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Leading edge erosion (LEE) of wind turbine blades has been identified as a major factor in decreased wind turbine blade lifetimes and energy output over time. Accordingly, the International Energy Agency Wind Technology Collaboration Programme (IEA Wind TCP) has created the Task 46 to undertake cooperative research in the key topic of blade erosion. Participants in the task are given in Table 1.
Current Ni-based alloys used in turbine blade applications are operating at 1100°C which is approximately 90% of the solidus of Ni-based alloys. Further increases in temperature can be achieved only through the use of alloys with higher solidus temperatures such as refractory alloys which include Mo, Nb, W, Ta alloys. Niobium has a unique combination of physical properties that include a high melting point (2468°C), lowest density (8.57 g/cc), and the lowest modulus amongst refractory alloys, a good thermal conductivity that increases from 45 W/mK at room temperature to 62 W/mK at 1093°C, good ductility with fabricability using traditional techniques, high strength, good creep resistance, and general chemical inactivity. Hence niobium alloys offer many advantages for use at the desired temperature of 1300°C. One of the major deterrents to the use of niobium and its alloys at high temperatures is achieving good oxidation resistance. In addition, achieving balanced properties of room temperature strength, ductility, fracture toughness, high temperature strength, and creep resistance required for 1300°C operation at a density of 9 g/cm 3 is extremely challenging since the addition of W which is a potent strengthener increases the density of the alloy. This project seeks to enable the development of a tri-layered turbine blade that can operate continuously at 1300°C with the core of the turbine blade providing good creep resistance, the second layer providing improved oxidation resistance over the core layer, and the third layer being an environmental barrier providing oxidation resistance. The objective of this Phase 1 project was to use computational modeling and advanced characterization tools to develop two classes of Nb alloys which could be used as the core layer and the transition layer.
Pitch bearings are an essential component in wind turbines used to connect the blade root to the hub. They support the resulting simultaneous radial, axial, and overturning moment loads while allowing relative rotation of the blade to the hub. The most recent evidence indicates the replacement rate for pitch bearings on 3+ MW turbines can be several percent per year, reaching 10% by year 5. This is a far higher replacement rate than both older 1.5 to 2 MW turbines and 2 to 3 MW turbines, which only reach a 10% replacement rate by 14 to 24 years compared to the expected design life of at least 20 years. Typical pitch bearing replacements require the use of a large, expensive crane and removal of the blade(s) or rotor, with a significant amount of downtime. Given the most recent developments in pitch bearing reliability and the publication of the updated NREL and Fraunhofer IWES pitch bearing design guide, the purpose of this report is to update the performance and rating analysis of the example 1.9-meter diameter pitch bearing representative of that installed on a 1.5 MW wind turbine, compare the rating life to the observed service life of similar pitch bearings, and validate the service life modification factor with this large population of bearings. The report will also summarize the pitch bearing contact conditions, thereby serving as a guide for planned bench-level fretting wear tests at Argonne National Laboratory.
Campaign I of the Floating Offshore-wind Controls Advanced Laboratory Experimental Program (FOCAL) aims to generate a dataset enabling the validation of aerodynamic performance of a scaled turbine mounted on a rigid tower in a fixed condition. The turbine considered in the FOCAL testing campaigns is the IEA-Wind 15MW Reference Wind Turbine. This scaled model is capable of simulating advanced blade-pitch control strategies in a high-quality wind field. The turbine is fully instrumented to record a variety of parameters in real time such as structural loads and dynamics. The test data considered was generated at the University of Maine's Harold Alfond Wind and Wave (W2) testing facility. The Load Cases (LC) considered in this testing campaign are as follows: LC 1.X - Constant wind and blade-pitch with varying rotor speeds LC 2.X - Constant wind and rotor speed with varying blade-pitch LC 3.X - Varying wind with active closed-loop control Detailed properties on the modeled system are found in the following reference: Lenfest E., Floating Offshore-wind Controls Advanced Laboratory (FOCAL) Experimental Program - Campaign I: 1:70 Model-scale Testing of the IEA-Wind 15MW Reference Turbine. UMaine ASCC Report Number 23-40-1183. Details on the results of the verification and validation are found in the following reference: Mendoza, Nicole et al., "Verification and Validation of Model-Scale Turbine Performance and Control for the IEA Wind 15 MW Reference Wind Turbine," Energies, vol. 15, no. 20, 2022, https://doi.org/10.3390/en15207649.
