Title: Post-Process Deformation of Thermoplastic Matrix Composites Applied to Vertical Axis Wind Turbine Blades

Authors: Jamison T. Bair, Mark E. Bourgeois, Samuel D. Strassler, Patrick A. Rodriguez, Donald W. Radford

DOI: 10.33599/nasampe/s.21.0601

Abstract: Thermoplastic matrix composites have become an important subcategory of structural composites, particularly due to the enhanced potential for recycling. While recyclability is clearly a key attribute, the ability to reshape and reform thermoplastic matrix composites also offers potential advantages from perspectives of design and manufacture. With the advent of thermoplastic matrix materials that are processed through in-situ polymerization, composite manufacturing processes that rely on low resin viscosities become possible. The resin infusion of the Elium thermoplastic resins has been described in numerous articles and is the basis for this research effort. However, the focus of this current article is on design and manufacturability possibilities offered by the resulting thermoplastic matrix composite, which allows complex designs to be realized from relatively simple molded geometries, through post-process deformation. As an example of the possibilities, thin straight, hollow carbon fiber reinforced Elium airfoils were infused. Following processing these airfoils were reheated to deform the ends and simultaneously fusion join to end attachment plates, followed by a second reheating step to bend the airfoils to form ‘C’-shaped blades for a small, Vertical Axis Wind Turbine technology demonstrator. End attachment plate joint test results are described, as are details of the post-process deformations carried out. The results of this manufacturing technology demonstration show that acceptable joint strengths are readily attained. Further, a technique was developed which enables bending of the airfoils with limited fiber buckling and at relatively low forces, resulting in good repeatability. Future efforts on post-process deformation would require more in-depth evaluation of the fiber path and fiber path lengths to remove fiber buckling in regions such as the inside of the bend.

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Conference: SAMPE NEXUS 2021

Publication Date: 2021/06/29

SKU: TP21-0000000601

Pages: 15

Price: FREE