Laser Deposition Joining of Composites for Wind Turbine Blade Repair

用于风力涡轮机叶片修复的复合材料的激光沉积连接

• 批准号: 1537512
• 负责人: Hongtao Ding
• 金额: $ 30万
• 依托单位: University of Iowa
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2015
• 资助国家: 美国
• 起止时间: 2015-09-01 至 2019-02-28
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=1537512&HistoricalAwards=false
• 关键词: Laser; Deposition; Joining; Composites; Wind

Cost-effective repair methods for composite blades are critically needed for the wind energy industry. Wind turbine blades are subject to considerable wear and degradation, and their repairs are often necessary. Currently, most blade repairs are performed using wet epoxy resins. Such repairs have low joining strength and require long processing time. The research supported under this award will establish the foundation for a novel laser-based process to repair composite blades. During the process, a repair patch of glass fibers is joined employing a laser-deposition joining method utilizing fine glass powders as filler material. Laser-deposition joining repair of fiber-reinforced composites will also have applications where repair of composite structures is needed; for example, those in defense, aerospace, automotive, and compressed gas storage industries. Consequently, the results of this research will benefit the U.S. economy and society. The research objectives are: (1) establishing the relationship between glass powder stream temperature and operational parameters (such as laser power density and powder flow rate), (2) quantifying the effect of the glass powder stream temperature on the glass viscous flow behavior through the repair patch of glass fibers, and (3) establishing the relationship between glass powder stream temperature and deposition joint quality (in terms of infiltration depth, porosity, flexural properties, and delamination resistance). To achieve these objectives, three research tasks will be completed. First, numerical modeling of coaxial powder flow and laser-particle interaction will be performed to predict glass powder stream temperature. The modeling results under various operational conditions will be verified using experimental measurements of powder stream temperature. Second, multi-physics modeling will be performed to evaluate the effect of powder stream temperature on the glass melt viscous flow through the random arrays of fibers media. The infiltration depth of the glass fill and porosity of the cooled deposition joint will be predicted and validated against optical and scanning electron microscopy measurements. Finally, the effect of glass powder stream temperature on the joint integrity will be experimentally determined based on microscopy measurements of infiltration depth and porosity and mechanical testing of flexural properties and delamination resistance.

风能行业迫切需要复合材料叶片的成本效益修复方法。风力涡轮机叶片经受相当大的磨损和退化，并且它们的修理通常是必要的。目前，大多数叶片维修是使用湿环氧树脂。这样的修补具有低的接合强度并且需要长的处理时间。该奖项支持的研究将为基于激光的新型复合材料叶片修复工艺奠定基础。在此过程中，玻璃纤维的修复补片采用激光沉积连接方法，利用细玻璃粉末作为填充材料进行连接。纤维增强复合材料的激光沉积连接修复也将应用于需要修复复合材料结构的地方;例如，国防，航空航天，汽车和压缩气体储存行业。因此，这项研究的结果将有利于美国的经济和社会。研究目标是：（1）建立玻璃粉料流温度与操作参数之间的关系，（如激光功率密度和粉末流率），（2）量化玻璃粉末流温度对通过玻璃纤维的修复补片的玻璃粘性流动行为的影响，以及（3）建立玻璃粉末流温度与沉积接头质量之间的关系（在渗透深度、孔隙率、挠曲性能和抗分层性方面）。为了实现这些目标，将完成三项研究任务。首先，将进行同轴粉末流和激光-颗粒相互作用的数值模拟以预测玻璃粉末流温度。将使用粉末流温度的实验测量来验证在各种操作条件下的建模结果。其次，将进行多物理模型来评估粉末流温度对玻璃熔体通过随机纤维介质阵列的粘性流动的影响。玻璃填充物的渗透深度和冷却沉积接头的孔隙率将根据光学和扫描电子显微镜测量进行预测和验证。最后，玻璃粉末流温度对接头完整性的影响将通过渗透深度和孔隙率的显微镜测量以及弯曲性能和抗分层性的机械测试来实验确定。

项目成果

3D finite element model of dynamic material behaviors for multilayer ultrasonic metal welding

多层超声波金属焊接动态材料行为的 3D 有限元模型

• DOI: 10.1016/j.jmapro.2020.12.039
• 发表时间: 2021
• 期刊: Journal of Manufacturing Processes
• 影响因子: 6.2
• 作者: Shen, Ninggang;Samanta, Avik;Cai, Wayne W.;Rinker, Teresa;Carlson, Blair;Ding, Hongtao
• 通讯作者: Ding, Hongtao

An efficient coupled Eulerian-Lagrangian finite element model for friction stir processing

• DOI: 10.1007/s00170-018-3000-z
• 发表时间: 2019-04-01
• 期刊: INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
• 影响因子: 3.4
• 作者: Ansari, Mohammad Ali;Samanta, Avik;Ding, Hongtao
• 通讯作者: Ding, Hongtao

Microstructure Simulations for Orthogonal Cutting via a Cellular Automaton Model

• DOI: 10.1016/j.procir.2017.03.264
• 发表时间: 2017
• 期刊: Procedia CIRP
• 作者: N. Shen;A. Samanta;Hongtao Ding

Selective laser melting of fiber-reinforced glass composites

纤维增强玻璃复合材料的选择性激光熔化

• DOI: 10.1016/j.mfglet.2017.09.001
• 发表时间: 2017
• 期刊: Manufacturing Letters
• 影响因子: 3.9
• 作者: Shen, Ninggang;Samanta, Avik;Wang, Qinghua;Ding, Hongtao
• 通讯作者: Ding, Hongtao

Predicting microstructure evolution for friction stir extrusion using a cellular automaton method

• DOI: 10.1088/1361-651x/ab044b
• 发表时间: 2019-04-01
• 期刊: MODELLING AND SIMULATION IN MATERIALS SCIENCE AND ENGINEERING
• 影响因子: 1.8
• 作者: Behnagh, Reza Abdi;Samanta, Avik;Ding, Hongtao
• 通讯作者: Ding, Hongtao