe surveys at two downstream stations. The effects of inlet turbulence intensity were also quantified. Total pressure loss data were integrated to determine overall loss levels for each of the three measured blade passages. Excellent periodicity was noted. For low inlet turbulence levels, losses were surprisingly lower for the thickest trailing edge at low Reynolds numbers, but were highest at the maximum Reynolds number. In general, losses were found to scale well with Reynolds number, although front loading was found to significantly reduce the sensitivity of loss to Reynolds number. For high inlet turbulence intensity, losses were found to scale with trailing edge thickness as expected, and the Reynolds number sensitivity was reduced for all three blade sets. Loss levels at the highest Reynolds number were comparable at low and high inlet turbulence intensity levels.

Paul W Giel↗

Aerodynamic Characterization of 3D Scanned Wind Turbine Blades Using Experimental and Computational Methods

This study presents an aerodynamic characterization of 3D scanned wind turbine blades using both experimental and computational methods. The research was conducted by Gulf Wind Technology and Sandia National Laboratories. The primary objective was to investigate the aerodynamic impacts of leading-edge manufacturing defects on wind turbine blades. The study utilized the Stratasys NEO 800 3D Printer for high-precision manufacturing and the GWT Accelerator Wind Tunnel for experimental testing. Computational simulations were performed using COMSOL Multiphysics to model the wind tunnel and analyze flow characteristics and OpenFOAM to study the aerodynamic impacts of leading-edge defects. OpenFAST was used to estimate how these defects can lead to revenue losses for wind farm operators as high as 6%. The results demonstrated significant aerodynamic performance variations due to defects, with detailed analysis provided through wind tunnel and CFD data. The findings contribute to the understanding of defect impacts on wind turbine blade performance and offer insights for future design improvements.

17 WIND ENERGY↗

Structural validation of a thermoplastic composite wind turbine blade with comparison to a thermoset composite blade

Reactive infusible thermoplastics have the potential to be advantageous for wind turbine blade composites because they are recyclable at end of life, can have reduced manufacturing costs, enable thermal joining and have similar, and in some cases better, structural properties than traditional thermoset epoxy composites. However, these materials are new to the wind industry and there is risk to investing in a material that has not been validated at a blade scale. Industry cannot adopt a new material such as this without large-scale validation and demonstration of system-level advantages in cost and/or performance. This paper presents structural characterization of a 13-m thermoplastic composite wind turbine blade compared to an identical geometry thermoset epoxy blade. In this work, the results of this comparison showed that the flatwise structural static performance and the fatigue performance of the two blades were similar, but the thermoplastic composite blade had increased damping compared to the epoxy blade, which may result in reduced operational loads.

17 WIND ENERGY↗

Smoother Turbine Blades Resist Thermal Shock Better

Surface treatment increases resistance of turbine blades to low-cycle fatigue. Smoothing removes small flaws where cracks start. Intended for blades in turbines subject to thermal shock of rapid starting. No recrystallization occurs at rocket-turbine operating temperatures.

Czerniak, Paul↗

Efficient derivative computation for unsteady fatigue-constrained nonlinear aero-structural wind turbine blade optimization

Gradient-based optimization offers significant efficiency advantages for wind turbine blade design, but its application has often been limited by the cost and accuracy of finite-difference derivative calculations, especially when fatigue constraints are considered. In this work, we systematically compare and evaluate four differentiation techniques, namely algorithmic differentiation, implicit differentiation, sparsity exploitation, and parallelization, to determine their effectiveness in computing accurate gradients through time-domain aero-structural simulations. By integrating these techniques with unsteady nonlinear aerodynamic and structural models, we develop software designed for accurate gradient computation. We show that combining these techniques addresses memory and runtime challenges associated with long simulations required by design load cases. Specifically, the most effective combination reduces derivative computation wall time by over an order of magnitude compared to finite differencing while maintaining superior accuracy. We demonstrate this approach in a proof-of-concept aero-structural optimization of a wind turbine blade that improves the cost of energy by 12.78 %. This comparative study establishes a viable approach for fatigue-aware blade design that balances computational efficiency with modeling accuracy.

17 WIND ENERGY↗

Microtextured Surfaces for Turbine Blade Impingement Cooling

Gas turbine engine technology is constantly challenged to operate at higher combustor outlet temperatures. In a modern gas turbine engine, these temperatures can exceed the blade and disk material limits by 600 F or more, necessitating both internal and film cooling schemes in addition to the use of thermal barrier coatings. Internal convective cooling is inadequate in many blade locations, and both internal and film cooling approaches can lead to significant performance penalties in the engine. Micro Cooling Concepts, Inc., has developed a turbine blade cooling concept that provides enhanced internal impingement cooling effectiveness via the use of microstructured impingement surfaces. These surfaces significantly increase the cooling capability of the impinging flow, as compared to a conventional untextured surface. This approach can be combined with microchannel cooling and external film cooling to tailor the cooling capability per the external heating profile. The cooling system then can be optimized to minimize impact on engine performance.

Fryer, Jack↗

Nonlinear structural analysis for fiber-reinforced superalloy turbine blades

A computational capability for predicting the nonlinear thermomechanical structural response of fiber-reinforced superalloy (FRS) turbine blades is described. This capability is embedded in a special purpose computer code (COBSTRAN) developed at the NASA Lewis Research Center. Special features of this computational capability include accounting for: fiber/matrix reaction, nonlinear and anisotropic material behavior, complex stress distribution due to local and global heterogeneity, and residual stresses due to initial fabrication and/or inelastic behavior during subsequent missions. Numerical results are presented from analyses of a hypothetical FRS turbine blade subjected to a fabrication process and subsequent mission cycle. The results demonstrate the capabilities of this computational tool to; predict local stress/strain response and capture trends of local nonlinear and anisotropic material behavior, relate the effects of this local behavior to the global response of a multilayered fiber-composite turbine blade, and trace material history from fabrication through successive missions.

