The Experts below are selected from a list of 4236 Experts worldwide ranked by ideXlab platform
Robynne E. Murray - One of the best experts on this subject based on the ideXlab platform.
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Manufacturing and Flexural Characterization of Infusion-Reacted Thermoplastic Wind Turbine Blade Subcomponents
Applied Composite Materials, 2019Co-Authors: Robynne E. Murray, Dylan Cousins, Ryan Beach, David Snowberg, Derek Berry, Yasuhito Suzuki, Dayakar Penumadu, Aaron StebnerAbstract:Reactive Thermoplastics are advantageous for wind turbine blades because they are recyclable at end of life, have reduced manufacturing costs, and enable thermal joining and shaping. However, there are challenges with manufacturing wind components from these new materials. This work outlines the development of manufacturing processes for a thick glass fiber–reinforced acrylic Thermoplastic Resin wind turbine blade spar cap, with consideration given to effects of the exothermic curing reaction on thick composite parts. Comparative elastic properties of these infusible Thermoplastic materials with epoxy thermoset materials, as well as Thermoplastic coupon components, are also included. Based on the results of this study it is concluded that the Thermoplastic Resin system is a viable candidate for the manufacturing of wind turbine blades using vacuum-assisted Resin transfer molding. Significant gains in energy savings are realized avoiding heated molds, ability for recycling, and providing an opportunity for utilizing thermal welding.
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Techno-economic analysis of a megawatt-scale Thermoplastic Resin wind turbine blade
Renewable Energy, 2019Co-Authors: Robynne E. Murray, David Snowberg, Derek Berry, Scott Jenne, Dylan S. CousinsAbstract:Abstract Two-part, in-situ reactive Thermoplastic Resin systems for composite wind turbine blades have the potential to lower the blade cost by decreasing cycle times, capital costs of both tooling and equipment, and energy consumption during manufacturing, and enabling recycling at the end of the blade life. This paper describes a techno-economic model used to estimate the cost of a Thermoplastic wind turbine blade relative to a baseline thermoset epoxy blade. It was shown that a 61.5-m Thermoplastic blade costs 4.7% less than an equivalent epoxy blade. Even though the Thermoplastic Resin is currently more expensive than epoxy, this cost reduction is primarily driven by the decreased capital costs, faster cycle times, and reduced energy requirements and labor costs. Although Thermoplastic technology for Resin infusion of wind turbine blades is relatively new, these results suggest that it is economically and technically feasible and warrants further research.
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Recycling glass fiber Thermoplastic composites from wind turbine blades
Journal of Cleaner Production, 2019Co-Authors: Dylan S. Cousins, Robynne E. Murray, Yasuhito Suzuki, Joseph R. Samaniuk, Aaron P. StebnerAbstract:Abstract Thermoplastic Resin systems have long been discussed for use in large-scale composite parts but have yet to be exploited by the energy industry. The use of these Resins versus their thermosetting counterparts can potentially introduce cost savings due to non-heated tooling, shorter manufacturing cycle times, and recovery of raw materials from the retired part. Because composite parts have high embedded energy, recovery of their constituent materials can provide substantial economic benefit. This study determines the feasibility of recycling composite wind turbine blade components that are fabricated with glass fiber reinforced Elium ® Thermoplastic Resin. Several experiments are conducted to tabulate important material properties that are relevant to recycling, including thermal degradation, grinding, and dissolution of the polymer matrix to recover the constituent materials. Dissolution, which is a process unique to Thermoplastic matrices, allows recovery of both the polymer matrix and full-length glass fibers, which maintain their stiffness (190 N/(mm g)) and strength (160 N/g) through the recovery process. Injection molded regrind material is stiffer (12 GPa compared to 10 GPa) and stronger (150 MPa compared to 84 MPa) than virgin material that had shorter fibers. An economic analysis of the technical data shows that recycling Thermoplastic–glass fiber composites via dissolution into their constituent parts is commercially feasible under certain conditions. This analysis concludes that 50% of the glass fiber must be recovered and resold for a price of $0.28/kg. Additionally, 90% of the Resin must be recovered and resold at a price of $2.50/kg.
