improving composites for the wind industry · wind, pipe, thermoplastic composites, industrial,...

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IMPROVING COMPOSITES FOR THE

WIND INDUSTRY 6 NOVEMBER 2018

GEORG ADOLPHS

AN UNRIVALED SUPPLY NETWORK

Key● Glass fiber manufacturing sites● Downstream fabrication sites

2

WHY CHOOSE OWENS CORNING?OUR GLASS REINFORCEMENT PRODUCTS

CHOPPED STRAND MAT AND CONTINUOUS FILAMENT MAT

Marine, transportation, recreation, corrosion resistance,construction

Construction, industrial, automotive, road paving

NON WOVEN VEIL

Wind, pipe, thermoplastic composites, industrial, recreational

KNITTED OR WOVEN FABRICS

Construction (panels and translucent panels), corrosion resistant pipe and tanks, consumer (sanitary, recreational vehicles), transportation (headliner, body parts, semi-structural parts)

CONTINUOUS FIBER MULTI-END ROVING

Transportation, consumer electrical/ electronics and appliances

CHOPPED STRAND, DRY-USE

Building products (roofing and gypsum), industrial specialties

CHOPPED STRAND, WET-USE

Chemical and sewage, oil, water processing (pipe and tanks), industrial (high-pressure vessels, pultruded items), wind energy, aerospace, ballistics, transportation (muffler filling), electrical (optical cable)

CONTINUOUS FIBER TYPE 30®SINGLE END ROVING

3

0

2

4

6

8

10

12

1985 1987 1990 1993 1996 1999 2001

Year

€ce

nt/k

Wh

1980 1990 2000 2010 2020

D=40mP=400kW

80m2MW

150m6MW

220m12MW

Rotor Diameter 14,x mRated Power 50kW

DEVELOPMENT OF WINDTURBINE SIZE AND POWER

?

?

Energy Cost

MORE EFFICIENT SOLUTIONS

5

SIZE INCREMENT REQUIRES

6

HIGH MODULUS GLASS – HIGH EFFICIENY FARBRICS

• Main application of High Modulus Glass in Spar caps

• In combination with High Efficiency Fabrics a reduction in processing time and cost is possible

• Higher fiber volume fraction (FVF) for higher modulus and reduced consumption of resin

• Reduced labor to lay-up less layer of fabrics… reduced cycle time of blade manufacturing

• Reduced blade weight with the increased FVF

UD 1200g/m² UD 1800g/m² UD 2400g/m²

HIGH FVF AND HIGH EFFICIENCY FABRICS

7

PRODUCTIVITY VACUUM INFUSION

0

10

20

30

40

50

60

2 6 10 16 26 38 50 60

Ave

rage

infu

sio

n l

en

gth

(cm

)

Time (min)

In Plane Infusion Test

ref

Out-of-Plane (Z-) Permeability In-Plane (X- or Y-) Permeability

Improvement of Infusion Speed of a 1800g/m2 fabric vs 1240g/m2

8

PRODUCTIVITY VACUUM INFUSION

NEW AND BETTER MATERIALS

9

SIZE INCREMENT REQUIRES

EXAMPLE WS2000 ADVANTEX GLASS

10

Cross fiber stress contributionabout 10-12MPa

Transversal Tensile Stress –NO cross fiber

Fiber

ADVH

50GPa

HIGH MODULUS GLASS – LAMINATE PERFORMANCE

• Higher FVF allows higher utilization of Glass properties

• High Modulus Glass is aiming for +50GPa at ~59% FVF

• Design for stiffness• To enable longer

blades

LIMIT MODULUS FOR A FIBER – RESIN COMBINATION

• Exccelent fatigue properties up to 59% FVF

• +60% FVF can become critical

SPAR CAP LIMIT MODULUS BY MAX FVF

FVF – Fiber Volume Fraction

OTHER OPTIONS FOR WEIGHT OPTIMIZATION

E-Glass

Advantex™ E-CR

H-Glass, R-glass, S-glass

Stress

Elongation [%]

[MPa]

Carbon

BEYOND GLASSFIBER PROPERTIES

CARBON/GLASS HYBRID – ULTRABLADE GC

Evaluation of Specific New Glass/Carbon Fiber UD Fabrics

Glass

Hybrid

Similar processing as today by vacuum infusion, similar strength and shear properties

Adjustable tensile modulusincrement of

+10% to +40%compared to HM-Glass UD

Ultrablade GC – Fabric Patent filed

OTHER OPTIONS FOR WEIGHT OPTIMIZATIONCARBON/GLASS HYBRID STRENGTH ULTLABLADE GC60

Load

[N

]

Deformation [mm]

Homogenous stress/strainbehavior during tests

(example: ASTM Rail Shear)

