Heat Transfer Functionality and Analysis of Thermal-Sprayed Coatings

在风力涡轮机行业，在运行过程中，叶片（翼型）上的结冰会导致边界层的破坏，增加阻力，影响气动和/或结构的稳定性，并带来严重的安全问题。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，由于这些材料的低传热性能，热流受到严重限制，限制了热通过防冰方案的复合材料的直接传播。因此，本研究计划提出了一种新型防冰系统的发展，这种系统可以很容易地批量生产，并且可以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。用于焦耳（电阻或欧姆）加热的复合材料结构上的金属涂层火焰喷涂沉积将提供所需的均匀加热，并且可以通过建立和可扩展的制造工艺轻松批量生产。

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.