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Manufacturing a 9-Meter Thermoplastic Composite Wind Turbine Blade
American Society for Composites 2017, 2017Co-Authors: Robynne E. Murray, Ryan Beach, David Snowberg, Derek Berry, Dana Swan, Sam RooneyAbstract:Currently, wind turbine blades are manufactured from a combination of glass and/or carbon fiber composite materials with a thermoset Resin such as epoxy, which requires energy-intensive and expensive heating processes to cure. Newly developed in-situ polymerizing Thermoplastic Resin systems for composite wind turbine blades polymerize at room temperature, eliminating the heating process and significantly reducing the blade manufacturing cycle time and embodied energy, which in turn reduces costs. Thermoplastic materials can also be thermally welded, eliminating the need for adhesive bonds between blade components and increasing the overall strength and reliability of the blades. As well, Thermoplastic materials enable end-oflife blade recycling by reheating and decomposing the materials, which is a limitation of existing blade technology. This paper presents a manufacturing demonstration for a 9-m-long Thermoplastic composite wind turbine blade. This blade was constructed in the Composites Manufacturing Education and Technology facility at the National Wind Technology Center at the National Renewable Energy Laboratory (NREL) using a vacuumassisted Resin transfer molding process. Johns Manville fiberglass and an Arkema Thermoplastic Resin called Elium were used. Additional materials included Armacellrecycled polyethylene terephthalate foam from Creative Foam and low-cost carbonfiber pultruded spar caps (manufactured in collaboration with NREL, Oak Ridge National Laboratory, Huntsman, Strongwell, and Chomarat). This paper highlights the development of the Thermoplastic Resin formulations, including an additive designed to control the peak exothermic temperatures. Infusion and cure times of less than 3 hours are also demonstrated, highlighting the efficiency and energy savings associated with manufacturing Thermoplastic composite blades.
Dylan S. Cousins - One of the best experts on this subject based on the ideXlab platform.
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Techno-economic analysis of a megawatt-scale Thermoplastic Resin wind turbine blade
Renewable Energy, 2019Co-Authors: Robynne E. Murray, David Snowberg, Derek Berry, Scott Jenne, Dylan S. CousinsAbstract:Abstract Two-part, in-situ reactive Thermoplastic Resin systems for composite wind turbine blades have the potential to lower the blade cost by decreasing cycle times, capital costs of both tooling and equipment, and energy consumption during manufacturing, and enabling recycling at the end of the blade life. This paper describes a techno-economic model used to estimate the cost of a Thermoplastic wind turbine blade relative to a baseline thermoset epoxy blade. It was shown that a 61.5-m Thermoplastic blade costs 4.7% less than an equivalent epoxy blade. Even though the Thermoplastic Resin is currently more expensive than epoxy, this cost reduction is primarily driven by the decreased capital costs, faster cycle times, and reduced energy requirements and labor costs. Although Thermoplastic technology for Resin infusion of wind turbine blades is relatively new, these results suggest that it is economically and technically feasible and warrants further research.
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Recycling glass fiber Thermoplastic composites from wind turbine blades
Journal of Cleaner Production, 2019Co-Authors: Dylan S. Cousins, Robynne E. Murray, Yasuhito Suzuki, Joseph R. Samaniuk, Aaron P. StebnerAbstract:Abstract Thermoplastic Resin systems have long been discussed for use in large-scale composite parts but have yet to be exploited by the energy industry. The use of these Resins versus their thermosetting counterparts can potentially introduce cost savings due to non-heated tooling, shorter manufacturing cycle times, and recovery of raw materials from the retired part. Because composite parts have high embedded energy, recovery of their constituent materials can provide substantial economic benefit. This study determines the feasibility of recycling composite wind turbine blade components that are fabricated with glass fiber reinforced Elium ® Thermoplastic Resin. Several experiments are conducted to tabulate important material properties that are relevant to recycling, including thermal degradation, grinding, and dissolution of the polymer matrix to recover the constituent materials. Dissolution, which is a process unique to Thermoplastic matrices, allows recovery of both the polymer matrix and full-length glass fibers, which maintain their stiffness (190 N/(mm g)) and strength (160 N/g) through the recovery process. Injection molded regrind material is stiffer (12 GPa compared to 10 GPa) and stronger (150 MPa compared to 84 MPa) than virgin material that had shorter fibers. An economic analysis of the technical data shows that recycling Thermoplastic–glass fiber composites via dissolution into their constituent parts is commercially feasible under certain conditions. This analysis concludes that 50% of the glass fiber must be recovered and resold for a price of $0.28/kg. Additionally, 90% of the Resin must be recovered and resold at a price of $2.50/kg.
Conchur M O Bradaigh - One of the best experts on this subject based on the ideXlab platform.
