Three-Dimension Woven Carbon-Glass Hybrid Wind Turbine Blades

70360S02-II Wind energy is a fast growing business area with state-of-the-art turbine blades approaching design limits based on glass reinforced composite materials. New materials and blade design approaches that utilize the higher performance of carbon fiber could enable lighter and larger blades that are more productive and efficient, yet cost effective. This project will develop thick three-dimensional woven fabrics, combined with new spar and skin sandwich designs that will enable lighter and larger blades, in order to improve the viability and competitiveness of wind-produced power. Phase I designed a carbon-glass hybrid, three-dimensional woven fabric along with a concept for a new blade design. A parametric survey was conducted and a model was developed to evaluate materials for weight and economic savings. The results confirmed that the carbon-glass hybrid materials could provide significant weight reduction and improved resin infusion processability. Phase II will demonstrate the new concepts and novel materials by conducting materials testing and then fabricating a prototype blade. The prototype blade will be tested for static and fatigue performance at the DOE National Renewable Energy Laboratory. Commercial Applications and Other Benefits as described by awardee: The materials, data and design approaches should be directly applicable to the design and manufacture of large wind turbine blades. The technology should enable the use of larger blades, thus making wind energy more competitive and widespread.