Given the industry-wide trend of continual increases in the size of utility-scale wind turbines, a point will come where reductions will need to be made in terms of the weight of the turbine’s blades to ensure they can be as long as needed without sacrificing structural stability. One such technique that may be considered is to decrease the material used for the shell and spar cap. While this will solve the weight issue, it creates a new one entirely—less material for the shell and spar cap will in turn create blades that are more flexible than what is currently used. This article aims to investigate how the oscillatory response of light-weight wind turbine rotors is affected by these flexibility changes. The object of our study is the Sandia National Lab National Rotor Testbed (SNL-NRT) wind turbine, which the authors investigated in the course of a research project supported by SNL. Using a reduced-order characterization (ROC) technique based on controlled gust pulses, introduced by the authors in a previous work, the aeroelastic dynamics of the NRT’s original baseline blade design and several of its flexible variations were studied via numerical simulations employing the CODEF multiphysics suite. Results for this characterization are presented and analyzed, including a generalization of the ROC of the SNL-NRT oscillatory dynamics to larger machines with geometrical similarity. The latter will prove to be valuable in terms of extrapolating results from the present investigation and other ongoing studies to the scale of current and future commercial machines.
Recent advancements in the use of active wake mixing (AWM) to reduce wake effects on downstream turbines open new avenues for increasing power generation in wind farms. However, a better understanding of the fluid dynamics underlying AWM is still needed to make wake mixing a reliable strategy for wind farm flow control. In this work, a spectral proper orthogonal decomposition (SPOD) is used to analyze the dynamics of coherent flow structures that are induced in the wake through blade pitch actuation. The data are generated using the ExaWind software suite to perform large eddy simulations of an NREL 2.8 MW turbine operating in a stable atmospheric boundary layer. SPOD tracks the modal behavior of flow structures from their generation in the turbine induction field through their growth in the near-wake region and to their subsequent evolution and energy transfers in the far wake. SPOD is shown to be a useful tool in the context of AWM because it translates the wavenumber and frequency inputs to the turbine controller to structures in the wake. A decomposition of the radial shear stress flux in the wake is also developed using SPOD to measure the contribution of coherent flow structures to mean flow turbulent entrainment and wake recovery. The effectiveness of AWM is connected to its ability to excite inherent structures in the wake of the turbine that arise using baseline controls. The effects of AWM on blade loading are also analyzed by connecting the axial force along the blade to the SPOD analysis of the turbine induction field. Lastly, the performance of different AWM strategies is demonstrated in a two-turbine array.
To reduce costs, offshore wind turbines are expected to be designed with significantly increased rotor diameters. Larger turbines become more flexible and span a larger portion of the atmospheric boundary layer. With these changes, the validity of traditional modeling assumptions should be investigated. This work challenges two common assumptions: (1) that the drivetrain can be considered rigid (except in torsion) and does not couple with the rotor and tower and 2) that wind directional change with height (veer) does not greatly influence the fatigue damage in the tower, blades and drivetrain. Two large semi-submersible floating wind turbines are considered: a 15 and a 22 MW reference turbine. Both use direct-drive generators. Aero-hydro-servo-elastic simulations are performed using OpenFAST, with drivetrain bending flexibility and main bearing response implemented in the coupled analysis. The turbines are subjected to a set of load cases at below-, near- and above-rated mean wind speeds, assembled based on the 3 km Norwegian reanalysis (NORA3) hourly wind and wave hindcast data for Utsira Nord, off the coast of Norway. In each load case, conditions with and without veer are simulated to evaluate the influence of veer on damage equivalent loads (DELs) of the turbine tower, blades and main bearings. Further, these load cases are applied to evaluate the influence of drivetrain flexibility on aero-elastic turbine response. The results indicate that, depending on the veer gradient, mean wind speed, operating regime and turbine size, veer can be very important for tower-top DELs and the fluctuations of main bearing radial loads, while main bearing and blade-root flapwise DELs are less affected. Considering these specific load cases and turbine models, drivetrain flexibility is found to significantly influence tower-top DELs of the largest turbine: the tower-top fore-aft and torsional damage equivalent moments of the 22 MW turbine are reduced by more than 20 % at near-rated wind speeds when the drivetrain is modeled as flexible.