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manufacturing of unidirectional stitched glass fabric reinforced polyamide 6 by Thermoplastic Resin transfer moulding
Materials & Design, 2020Co-Authors: James J Murray, Colin Robert, Klaus Gleich, Edward D Mccarthy, Conchur M O BradaighAbstract:Abstract This study aims to address barriers which remain to adoption of reactive Thermoplastic Resin transfer moulding in terms of knowledge and equipment. Glass fibre reinforced polyamide 6 composites with ~52% fibre volume fraction and ~1% voids were produced within 5 min using Thermoplastic Resin transfer moulding by injection of low viscosity monomer precursors and in-situ polymerisation. Unidirectional laminates were produced using injection pressures of around 10% of those required to achieve the same fibre volume fraction and degree of wet-out using a typical thermoset RTM Resin, negating the need for expensive equipment. The equipment and process employed are described in detail and the quality and properties of the polymer matrix and composite laminates were characterised extensively in terms of chemical, thermo-morphological and mechanical properties. The paper demonstrates the high quality parts that can be achieved by accurately controlling some of the most important parameters.
David Snowberg - One of the best experts on this subject based on the ideXlab platform.
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Manufacturing and Flexural Characterization of Infusion-Reacted Thermoplastic Wind Turbine Blade Subcomponents
Applied Composite Materials, 2019Co-Authors: Robynne E. Murray, Dylan Cousins, Ryan Beach, David Snowberg, Derek Berry, Yasuhito Suzuki, Dayakar Penumadu, Aaron StebnerAbstract:Reactive Thermoplastics are advantageous for wind turbine blades because they are recyclable at end of life, have reduced manufacturing costs, and enable thermal joining and shaping. However, there are challenges with manufacturing wind components from these new materials. This work outlines the development of manufacturing processes for a thick glass fiber–reinforced acrylic Thermoplastic Resin wind turbine blade spar cap, with consideration given to effects of the exothermic curing reaction on thick composite parts. Comparative elastic properties of these infusible Thermoplastic materials with epoxy thermoset materials, as well as Thermoplastic coupon components, are also included. Based on the results of this study it is concluded that the Thermoplastic Resin system is a viable candidate for the manufacturing of wind turbine blades using vacuum-assisted Resin transfer molding. Significant gains in energy savings are realized avoiding heated molds, ability for recycling, and providing an opportunity for utilizing thermal welding.
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Techno-economic analysis of a megawatt-scale Thermoplastic Resin wind turbine blade
Renewable Energy, 2019Co-Authors: Robynne E. Murray, David Snowberg, Derek Berry, Scott Jenne, Dylan S. CousinsAbstract:Abstract Two-part, in-situ reactive Thermoplastic Resin systems for composite wind turbine blades have the potential to lower the blade cost by decreasing cycle times, capital costs of both tooling and equipment, and energy consumption during manufacturing, and enabling recycling at the end of the blade life. This paper describes a techno-economic model used to estimate the cost of a Thermoplastic wind turbine blade relative to a baseline thermoset epoxy blade. It was shown that a 61.5-m Thermoplastic blade costs 4.7% less than an equivalent epoxy blade. Even though the Thermoplastic Resin is currently more expensive than epoxy, this cost reduction is primarily driven by the decreased capital costs, faster cycle times, and reduced energy requirements and labor costs. Although Thermoplastic technology for Resin infusion of wind turbine blades is relatively new, these results suggest that it is economically and technically feasible and warrants further research.
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Manufacturing a 9-Meter Thermoplastic Composite Wind Turbine Blade
American Society for Composites 2017, 2017Co-Authors: Robynne E. Murray, Ryan Beach, David Snowberg, Derek Berry, Dana Swan, Sam RooneyAbstract:Currently, wind turbine blades are manufactured from a combination of glass and/or carbon fiber composite materials with a thermoset Resin such as epoxy, which requires energy-intensive and expensive heating processes to cure. Newly developed in-situ polymerizing Thermoplastic Resin systems for composite wind turbine blades polymerize at room temperature, eliminating the heating process and significantly reducing the blade manufacturing cycle time and embodied energy, which in turn reduces costs. Thermoplastic materials can also be thermally welded, eliminating the need for adhesive bonds between blade components and increasing the overall strength and reliability of the blades. As well, Thermoplastic materials enable end-oflife blade recycling by reheating and decomposing the materials, which is a limitation of existing blade technology. This paper presents a manufacturing demonstration for a 9-m-long Thermoplastic composite wind turbine blade. This blade was constructed in the Composites Manufacturing Education and Technology facility at the National Wind Technology Center at the National Renewable Energy Laboratory (NREL) using a vacuumassisted Resin transfer molding process. Johns Manville fiberglass and an Arkema Thermoplastic Resin called Elium were used. Additional materials included Armacellrecycled polyethylene terephthalate foam from Creative Foam and low-cost carbonfiber pultruded spar caps (manufactured in collaboration with NREL, Oak Ridge National Laboratory, Huntsman, Strongwell, and Chomarat). This paper highlights the development of the Thermoplastic Resin formulations, including an additive designed to control the peak exothermic temperatures. Infusion and cure times of less than 3 hours are also demonstrated, highlighting the efficiency and energy savings associated with manufacturing Thermoplastic composite blades.
