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At least 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Healable Coatings as a Mechanism to Repair Leading Edge Erosion in Wind Energy

Wind turbine blades are highly engineered structures designed to face temperature extremes and high winds. However, erosion of the blade's leading edge and subsequent repair remains a significant and costly challenge for the wind energy industry. Repair of these leading edges can lead to large amounts of downtime for the turbine and significant operational inefficiencies. In this work, the strength of adhesion and healing ability of a commercially available vitrimer (Mallinda's VITRIMAX) was compared to that of a thermoplastic resin, which has previously been demonstrated in wind energy applications (Arkema's Elium) to evaluate their efficacy as surface coatings for wind turbine blades, particularly their leading edges. Vitrimers are a class of inherently reprocessable thermosets, and it was theorized that vitrimer-based leading edge coatings could enable more robust and efficient wind turbine blades with decreased operational downtime and safer maintenance practices. It was found that the VITRIMAX adhered better to the wind blades' surfaces than both the manufacturer's paint and Elium, with increases in pull-off strength of adhesion ranging from 24% to 83% above that of the original paint. Furthermore, the VITRIMAX adhered strongly to the underlying composite of each blade with strength of adhesion values increasing in ranges from 42% to 97% above that of the original paint. Finally, the vitrimer coating showed an 88% decrease in surface roughness compared to end-of-life blade materials, and initial healing demonstrations in which coatings were manually scratched and subsequently healed exhibited an ~84.5% decrease in scratch depths.

Hubbard, Amber [ORNL]↗
DOE OSTI2025

Development of Niobium-based alloys for Turbine Applications: 20/CJ000/08/09 (ULTIMATE Phase I project)

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.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Experimental trials of species-specific bat flight responses to an ultrasonic deterrent

Unintended consequences of increasing wind energy production include bat mortalities from wind turbine blade strikes. Ultrasonic deterrents (UDs) have been developed to reduce bat mortalities at wind turbines. Our goal was to experimentally assess the species-specific effectiveness of three emission treatments from the UD developed by NRG Systems. We conducted trials in a flight cage measuring approximately 60 m × 10 m × 4.4 m (length × width × height) from July 2020 to May 2021 in San Marcos, Texas, USA. A single UD was placed at either end of the flight cage, and we randomly selected one for each night of field trials. Trials focused on a red bat species group (Lasiurus borealis and Lasiurus blossevillii; n = 46) and four species: cave myotis (Myotis velifer; n = 57), Brazilian free-tailed bats (Tadarida brasiliensis; n = 73), evening bats (Nycteceius humeralis; n = 53), and tricolored bats (Perimyotis subflavus; n = 17). The trials occurred during three treatment emissions: low (emissions from subarrays at 20, 26, and 32 kHz), high (emissions from subarrays at 38, 44, and 50 kHz), and combined (all six emission frequencies). We placed one wild-captured bat into the flight cage for each trial, which consisted of an acclimation period, a control period with the UD powered off, and the three emission treatments (order randomly selected), each interspersed with a control period. We tracked bat flight using four thermal cameras placed outside the flight cage. We quantified the effectiveness of each treatment by comparing the distances each bat flew from the UD during each treatment vs. the control period using quantile regression. Additionally, we conducted an exploratory analysis of differences between sex and season and sex within season using analysis of variance. Broadly, UDs were effective at altering the bats’ flight paths as they flew farther from the UD during treatments than during controls; however, results varied by species, sex, season, and sex within season. For the red bat group, bats flew farther from the UD during all treatments than during the control period at all percentiles (p < 0.001), and treatments were comparable in effectiveness. For cave myotis, all percentile distances were farther from the UD during each of the treatments than during the control, except the 90th percentile distance during high, and low was most effective. For evening bats and Brazilian free-tailed bats, results were inconsistent, but high and low were most effective, respectively. For tricolored bats, combined and low were significant at the 10th–75th percentiles, high was significant at all percentiles, and combined was most effective. Results suggest UDs may be an effective means of reducing bat mortalities due to wind turbine blade strikes. We recommend that continued research on UDs focus on low emission treatments, which have decreased sound attenuation and demonstrated effectiveness across the bat species evaluated in this study.

