Publications

Mandell et al. have recently presented an updated constant-life diagram (CLD) for a fiberglass composite that is a typical wind turbine blade material. Their formulation uses the MSU/DOE fatigue data base to develop a CLD with detailed S-N information at 13 R-values. This diagram is the most detailed to date, and it includes several loading conditions that have been poorly represented in earlier studies. Sutherland and Mandell have used this formulation to analyze typical loads data from operating wind farms and the failure of coupons subjected to spectral loading. The detailed CLD used in these analyses requires a significant investment in materials testing that is usually outside the bounds of typical design standards for wind turbine blades. Thus, the question has become: How many S-N curves are required for the construction of a CLD that is sufficient for an "accurate" prediction of equivalent fatigue loads and service lifetimes? To answer this question, the load data from two operating wind turbines and the failure of coupons tested using the WISPERX spectra are analyzed using a nonlinear damage model. For the analysis, the predicted service lifetimes that are based on the CLD constructed from 13 R-values are compared to the predictions for CLDs constructed with fewer R-values. The results illustrate the optimum number of R-values is 5 with them concentrated between R-values of -2 and 0.5, or -2 and 0.7. Copyright © 2005 by ASME.

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This report addresses the effects of spectrum loading on lifetime and residual strength of a typical fiberglass laminate configuration used in wind turbine blade construction. Over 1100 tests have been run on laboratory specimens under a variety of load sequences. Repeated block loading at two or more load levels, either tensile-tensile, compressive-compressive, or reversing, as well as more random standard spectra have been studied. Data have been obtained for residual strength at various stages of the lifetime. Several lifetime prediction theories have been applied to the results. The repeated block loading data show lifetimes that are usually shorter than predicted by the most widely used linear damage accumulation theory, Miner's sum. Actual lifetimes are in the range of 10 to 20 percent of predicted lifetime in many cases. Linear and nonlinear residual strength models tend to fit the data better than Miner's sum, with the nonlinear providing a better fit of the two. Direct tests of residual strength at various fractions of the lifetime are consistent with the residual strength models. Load sequencing effects are found to be insignificant. The more a spectrum deviates from constant amplitude, the more sensitive predictions are to the damage law used. The nonlinear model provided improved correlation with test data for a modified standard wind turbine spectrum. When a single, relatively high load cycle was removed, all models provided similar, though somewhat non-conservative correlation with the experimental results. Predictions for the full spectrum, including tensile and compressive loads were slightly non-conservative relative to the experimental data, and accurately captured the trend with varying maximum load. The nonlinear residual strength based prediction with a power law S-N curve extrapolation provided the best fit to the data in most cases. The selection of the constant amplitude fatigue regression model becomes important at the lower stress, higher cycle loading cases. The residual strength models may provide a more accurate estimate of blade lifetime than Miner's rule for some loads spectra. They have the added advantage of providing an estimate of current blade strength throughout the service life.

This report presents the major findings of the Montana State University Composite Materials Fatigue Program from 1997 to 2001, and is intended to be used in conjunction with the DOE/MSU Composite Materials Fatigue Database. Additions of greatest interest to the database in this time period include environmental and time under load effects for various resin systems; large tow carbon fiber laminates and glass/carbon hybrids; new reinforcement architectures varying from large strands to prepreg with well-dispersed fibers; spectrum loading and cumulative damage laws; giga-cycle testing of strands; tough resins for improved structural integrity; static and fatigue data for interply delamination; and design knockdown factors due to flaws and structural details as well as time under load and environmental conditions. The origins of a transition to increased tensile fatigue sensitivity with increasing fiber content are explored in detail for typical stranded reinforcing fabrics. The second focus of the report is on structural details which are prone to delamination failure, including ply terminations, skin-stiffener intersections, and sandwich panel terminations. Finite element based methodologies for predicting delamination initiation and growth in structural details are developed and validated, and simplified design recommendations are presented.

In support of two major SNL programs, the Long-term Inflow and Structural Test (LIST) program and the Blade Manufacturing Initiative (BMI), three Micon 65/13M wind turbines have been erected at the USDA Agriculture Research Service (ARS) center in Bushland, Texas. The inflow and structural response of these turbines are being monitored with an array of 60 instruments: 34 to characterize the inflow, 19 to characterize structural response and 7 to characterize the time-varying state of the turbine. The primary characterization of the inflow into the LIST turbine relies upon an array of five sonic anemometers. Primary characterization of the structural response of the turbine uses several sets of strain gauges to measure bending loads on the blades and the tower and two accelerometers to measure the motion of the nacelle. Data are sampled at a rate of 30 Hz using a newly developed data acquisition system. The system features a time-synchronized continuous data stream and telemetered data from the turbine rotor. This paper documents the instruments and infrastructure that have been developed to monitor these turbines and their inflow.

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The Long-term Inflow and Structural Test (LIST) program is collecting long-term, continuous inflow and structural response data to characterize the extreme loads on wind turbines. A heavily instrumented Micon 65/13M turbine with SERI 8-m blades is being used as the first test turbine for this test program. This turbine and its two sister turbines are located in Bushland, TX a test site that exposes the turbines to a wind regime that is representative of a Great Plains commercial site. The turbines and their inflow are being characterized with 60 measurements: 34 to characterize the inflow, 19 to characterize structural response, and 7 to characterize the time-varying state of the turbine. The primary characterization of the inflow into the LIST turbine relies upon an array of five sonic anemometers. These three-axis anemometers are placed approximately 2-diameters upstream of the turbine in a pattern designed to describe the inflow. Primary characterization of the structural response of the turbine uses several sets of strain gauges to measure bending loads on the blades and the tower and two accelerometers to measure the motion of the nacelle. Data from the various instruments are sampled at a rate of 30 Hz using a newly developed data acquisition system that features a time-synchronized continuous data stream that is telemetered from the turbine rotor. The data, taken continuously, are automatically divided into 10-minute segments and archived for analysis. Preliminary data are presented to illustrate the operation of the turbine and the data acquisition and analysis system.