Hopkins, D. A.↗

Effects of geometry and materials on low cycle fatigue life of turbine blades in LOX/hydrogen rocket engines

This paper presents the results of an advanced turbine blade test program aimed at improving turbine blade low cycle fatigue (LCF) life. A total of 21 blades were tested in a blade thermal tester. The blades were made of MAR-M-246(Hf)DS and PWA-1480SC in six different geometries. The test results show that the PWA-1480SC material improved life by a factor of 1.7 to 3.0 over the current MAR-M-246(Hf)DS. The geometry changes yielded life improvements as high as 20 times the baseline blade made of PWA-1480SC and 34 times the baseline MAR-M-246DS blade.

Ryan, R. M.↗

Application of a personal computer for the uncoupled vibration analysis of wind turbine blade and counterweight assemblies

A research effort was undertaken to develop personal computer based software for vibrational analysis. The software was developed to analytically determine the natural frequencies and mode shapes for the uncoupled lateral vibrations of the blade and counterweight assemblies used in a single bladed wind turbine. The uncoupled vibration analysis was performed in both the flapwise and chordwise directions for static rotor conditions. The effects of rotation on the uncoupled flapwise vibration of the blade and counterweight assemblies were evaluated for various rotor speeds up to 90 rpm. The theory, used in the vibration analysis codes, is based on a lumped mass formulation for the blade and counterweight assemblies. The codes are general so that other designs can be readily analyzed. The input for the codes is generally interactive to facilitate usage. The output of the codes is both tabular and graphical. Listings of the codes are provided. Predicted natural frequencies of the first several modes show reasonable agreement with experimental results. The analysis codes were originally developed on a DEC PDP 11/34 minicomputer and then downloaded and modified to run on an ITT XTRA personal computer. Studies conducted to evaluate the efficiency of running the programs on a personal computer as compared with the minicomputer indicated that, with the proper combination of hardware and software options, the efficiency of using a personal computer exceeds that of a minicomputer.

White, P. R.↗

Chimera grids in the simulation of three-dimensional flowfields in turbine-blade-coolant passages

When computing flows inside geometrically complex turbine-blade coolant passages, the structure of the grid system used can affect significantly the overall time and cost required to obtain solutions. This paper addresses this issue while evaluating and developing computational tools for the design and analysis of coolant-passages, and is divided into two parts. In the first part, the various types of structured and unstructured grids are compared in relation to their ability to provide solutions in a timely and cost-effective manner. This comparison shows that the overlapping structured grids, known as Chimera grids, can rival and in some instances exceed the cost-effectiveness of unstructured grids in terms of both the man hours needed to generate grids and the amount of computer memory and CPU time needed to obtain solutions. In the second part, a computational tool utilizing Chimera grids was used to compute the flow and heat transfer in two different turbine-blade coolant passages that contain baffles and numerous pin fins. These computations showed the versatility and flexibility offered by Chimera grids.

Stephens, M. A.↗

Unsupervised acoustic detection of fatigue-induced damage modes from wind turbine blades

This paper proposes a new in-situ damage detection approach for wind turbine blades, which leverages blade-internal non-stationary acoustic pressure fluctuations caused by the mechanical loading as the main source of excitation. This acoustic excitation was leveraged for the detection of fatigue-related damage modes on a full-scale wind turbine blade undergoing edgewise fatigue testing. An unsupervised, data-driven structural health monitoring strategy was developed to learn the normal cavity-internal acoustic sequences generated by the blade’s load cycles and to detect damage-related anomalies in the context of those sequences. A linear cepstral-coefficient based feature set was used to characterize the cavity-internal acoustics and LSTM-autoencoders were trained to accurately reconstruct healthy-case sequences. The reconstruction error was then used to characterize anomalous acoustic patterns within the blade cavity. The technique was able to detect a damage event earlier than a strain-based system by 120,000 load cycles.

17 WIND ENERGY↗

Effect of Chord Size on Weight and Cooling Characteristics of Air-Cooled Turbine Blades

An analysis has been made to determine the effect of chord size on the weight and cooling characteristics of shell-supported, air-cooled gas-turbine blades. In uncooled turbines with solid blades, the general practice has been to design turbines with high aspect ratio (small blade chord) to achieve substantial turbine weight reduction. With air-cooled blades, this study shows that turbine blade weight is affected to a much smaller degree by the size of the blade chord.

Esgar, Jack B↗

Methods for thermal welding of wind turbine blades

Disclosed herein are methods, devices, and systems for manufacturing wind turbine blades which in some instances require using new blade joint designs. The blade joint designs described herein may allow for contact in places where welds will be made, which allows for existing manufacturing tolerances to be used while still enabling the use of thermal welding for wind turbine blades.

17 WIND ENERGY↗

Predicted inlet gas temperatures for tungsten fiber reinforced superalloy turbine blades

Tungsten fiber-reinforced superalloy composite (TFRS) impingement-cooled turbine blade inlet gas temperatures were calculated taking into account material spanwise strength, thermal conductivity, material oxidation resistance, fiber-matrix interaction, and coolant flow. Measured values of TFRS thermal conductivities are presented. Calculations indicate that blades made of 30 volume percent fiber content TFRS having a 12,000 N-m/kg stress-to-density ratio while operating at 40 atm and a 0.06 coolant flow ratio could permit a turbine blade inlet gas temperature of over 1900 K. This is more than 150 K greater than similar superalloy blades.

Winsa, E. A.↗