17 WIND ENERGY↗
DOE OSTI2020

Measurements of the Flow in the Vicinity of an Additively Manufactured Turbine Leading-Edge Using X-Ray Particle Tracking Velocimetry

X-ray particle tracking velocimetry (PTV) is performed, for the first time, to measure the velocity field inside a leading-edge of a turbine blade made by laser-additive-manufacturing (LAM) process. The traditional showerhead holes were replaced by a porous matrix in the leading-edge. The flow through such a leading-edge piece cannot be faithfully recreated by traditional prototype testing methods due to the surface roughness and imperfections caused by LAM process. Hence, direct measurement is the only option. However, it is difficult to measure flow inside such pieces with traditional velocimetry measurements due to the existence of metallic walls. Moreover, small internal size and high flow speeds call for a measurement technique with high spatial and temporal resolutions. To address these issues, we performed time-resolved X-ray PTV using the Advanced Photon Source (APS) synchrotron facility at the Argonne National Laboratory (ANL). A hydraulic system was constructed to run water, mixed with seeding particles, through the leading-edge piece. A high-speed camera captured the images of the seeding particles, which were later processed to create particle tracks. The time-averaged velocity field showed distinct pairs of vortices located in front of the porous outlet inside the leading-edge piece. The inlet channel showed reversed flow due to partial obstruction by the porous inlet of the test piece. Such knowledge of the flow field inside a leading-edge of a turbine blade will help us to design better cooling paths leading to higher cooling efficiency and increased life-span of a turbine blade.

42 ENGINEERING↗
DOE OSTI2026

Species-specific acoustic responses by bats to ultrasonic stimuli used for reducing bat-wind turbine interactions

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.

17 WIND ENERGY↗
DOE OSTI2022

Hybrid RANS-LES of the Atmospheric Boundary Layer for Wind Farm Simulations: Preprint

Wind farm simulations often do not accurately represent wake-atmospheric boundary layer (ABL) interactions, blade boundary layer (BL) dynamics, and turbine-turbine interactions. In this work, we use Active Model Split (AMS), a new hybrid Reynolds-Averaged Navier Stokes (RANS)-large eddy simulation (LES) model, which is well suited to capture these effects because the model can (i) accurately simulate the ABL with the Coriolis effect, (ii) is accurate in adverse pressure gradients such as those near wind turbine blades, and (iii) has sufficiently low computational cost to simulate multiple turbines while resolving the blade BL. For simplicity and consistency we develop AMS to be used throughout the domain rather than in a zonal method. We implement our work in the massively parallel flow solver, Nalu-Wind, so that our model can access the compute resources needed for blade-resolved simulations of multiple wind turbines. To accomplish these aims, we modify the baseline AMS by changing the RANS contribution to SST k - omega with a length scale limiter, adding the Coriolis effect, and developing an appropriate wall treatment. We show that AMS of the ABL with the Coriolis effect matches LES reference results better than those obtained with RANS. We describe our plans to add buoyancy effects and wind turbines to our AMS simulations.

atmospheric boundary layer↗
DOE OSTI2025

Accuracy of LEE performance loss model based on field observations

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.

17 WIND ENERGY↗
DOE OSTI2021

Towards Resolving the Risk of Turbine Collision on Fish: FY21-22 Seedling Report Phase I

The most important concern for permitting tidal and river turbines is the collision risk of marine animals with the turbine blades. Our understanding of the risk to individual fish from colliding with turbine blades is poor; if these collisions were to occur, it is unknown whether fish will sustain recoverable injuries or be killed. Equally unknown is the impact these collisions might have on populations, particularly for threatened, endangered, or commercially managed fish species. In addition to observations of interactions of fish with turbines, numerical models need to be developed or expanded to predict impacts on fish populations. These models could replace expensive and technically challenging monitoring programs in high energy, often murky, tidal or river waters. In this project, a multi-pronged approach was taken to understand the state of knowledge for collision risk of fish with turbines and build a pathway forward. This approach included a workshop with experts, a literature review of modeling and empirical studies, the development of a research framework, and the identification of case studies to address through future work. This project is a first step towards the future development of effective and robust numerical models for assessing the collision risk of fish around turbines. This will achieve a balanced and improved estimate of the severity of collision risk to fish at the population scale.

Garavelli, Lysel↗
DOE OSTI2025

Effect of Surface Roughness on Dynamic Stall in Pitching Motion

Dynamic stall plays a critical role in determining the performance and stability of a wide range of fluid-dynamics systems in various engineering applications. This unsteady aerodynamic phenomenon is particularly significant for maneuvering aircraft wings, jet aircraft subjected to gust encounters, helicopter rotor blades, and wind turbine blades [1–3]. The prediction of the dynamic stall vortex (DSV) is challenging due to factors such as unsteady aerodynamics, three-dimensional (3-D) effects, turbulence and flow separation, incoming gust, and surface impact effects [4–6]. Hence, advanced computational techniques and modeling approaches in computational fluid dynamics (CFD) would be required to enhance the accuracy and reliability of DSV predictions in dynamic stall scenarios. In the past, Batther and Lee [7] employed delayed detached eddy simulations (DDES) to understand the flow physics associated with the onset of dynamic stall. Their approach demonstrated that DDES achieves results comparable to those obtained from large-eddy simulations at a reduced computational cost. In another study, Khalifa et al. [8] examined the 3-D aspects of dynamic stall on a NACA 0012 airfoil using DES solvers. In conclusion, the findings underlined the superiority of 3-D simulations over two-dimensional approaches, particularly in predicting the lift coefficient values and capturing dynamic stall stages more precisely.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