Composites structures are widely used in aerospace and wind energy applications for their excellent stiffness and strength-to-weight properties. In these structures, structural damping is critical to predict vibration amplitudes, performance, and reliability. Structural damping is of particular interest for slender wings, rotorcraft blades, and wind turbine blades that can exhibit complex vibration phenomena and are frequently modeled with geometrically exact beam theory (GEBT). Standard approaches of stiffness proportional or modal damping merely assign user defined values and cannot predict damping behavior. This work compares stiffness proportional damping to two more advanced damping approaches: modal strain energy and Prony series. The modal strain energy approach uses a sectional analysis tool to calculate the beam stiffness and postprocess internal stresses from GEBT simulations. The internal stresses are then used to calculate modal damping factors. The Prony series is implemented within GEBT to directly model viscoelastic behavior of the composites. These approaches are compared by modeling the evolution of the damping factors of a realistic flexible wind turbine blade with varying rotational speed. Discrepancies between the approaches suggest areas for future modeling development, but differences in nonlinear damping values are less than current uncertainties about the magnitude of structural damping.
In this webinar hosted by the U.S. Department of Energy's WINDExchange initiative, experts from the National Renewable Energy Laboratory introduce attendees to key concepts in end-of-service processes for wind energy technologies and infrastructure, including decommissioning, repowering, and recycling. As wind energy projects across the United States become older, decisions about end-of-service options and component processing are of growing importance to project owners and operators, state and local decision-makers, and neighboring communities. There is also concern about the blade waste that must be processed, with a number of recycling solutions being developed to meet this need. This webinar introduces the processes and activities involved at the end of a wind energy project's lifespan; discusses the impacts these activities have on communities, landowners, the wind energy industry, and other stakeholders; explains different blade recycling methods; and discusses the future of recycling in the wind energy industry.
This white paper outlines a roadmap to inform future research efforts around the wind turbine rotors of the future. The document is authored by researchers that have been working on the Big Adaptive Rotor (BAR) and related initiatives at the National Renewable Energy Laboratory and Sandia National Laboratories. The Wind Energy Technologies Office of the U.S. Department of Energy has been funding BAR since 2018. The learnings from BAR have been documented in dozens of publications. This new paper identifies unresolved critical challenges in wind turbine rotor technology and structures them in four large topic areas: 1. Predictive and validated numerical tools. 2. Design methods and standards. 3. Improvements in manufacturing. 4. Technological innovations. Although wind turbines have not changed in their core architecture, with the market almost entirely dominated by three-bladed upwind rotors, a vast amount of research has allowed to introduce technological innovations resulting in a reduction in levelized cost of energy that made wind competitive with all traditional sources of electricity. Focusing on the rotor, blades will keep following the trend of mass and stiffness reduction, will adopt segmentation, and will keep growing in length, both land-based and offshore. To support this continuous innovation, this white paper argues that research efforts in rotor technology at the national labs are best directed to the first three topic areas and to low technology-readiness-levels (1-3) innovations, leaving the task of implementing higher-TRL (4-9) technological innovations to industry stakeholders. This research roadmap is also well aligned with the upcoming roadmap defined during the International Energy Agency 109th Topical Expert Meeting on the Grand Challenges of Wind Energy.
Blade element momentum (BEM) theory is the backbone of many industry-standard wind turbine aerodynamic models. To be applied to a broader set of engineering problems, BEM models have been extended since their inception and now include several empirical corrections. These models have benefitted from decades of development and refinement and have been extensively used and validated, proving their adequacy in predicting aerodynamic forces of horizontal-axis wind turbine rotors in most scenarios. However, the analysis of floating offshore wind turbines (FOWTs) introduces new sets of challenges, especially if new-generation large and flexible machines are considered. In fact, due to the combined action of wind and waves and their interaction with the turbine structure and control system, these machines are subject to unsteady motion and thus unsteady inflow on the wind turbine's blades, which could put BEM models to the test. Consensus has not been reached on the accuracy limits of BEM in these conditions. This study contributes to the ongoing research on the topic by systematically comparing four different aerodynamic models, ranging from BEM to computational fluid dynamics, in an attempt to shed light on the unsteady aerodynamic phenomena that are at stake in FOWTs and whether BEM is able to model them appropriately. Simulations are performed on the UNAFLOW 1:75 scale rotor during imposed harmonic surge and pitch motion. Experimental results are available for these conditions and are used for baseline validation. The rotor is analyzed in both rated operating conditions and low wind speeds, where unsteady aerodynamic effects are expected to be more pronounced. Results show that BEM, despite its simplicity, can adequately model the aerodynamics of FOWTs in most conditions if augmented with a dynamic inflow model.
