1 Presentation name Thermoplastic Composite Development for Wind Turbine Blades NREL: Derek Berry and David Snowberg, TPI Composites: Steven Nolet CSM: John R. Dorgan , Yasuhito Suzuki, Dylan Cousins, Aaron Frary, David Ruehle JohnsMaville: Jawed Asrar, Klaus Gleich, Mingfu Zhang, Michael Block Arkema Chemical: Dana Swan, Robert Barsotti, Mark Aubart Colorado OEDIT: Katie Woslager
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1Presentation name
Thermoplastic Composite
Development for Wind Turbine Blades
NREL: Derek Berry and David Snowberg, TPI Composites: Steven Nolet
CSM: John R. Dorgan, Yasuhito Suzuki, Dylan Cousins, Aaron Frary, David RuehleJohnsMaville: Jawed Asrar, Klaus Gleich, Mingfu Zhang, Michael Block
Arkema Chemical: Dana Swan, Robert Barsotti, Mark AubartColorado OEDIT: Katie Woslager
2Presentation name
Thermoplastic Composite Development for Wind Turbine Blades
• Wind, Project 4.2
• TRL/MRL Impact: from 3 to 4
• Challenge: Fiber reinforced polymer composites are the material of choice for large scale wind turbine components, but challenges in manufacturing costs, performance, and recyclability are limiting.
• Approach: Development of thermoplastic materials to lower production costs and improve recyclability of wind turbine blades and applicability to components demonstrated at large scale.
• Impact: Cost reductions in composite materials for wind turbine blades will enable lower cost of electricity; property improvements enable larger scale and increased efficiency.
• Partners: NREL, TPI, Johns Manville, Colorado School of Mines. Arkema joined in BP2 (new partners expected in BP3).• Cross-cutting partnering includes
NDE team from Vanderbilt, and ORNL/University of Tennessee.
• Simulation tool development in conjunction with Purdue group and Convergent
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Thermoplastic Composites – Accomplishments
• Added Arkema as major new corporate partner
– Work plan expanded to include innovative EliumTM system
• Commissioned two new facilities
– VARTM lab at Colorado School of Mines (CSM) (Fabricated proof of concept panels at CSM, JohnsManville, and Arkema).
– Blade component manufacture at NREL Wind Technology Center (thick root section mold arriving soon – demonstration at scale)
• Property database creation
– Collected rheological data for liquid precursor and curing resin
– Established testing protocols and plan for comparison to thermosets
• Cross-cutting: Modeling and Simulation
– Developed chemical kinetics / heat transfer model and initiated transfer to Convergent for incorporation into Raven process simulator.
• Cross-cutting: Non Destructive Evaluation (NDE)
– Established thermal imaging / emission FTIR
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• Complementary facilities at Johns Manville in
Littleton, Colorado (just 15 miles away).
VARTM Lab at CSM
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Demonstration scale at NREL
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Wind Turbines - More and Bigger
A 60m blade weighs 10 tons and is 30 wt% polymer resin.
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Wind Turbines – Program Goals
• Increase jobs for American workers.
• Increase domestic production capacity.
• Reduce life cycle energy use and associated greenhouse gas emissions. Double the energy productivity of fiber reinforced polymer composite manufacturing.
• Demonstrate at scale reduced embodied energy and associated greenhouse gas emissions.
• Demonstrate at scale greater than 80% recyclability.
Thermoplastic based composites enable reaching these goals!
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Why Thermoplastics?
Plastics are characterized according to their response to temperature:
Thermoplastics - soften and flow upon heating:
Tg - Glass Transition Temperature
(beginning of chain motion over several segments)
Tm - Melting Temperature (chains can self-diffuse)
(for semi-crystalline polymers)
Some thermoplastics are amorphous glasses without melting temperatures.
Thermosets - rigid until thermal decomposition
Epoxies, unsaturated polyesters, and other
network forming materials that are used today
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Why Thermoplastics?
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Thermoplastic infusion
VARTM – Vacuum Assisted Resin
Transfer Molding.
Low viscosity resins infused
and then cured in mold / autoclave.
Not injecting high viscosity preformed polymers!
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Thermoplastic infusion
“Acrlylate based”
- Dana Swan
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Johns Manville Innovation
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Johns Manville Innovation
TRL is suitable for NNMI
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Experiments at CSM
• Samples of methylmethacrylate (MMA) monomer immersed in constant T bath.
• J-Type thermocouples with a data logger.