G2Aero: A Python package for separable shape tensors

G2Aero is a Python package for the design and deformation of discrete planar curves and tubular surfaces using a geometric data-driven approach. G2Aero utilizes a topology of product manifolds: the Grassmannian, $\mathcal{G}$($\mathcal{n}$, 2) - the set of 2-dimensional subspaces in $\mathbb{R}$ $\mathcal{n}$ - and the symmetric positive-definite (SPD) manifold, $\mathcal{S}^{2}_{++}$ - the set of 2x2 SPD matrices. The package provides a novel framework for representing separable deformations to shapes, which consist of stretching, scaling, rotating, and translating - also known as affine deformations - and a set of complementary deformations - which we refer to as undulation-type deformations. We focus on airfoil and blade design applications to emphasize the utility of the methods in an environment where the separation of affine and undulation-type deformations is critical. Notable functionalities of the framework for blade design include: 1) generating novel 2D (airfoil) shapes informed by a database of physically relevant airfoils, 2) building 3D blades by interpolating sequences of 2D airfoil cross-sections, and 3) generating blades with consistent perturbations along the blade span. We discuss the framework and provide examples in the context of wind energy applications, specifically wind turbine blade design. Figure 1 shows the wire frame obtained by interpolating airfoils defining the IEA 15-MW wind turbine blade and applying affine transformations corresponding to twist, chordal scaling, and bending. This, and all other figures in the paper, can be reproduced following examples and referencing supporting documentation provided in the G2Aero package.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

pyNuMAD v.0.1

SAND2024-08606O The pyNuMAD software is used for managing wind turbine blade model data. pyNuMAD specializes in defining the geometry, materials, and boundary conditions for structural analysis of wind turbine blades. This includes loading in data files and providing an interface for users to make updates to the model. The software also features meshing functionality, which takes the blade model and creates a shell or brick mesh for use in finite element analysis. A typical user workflow might be: load in blade information from a yaml file, make adjustments to the blade properties, update the blade based on the adjustments, create a mesh of the blade, export this blade to another software for structural analysis. Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525.

Paquette, Joshua↗
DOE OSTI2022

Leading Edge Erosion Classification System

The leading edge erosion of wind turbine blades is a common issue that can have a range of implications for the operation and maintenance of the turbine. A variety of methods have attempted to determine the severity of erosion damage, applied in different academic, testing and in-situ settings. This paper describes the current state of the art in categorization, and the individual drivers in assessment. From this foundation, the IEA Wind Task 46 WP3 group collated key considerations from the process of categorizing erosion damage and a proposed erosion classification system was put forward. Trial assessments were performed using the initial system, which led to adjustments to the original proposition. The refined system defines discrete severity levels that concern the wind turbine blade: (1) Visual Condition (concerning blades with/without leading edge protection); (2) Mass Loss; (3) Aerodynamic Performance; and (4) Structural Integrity. The classification system presented is not intended to be a fixed entity. The Task 46 group has already identified specific challenges and opportunities that are applicable to individual use and the overall wind energy industry. The intention is for the system to evolve as improvements are identified, technology improves, and work progresses through other Task 46 activities. Several considerations and recommendations are discussed that could be applicable for future implementation of the system.

17 WIND ENERGY↗
DOE OSTI2021

A Biomimetic Ultrasonic Whistle for Use as a Bat Deterrent on Wind Turbines

Our project goal was to design a novel mechanical ultrasonic deterrent for use on wind turbines in order to reduce bat fatalities around these structures. Our proposed deterrent design would be composed of a series of ultrasonic pulse generators, or whistles, affixed to a wind turbine blade, which produce ultrasound through mechanical means. The whistles would produce sounds mimicking the spectrotemporal patterns of bat echolocation pulses, thereby enhancing the bats’ ability to detect, localize and avoid the moving blades. These whistles are intended to be operated passively, blown by the wind, and to be positioned at intervals along a turbine blade. Because the source of sound generation will be mechanical in nature, these devices will require no external power source, should require little maintenance, and will be small and cost-effective.