An unintended consequence of wind energy generation is bat fatalities caused by wind turbine blade strikes. One potential approach to reduce collision risk is to use ultrasound to create an uncomfortable or disorienting airspace around wind turbine blades. Ultrasonic deterrents (UDs) have produced mixed results in experimental field studies at commercial wind energy facilities, with effectiveness varying by species and location. It is possible that some species can alter their normal echolocation characteristics to counter the signal of UDs. Our broad objective was to maximize the effectiveness of a UD by comparing changes in echolocation characteristics during three UD frequency emissions among species, between seasons, and between sex. We hypothesized that UD emissions with frequencies most similar to each species’ echolocation characteristics would be more likely to alter the bats’ echolocation, and bat responses would vary between seasons and sex for each species. We released wild-captured bats into a 60 m × 10 m × 4.4 m (length × width × height) flight cage located in San Marcos, Texas, USA, from July to October 2020 and March to May 2021 and monitored echolocation frequencies with ultrasonic microphones. We conducted trials on Brazilian free-tailed bats ( Tadarida brasiliensis ; n = 54), cave myotis ( Myotis velifer ; n = 44), red bats ( Lasiurus blossevilli , Lasiurus borealis ; n = 41), evening bats ( Nycticeius humeralis ; n = 32), and tricolored bats ( Perimyotis subflavus ; n = 8). We found that species with high-frequency echolocation calls altered their echolocation signatures more commonly during high-frequency UD emissions, whereas low-frequency bats altered their echolocation signatures more commonly during low-frequency UD emissions. Additionally, echolocation responses varied between seasons and sexes for several species. Variations in responses may be dependent on species migratory status, differences in mating behavior and mating season, hormonal differences between sexes and seasons, and/or constraints on echolocation adaptability. Our results offer insights into the variable effectiveness of UDs at reducing bat fatalities at wind turbines and provide information for potential adjustments to UDs for improved success.
Abstract Wind speed and direction variations across the rotor affect power production. As utility‐scale turbines extend higher into the atmospheric boundary layer (ABL) with larger rotor diameters and hub heights, they increasingly encounter more complex wind speed and direction variations. We assess three models for power production that account for wind speed and direction shear. Two are based on actuator disc representations, and the third is a blade element representation. We also evaluate the predictions from a standard power curve model that has no knowledge of wind shear. The predictions from each model, driven by wind profile measurements from a profiling LiDAR, are compared to concurrent power measurements from an adjacent utility‐scale wind turbine. In the field measurements of the utility‐scale turbine, discrete combinations of speed and direction shear induce changes in power production of −19% to +34% relative to the turbine power curve for a given hub height wind speed. Positive speed shear generally corresponds to over‐performance and increasing magnitudes of direction shear to greater under‐performance, relative to the power curve. Overall, the blade element model produces both higher correlation and lower error relative to the other models, but its quantitative accuracy depends on induction and controller sub‐models. To further assess the influence of complex, non‐monotonic wind profiles, we also drive the models with best‐fit power law wind speed profiles and linear wind direction profiles. These idealized inputs produce qualitative and quantitative differences in power predictions from each model, demonstrating that time‐varying, non‐monotonic wind shear affects wind power production.
Tidal stream turbines deployed at highly energetic open water sites are subjected to sheared inflow in the rotor plane. The inflow shear is expected to cause asymmetric loading on the rotor blades and affect the downstream wake. In the current study, two different turbulent inflow conditions, static-high shear and dynamic shear, were generated via an active-grid turbulence generator. A 1:20 scaled three-bladed horizontal axis tidal turbine model was tested in those conditions. The results were compared to a quasi-laminar case with no imposed turbulence or shear. The results show that the high shear reduces the average performance, with a drop of up to 16% in the optimal power coefficient. Besides, the shear profiles increase torque fluctuations and induce significant differences in wake hydrodynamics between the high-speed (upper) and low-speed (lower) regions. The large integral length scales further enhance the load fluctuations perceived by the rotor but have a negligible effect on the mean wake field quantities and the wake recovery. The lower half region featured a faster breakdown of tip vortex structure and a rapid drop of swirl number, a phenomenon conjectured to be a consequence of the strong turbulence intensities and Reynolds stresses in the lower half region. Furthermore, the sheared turbulent inflow also results in a very intensive energy redistribution process towards large-scale, low-frequency motions, which is important to the downstream turbines.