Wall temperature
25 C
2 hour cure time
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Experiments at CSM
0 20 40 60 80 100
20
40
60
80
100
Tem
pera
ture
(oC
)
Time (min)
Initiator concentration
0.5 wt%
1 wt%
3 wt%
5 wt%
Elium has a lower exotherm.
Initiator is analogous to hardener / curative in epoxy systems.
Less initiator means slower reaction and lower peak temperatures due to increased time for heat transfer
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Cross-Cutting : Model Development
Chemical kinetics coupled to heat transfer and including “gel effect” due to diffusional limitations
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Cross-Cutting: Model Development
0 10 20 30 40 50
20
30
40
50
60
70
80
90
100
Tem
pera
ture
(oC
)
Time (min)
0.5 wt%
1.0 wt%
2.0 wt%
3.0 wt%
Initiator concentration
0 10 20 30 40 50 60 70 8020
40
60
80
100
120
Tem
pera
ture
(oC
)
Time (min)
0.5 wt%
2.0 wt%
5.0 wt%
Qualitative description based on literature values
Determining parameter set for quantitative description
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Process Modeling with RAVEN
RAVEN is a desktop composites processing analysis program that allows users to design, optimize, and troubleshoot processing of composites.
RAVEN is used for:
• Cure cycle optimization
• Thermal profiling
• Troubleshooting
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2000 4000 6000 8000 100001000
10000
100000
1000000G
' [P
a]
Reaction time [s]
Elium Polymerization at 40°C
Elium reaction rheology experiments take place in two steps:
1) Measure the viscosity as a function of time at a constant shear rate of 100 1/s with the gap fixed at 1 mm:
0 500 1000 1500 2000 2500
0.1
1
10
100
[P
a s
]
Reaction time [s]
Elium Polymerization 40°C
.
2) When the torque on the geometry reaches a cutoff value, switch to an oscillatory measurement at 3.33 rad/s and allow the gap to change to produce an applied normal force of 0.5 N:
2000 4000 6000 8000 10000
3
4
5
6
7
8
9
10
11
12
13
14
Volu
metr
ic S
hrinkag
e (
%)
Reaction time [s]
Elium Polymerization at 40°C
𝜀𝑣 = 1 +1
3
ℎ − ℎ0ℎ0
3
− 1
h = gap heightho = initial gap height
Rheology and shrinkage data for simulation
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• Elium with 3 wt% initiator package
• 40 minutes time lapse
• Frame speed is 1 min or 30 s during rapid temperature change.
Heat imaging during infusion
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Phase Change Materials (PCMs)
• Recall:
– “Sensible” heat is energy to raise the T of a given phase (water in this graph).
– “Latent” heat is the energy needed to change phases; to melt a crystal for example. This is more properly the “heat of fusion”.
– Latent heats are much larger than sensible heats.
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Phase Change Materials (PCMs)
• PCMs have become widely used:• Domino Pizza “Heat Wave” bag
• Every laptop has a “heat pipe” which uses liquid to gas vaporization
• Outlast Technology (now part of CoorsTek) adopted NASA space suit technology to outdoor clothing.
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Effect of commercial PCMs on EliumTM
0 500 1000 1500 2000 2500 3000 3500 4000
20
30
40
50
60
70
80
90
100
Te
mp
era
ture
(oC
)
Time (s)
Elium
Elium +10 wt% PCM
Elium +20 wt% PCM
Crystallization of PCM
Same initiator composition
0 10 20 30 4020
40
60
80
100
Tem
pera
ture
(oC
)
Time (min)
5.0 wt%
5.0 wt% (with PCM)
3.0 wt%
PCMs enableshorter cycle times!
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Slow motion during the curing reaction
NDE – cold spots reveal problems and in situ
emission FTIR can provide cure information
With PCMWithout PCM
Heat imaging during infusion
Tpeak = 104 C Tpeak = 84 C
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Thermoplastic Composites Team
• Met all budget period 1 milestones and on-track to meet all period 2 milestones
• Commissioned two new facilities
– VARTM lab at Colorado School of Mines (CSM)
– Blade component manufacture at NREL
• Property database creation
– Collected rheological data for liquid precursor and curing resin
– Established testing protocols and plan for comparison to thermosets
• Developed chemical kinetics / heat transfer model
– Initiated tech transfer to Convergent for Raven process simulator.
• Developed NDE plan (Vanderbuilt / ORNL group)
• Demonstrated that PCMs can shorten cycle times
• Filed 1 patent, submitted 1 paper + 1 CAMX abstract, 2 more patents in preparation.
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Acknowledgements
• Colorado Office of Economic Development Industry and Trade (CO OEDIT) with special thanks to Katie Woslager.