Similar tensile and compression strength than

current HM-Glasslaminates

UB GC60 UB GC60

OTHER OPTIONS FOR WEIGHT OPTIMIZATIONCARBON/GLASS HYBRIDS IN FATIGUE

Fatigue strengthproperties improve

vs HM-Glass

Standard resins, infusión conditions and test procedures have been used

NEW AND BETTER DESIGNS

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SIZE INCREMENT REQUIRES

▪ Ultrablade® TRIAX G3 fabric construction and modulus optimized for root and shell performance

USE OF HIGH EFFICIENCY FABRICS IN ROOT – H GLASS

USE OF HIGH EFFICIENCY FABRICS IN ROOT – H GLASS

Standard Solution

After Optimization

Bolt

Laminate

Effect shown in a Rigging Diagram

USE OF HIGH EFFICIENCY FABRICS IN SHELL – H GLASS

Triaxial 0º fabrics in shell laminate offer additional stiffening, area weight up to1800 g/m2 is available . A more homogenous laminate modulus is achieved

MATERIALS AND SUPPLY MUST BE ROBUST

21

WIND INDUSTRY IS INTERNATIONAL BUSINESS

INNITIAL PERFORMANCE LEVEL

22

time axis

performance parameter(s)

observations

possible performance limit

intervall “95/5” of innitial values

Tension in 0º and 90ºStrength, modulus, elongation

Compression on 0º and 90º Strength, modulus and elongation

Shear “12”, “23”, and ILSS

Fatigue R = 0,1

Fatigue R = -1

Fatigue R = 10

After natural or artificial ageing ofthe laminate (ie boiling, moisture

absorption, …)

CORRECT DEFINITION OF SHELF LIFE ?

23

time axis

performance parameter(s)

interval “95/5” ofinitial valuesparameter

storage conditions x, y, zUpper performance limit of

a chosen performance parameter

Risc evaluation is posible

Performance can be ratedbased on

- Average- Distribution/Risc

AGEING IS DEPENDING ON TEMPERATURE AND HUMIDITY

STORAGE SITES:- Amarillo (US)- Merida (MX)- Yuhan/Hangzhou (PRC)- Taloja/Bombay (India)

KEY PARAMETER: - Temperature (ºC)- Relative humidity (rH%)

“NATURAL AGEING”

“LABORATORY or FAST AGEING”

KEY PARAMETER: - Temperature (ºC)- Relative humidity (rH%)- Simulated storage/transport conditions

to simulate the natural ageing process- Use of a conventional climate chamber

- Amount of reactive components- Mechanical laminate performance

ANALYTIC CHEMISTRY/ MECHANICAL TESTING

AGEING – KEY TEST RESULTS ROVING

Fresh 2 months 4 months 6 months 8 months 12 months

1600

1500

1400

1300

1200

1100

1000

900

TensileStrengt h(M

Pa)

IVP of Aging Effect onWS3000 Tensile Performance

1600

1500

1400

1300

1200

1100

1000

900

TensileSt rengt h

(MPa)

IVP of Aging Effect on Jushi E7 380 Tensile Performance

Fresh 2 months 4 months 6 months 8 months 12 months

Tensile Strength – WS3000 Tensile Strength – Other

70

60

50

40

30

20

10

0

Transver seTensileStrengt h

(MPa)

IVP of Aging Effect onWS3000 Transverse Performance

70

60

50

40

30

20

10

0

TensileTransver seStrengt h(M

Pa)

IVP of Aging Effect on Jushi E7 380 Transverse Performance

Fresh 2 months 4 months 6 months 8 months 12 monthsFresh 2 months 4 months 6 months 8 months 12 months

Transversal Tensile Strength – WS3000 Transversal Tensile Strength – Other

AGEING – KEY TEST RESULTS ROVING

HM Glass - OtherHM Glass – WS 3000

Aged

Fresh

Fresh

Aged

Fatigue properties might be affected as well by ageing

AGEING – KEY TEST RESULTS FABRICS

SUMMARY

• Ageing is not to be mistaken with transport damage and is a controlable problem. It can however affect severly key properties and reduce drasticallymaterial performance. Neither fast ageing (laboratory) procedures nor chemicalanalysis are delivering a satisfactoring result to answer limit storage times.

• By using improved fabric processing technologies and with current resin systemsheavier High Efficiency Fabrics (UD and Triaxial) up to +1800g/m2 can be processed. The limit FVF observed until now is at around 59-60% for EP resins which delivers a laminate modulus of +50GPa (HM Glasses). Further use can be made in shell laminatesand root.

• Further increases in modulus can be realized by Carbon/Glass fiber hybrids, whichshow similar strength properties than current HM-Glass laminates and can beprocessed similar than today by vacuum infusion. The possibilityto adjust their Carbon fiber percentage makes them easily adjaustable tomodulus requirements.