Derek Berry - One of the best experts on this subject based on the ideXlab platform.
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Manufacturing and Flexural Characterization of Infusion-Reacted Thermoplastic Wind Turbine Blade Subcomponents
Applied Composite Materials, 2019Co-Authors: Robynne E. Murray, Dylan Cousins, Ryan Beach, David Snowberg, Derek Berry, Yasuhito Suzuki, Dayakar Penumadu, Aaron StebnerAbstract:Reactive Thermoplastics are advantageous for wind turbine blades because they are recyclable at end of life, have reduced manufacturing costs, and enable thermal joining and shaping. However, there are challenges with manufacturing wind components from these new materials. This work outlines the development of manufacturing processes for a thick glass fiber–reinforced acrylic Thermoplastic Resin wind turbine blade spar cap, with consideration given to effects of the exothermic curing reaction on thick composite parts. Comparative elastic properties of these infusible Thermoplastic materials with epoxy thermoset materials, as well as Thermoplastic coupon components, are also included. Based on the results of this study it is concluded that the Thermoplastic Resin system is a viable candidate for the manufacturing of wind turbine blades using vacuum-assisted Resin transfer molding. Significant gains in energy savings are realized avoiding heated molds, ability for recycling, and providing an opportunity for utilizing thermal welding.
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Techno-economic analysis of a megawatt-scale Thermoplastic Resin wind turbine blade
Renewable Energy, 2019Co-Authors: Robynne E. Murray, David Snowberg, Derek Berry, Scott Jenne, Dylan S. CousinsAbstract:Abstract Two-part, in-situ reactive Thermoplastic Resin systems for composite wind turbine blades have the potential to lower the blade cost by decreasing cycle times, capital costs of both tooling and equipment, and energy consumption during manufacturing, and enabling recycling at the end of the blade life. This paper describes a techno-economic model used to estimate the cost of a Thermoplastic wind turbine blade relative to a baseline thermoset epoxy blade. It was shown that a 61.5-m Thermoplastic blade costs 4.7% less than an equivalent epoxy blade. Even though the Thermoplastic Resin is currently more expensive than epoxy, this cost reduction is primarily driven by the decreased capital costs, faster cycle times, and reduced energy requirements and labor costs. Although Thermoplastic technology for Resin infusion of wind turbine blades is relatively new, these results suggest that it is economically and technically feasible and warrants further research.
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Manufacturing a 9-Meter Thermoplastic Composite Wind Turbine Blade
American Society for Composites 2017, 2017Co-Authors: Robynne E. Murray, Ryan Beach, David Snowberg, Derek Berry, Dana Swan, Sam RooneyAbstract:Currently, wind turbine blades are manufactured from a combination of glass and/or carbon fiber composite materials with a thermoset Resin such as epoxy, which requires energy-intensive and expensive heating processes to cure. Newly developed in-situ polymerizing Thermoplastic Resin systems for composite wind turbine blades polymerize at room temperature, eliminating the heating process and significantly reducing the blade manufacturing cycle time and embodied energy, which in turn reduces costs. Thermoplastic materials can also be thermally welded, eliminating the need for adhesive bonds between blade components and increasing the overall strength and reliability of the blades. As well, Thermoplastic materials enable end-oflife blade recycling by reheating and decomposing the materials, which is a limitation of existing blade technology. This paper presents a manufacturing demonstration for a 9-m-long Thermoplastic composite wind turbine blade. This blade was constructed in the Composites Manufacturing Education and Technology facility at the National Wind Technology Center at the National Renewable Energy Laboratory (NREL) using a vacuumassisted Resin transfer molding process. Johns Manville fiberglass and an Arkema Thermoplastic Resin called Elium were used. Additional materials included Armacellrecycled polyethylene terephthalate foam from Creative Foam and low-cost carbonfiber pultruded spar caps (manufactured in collaboration with NREL, Oak Ridge National Laboratory, Huntsman, Strongwell, and Chomarat). This paper highlights the development of the Thermoplastic Resin formulations, including an additive designed to control the peak exothermic temperatures. Infusion and cure times of less than 3 hours are also demonstrated, highlighting the efficiency and energy savings associated with manufacturing Thermoplastic composite blades.