Unsteady aerodynamic loads significantly influence the design and wake flow field of floating offshore wind turbines, especially due to wave- or vibration-induced tower top motions triggering various unsteady phenomena. Recent studies show that increasing turbine sizes amplify unsteady aerodynamic effects, as their impact typically grows with rotor diameter. This work combines recent findings from experiments and simulations on model-scale FOWT aerodynamics with new numerical analyses of large-scale rotors, providing a comprehensive understanding of unsteady phenomena occurrence and impact. Numerical analyses of the IEA 15-MW and 22-MW rotors undergoing surge motions characterise the combined influence of motion-induced unsteady phenomena on rotor thrust. Results indicate that unsteady effects can reduce thrust force variations by up to 40% at realistic surge periods. These findings contrast with prior model-scale rotor investigations, attributed to the specialised design of the model rotors. Comparisons between numerical methods - the dynamic blade element momentum method in OpenFAST and free vortex wake modules in panMARE and OpenFAST - reveal persistent differences in thrust predictions under both idealised and realistic conditions. This highlights that classical blade element momentum approaches require enhancement to accurately capture unsteady loads on large-scale floating offshore wind turbines at low wind speeds.
Carbon fibre-reinforced polymers (CFRPs) are used in many applications in the global energy transition, including for lightweighting aircraft and vehicles and in wind turbine blades, shipping containers and gas storage vessels1,2,3,4. Given the high cost and energy-intensive manufacture of CFRPs5,6,7, recycling strategies are needed that recover intact carbon fibres and the epoxy-amine resin components. Here we show that acetic acid efficiently depolymerizes both aliphatic and aromatic epoxy-amine thermosets used in CFRPs to recoverable monomers, yielding pristine carbon fibres. Deconstruction of materials from multiple sectors demonstrates the broad applicability of this approach, providing clean fibres from 2 h reactions. The optimal conditions were scaled to 80.0 g of post-consumer CFRPs, and demonstrative composites were fabricated from the recycled carbon fibres, which were recycled two more times, maintaining their strength throughout. Process modelling and techno-economic analysis, with feedstock cost informed by wind turbine blade waste generation8, indicates this method is cost effective, with a minimum selling price of US$1.50 per kg for recycled carbon fibres whereas life cycle assessment shows process greenhouse gas emissions around 99% lower than virgin carbon fibre production. Overall, this approach could enable recycling of industrial CFRPs as it provides clean, mechanically viable recycled carbon fibres and recoverable resin monomers from the thermoset.
Wind energy’s rapid expansion has led to unintended consequences for wildlife, with migratory bats among the species most at risk. The behavioural mechanisms underlying collisions remain poorly understood, but one hypothesis is that bats are attracted to wind turbine structures. Vision is important to bat orientation and obstacle avoidance, yet it has been relatively understudied in the context of bat–turbine interactions. We hypothesize that light reflected off turbine surfaces could attract bats, acting as a sensory pollutant that may increase collision risk. To test whether reflective turbine surfaces elicit attraction, we flew 242 Lasiurus cinereus and 154 Lasionycteris noctivagans through Y-maze assays. Bats were at least twice as likely to fly towards white turbine blade sections compared to less reflective black ones. This attraction intensified when the alternative exit was a dark, empty flyway, with 74% of L. cinereus and 97% of L. noctivagans flying towards the white turbine blade. These findings provide evidence that visual sensory pollutants could underlie bat–turbine interactions, and if so, wind turbines could be ecological traps.
Internal cooling features such as pin-fins, impingement jets, and rib-turbulators are necessary to keep turbine components cool, but if sufficiently advanced can potentially also eliminate the need for film cooling on turbine blades particularly in industrial gas turbines where temperatures are not extreme. Furthermore, by leveraging additive manufacturing, other advanced designs such as lattice and incremental impingement configurations are possible and have recently been experimentally tested. While the performance of such configurations has been quantified through means of overall cooling effectiveness, it is not as clear why certain designs were better than others, or what the mechanisms were behind the observed external cooling patterns. The purpose of this study was to computationally analyze different advanced turbine blade internal cooling designs previously tested by the National Energy Technology Laboratory.