Heat Transfer Functionality and Analysis of Thermal-Sprayed Coatings

在风力涡轮机工业中，在操作期间叶片（翼型件）上的冰形成导致边界层的破坏，增加阻力，影响空气动力学和/或结构稳定性，并且造成严重的安全问题。为了制造坚韧、高强度、轻质的结构，使用纤维增强复合材料。然而，由于这些材料的低热传输特性，热流受到显著限制，限制了用于防冰程序的热通过复合材料的直接传播。因此，本研究计划提出开发一种新型防冰系统，该系统易于大规模生产，并可提供均匀的表面加热，以提高风力涡轮机翼型的性能和安全运行。将金属涂层火焰喷涂沉积到复合材料结构上以用于焦耳（电阻或欧姆）加热将提供所需的均匀加热，并且将通过已建立的和可扩展的制造工艺容易地大规模生产。 拟议的研究计划还将耦合先进的传热建模与微观结构观察，以确定温度分布对冷喷涂金属和金属基复合材料涂层的内聚力和附着力的影响。这将有助于在工业实践中提高涂层质量，从而减轻基材（机器部件）损坏并避免设备停机和生产率损失。

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.