Heat Transfer Functionality and Analysis of Thermal-Sprayed Coatings

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In the wind turbine industry, ice formation on the blades (airfoils) during operation causes the disruption of boundary layers, increases drag, affects aerodynamic and/or structural stability, and poses serious safety problems. In order to fabricate tough, high-strength, lightweight structures, fiber-reinforced composites are used. However, due to the low heat transport properties of these materials, heat flow is significantly restricted, limiting the direct propagation of heat through the composite for anti-icing programs. Therefore, this research program proposes the development of a novel anti-icing system that can be easily mass produced and that can provide uniform surface heating to improve the performance and safe operation of airfoils on wind turbines. Flame spray deposition of a metal coating onto the composite material structure for use in Joule (resistive or Ohmic) heating will provide the uniform heating required and will be easily mass produced by an established and scalable manufacturing process.