Heat Transfer Functionality and Analysis of Thermal-Sprayed Coatings

在风力涡轮机工业中，叶片(翼型)在运行过程中结冰会导致边界层破坏，增加阻力，影响气动和/或结构稳定性，并造成严重的安全问题。为了制造坚韧、高强、轻质的结构，纤维增强复合材料应运而生。然而，由于这些材料的低热传输特性，热流受到显著限制，限制了热通过防冰方案的复合材料的直接传播。因此，本研究计划提出开发一种新型的防冰系统，该系统可以方便地大规模生产，并且可以提供均匀的表面加热，以提高风力机上翼型的性能和安全运行。火焰喷雾沉积金属涂层到复合材料结构上，用于焦耳(电阻或欧姆)加热，将提供所需的均匀加热，并将很容易通过既定的可扩展制造工艺批量生产。 该研究计划还将结合先进的传热学模型和微观结构观察，以确定温度分布对冷喷涂金属和金属基复合涂层的内聚力和附着力的影响。这将在工业实践中提高涂层质量，从而减轻基材(机器部件)的损坏，避免设备停机和生产力损失。

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. The proposed research program will also couple advanced heat transfer modeling with microstructural observations to determine the effects of temperature distribution on the cohesion and adhesion of cold-sprayed metal and metal matrix composite coatings. This will enable improvement of coating quality in industrial practice, which will mitigate substrate (machine component) damage and avoid equipment shut-down and loss of productivity.