17 WIND ENERGY↗
DOE OSTI2025

Bats flying through a Y-maze are visually attracted to wind turbine surfaces

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.

17 WIND ENERGY↗
DOE OSTI2021

Leveraging the Advantages of Additive Manufacturing to Produce Advanced Hybrid Composite Structures for Marine Energy Systems

Many marine energy systems designers and developers are beginning to implement composite materials into the load-bearing structures of their devices, but traditional mold-making costs for composite prototyping are disproportionately high and lead times can be long. Furthermore, established molding techniques for marine energy structures generally require many manufacturing steps, such as secondary bonding and tooling. This research explores the possibilities of additively manufactured internal composite molds and how they can be used to reduce costs and lead times through novel design features and processes for marine energy composite structures. In this approach, not only can the composite mold be additively manufactured but it can also serve as part of the final load-bearing structure. We developed a conceptual design and implemented it to produce a reduced-scale additive/composite tidal turbine blade section to fully demonstrate the manufacturing possibilities. The manufacturing was successful and identified several critical features that could expedite the tidal turbine blade manufacturing process, such as single-piece construction, an integrated shear web, and embedded root fasteners. The hands-on manufacturing also helped identify key areas for continued research to allow for efficient, durable, and low-cost additive/composite-manufactured structures for future marine energy systems.

16 TIDAL AND WAVE POWER↗
DOE OSTI2021

A Heterogeneous System for Eagle Detection, Deterrent, and Wildlife Collision Detection for Wind Turbines (Final Technical Report)

This report summarizes the design, implementation, and test of an integrated system for automated detection and deterrence of eagles, with included wind turbine blade strike detection and imaging functionality. A machine learning approach was used in conjunction with a 360° camera system for automated detection and classification of golden eagles. This was developed using footage obtained from trained golden eagles and other raptors, in collaboration with wildlife biologists and professional bird handlers. Oregon State University developed a visual deterrent system, which uses inflatable anthropomorphic sculptures with random, kinetic motion to deter eagles, and conducted limited field testing on live eagles; the deterrent can be triggered by the visual detection of eagles using the vision system. Finally, a multi-sensor module was developed that is mounted at the turbine blade root. This module measures vibration and other motions to detect blade strikes, and an integrated on-blade camera captures an image of any impacting objects. Long-term, this blade strike detection system is intended to support an automatic monitoring and certification system for the eagle detection and deterent system. Independent field testing of each system component is described. Testing of the integrated system on an operational wind turbine was conducted across three separate field tests. This includes multi-day fields tests on a General Electric 1.5MW wind turbine at the National Renewable Energy Laboratory (NREL) National Wind Technology Center (NWTC) in Boulder, CO in October 2018 and July 2019; installation procedures, test procedures, and a summary of collected data are presented. A third multi-day on-turbine field test is also presented, which was performed using a General Electric 1.5MW wind turbine at the North American Wind Research and Training Center (NAWRTC) at Mesalands Community College, Tucumcari, NM in April 2019. Across these field tests, the vision system was demonstrated using unmanned aerial vehicles (UAV), and the eagle classification algorithm was not tested; the visual deterrent system was demonstrated, including automatic, remote deployment following surrogate visual detections; and, multi-sensor on-blade data was recorded across multiple wind turbine operational conditions and through more than 100 surrogate blade strikes using soft projectiles, including the successful demonstration of automatic image capture of striking objects. This data set was also used for offline development and validation of enhanced collision detection algorithms. As summarized in this report, the development and field validation of an integrated detection, deterrent, and blade collision detection system represents a critical proof of concept for future technology development of related detection and deterrent technologies, where both deterrent as well as collision detection recording devices are needed for future siting, monitoring, and operation of wind turbine installations, both onshore and offshore.

17 WIND ENERGY↗
DOE OSTI2026

Triggerable adhesives with infinite working life for large area application

Oak Ridge National Laboratory (ORNL) Manufacturing Demonstration Facility (MDF) entered a User Proposal with Perseus Materials in Knoxville, TN. By reinventing how composites are made, we unlock a new era of structural materials: faster to produce, easier to assemble, and strong enough for real-world scale. Perseus Materials was targeting the wind turbine industry to make large adhesive joints for composite turbine blades without the limitations of cure time and room temperature cure without the needs to have work times. The triggerable aspect would increase manufacturing rates for composite wind turbine blades.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Numerical Manufacturing And Design tool

NuMAD helps to enable efficient creation and use of high fidelity wind turbine blade models for structural and aerodynamic analysis. NuMAD is a GUI-based tool used to manage the specific geometry and materials inputs required to fully describe a wind turbine blade.

Berg, Jonathan↗