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Copyright © 2018 Owens Corning. All Rights Reserved. IMPROVING COMPOSITES FOR THE WIND INDUSTRY 6 NOVEMBER 2018 GEORG ADOLPHS
Copyright © 2018 Owens Corning. All Rights Reserved.
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
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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
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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
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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
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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 ?
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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.
