Abstract: A downwind morphing rotor that exhibits bending loads that will be reduced by aligning the rotor blades with the composite forces. This reduces the net loads on the blades which therefore allow for a reduced blade mass for a given maximum stress. Also provided is a pre-aligned configuration rotor whereby the rotor geometry and orientation does not change with wind speed, and instead is fixed at a constant downwind deflection consistent with alignment at or near the rated wind speed conditions. Also provided is a twist morphing rotor where the airfoil-shapes around the spars twist relative to the wind due to aerodynamic forces so as to unload the rotors when there is a gust. This can help reduce unsteady stresses on the blade and therefore may allow for reduced blade mass and cost. The twist morphing rotor may be combined with either downwind morphing rotor or pre-alignment rotor.

Abstract: The invention concerns a wind power installation rotor blade. The rotor blade has a rotor blade root, a rotor blade tip, a rotor blade leading edge and a rotor blade trailing edge. The rotor blade further has a pressure side and a suction side as well as at least one web at least partially between the suction and pressure sides. The rotor blade has a longitudinal direction between the rotor blade root and the rotor blade tip. The web is of a wave-shaped configuration in the longitudinal direction of the rotor blade.

Abstract: A method of forming an airfoil includes forming a metal portion of the airfoil including a tip, a leading edge, a trailing edge, a pressure side and a suction side; forming a plurality of grooves into one side of the airfoil; and filling the plurality of grooves with composite material.

Abstract: Blade insert connected in the lamination of a blade determining a double shear joint between insert and lamination. The insert is made up of two defined parts, head (2), designed to screw the insert to another structure (2?), and the body (3) that determines a cylindrical or conical shape with an internal conical cavity. In an embodiment, the insert is designed to be joined to the lamination (1) of the blade with adhesive means (4). In another embodiment, the insert is embedded in the blade lamination with an inner part (5) stuck to the body (3) of the insert.

Abstract: A method of manufacturing an aerofoil for a gas turbine engine (10). The method comprises the steps of providing first and second panels (16, 18), providing a web (30) between the first and second panels, deforming the panels and the web by applying internal pressure between the panels so as to form a series of internal cavities partitioned by the web. The method further includes the step of either cutting the web (30) across its entire width or causing the web to fail across its entire width so as to define an aerofoil having first and second panels with at least one protrusion extending from the first panel partially across the space between the first and second panels.

Abstract: A method of repairing delaminated plies of a composite includes drilling a plurality of holes in the plies, stitching one or more tows into the plurality of holes, and tensioning the tows. The holes are disposed across an area of the plies that is delaminated. The method introduces a resin into the area of the plies that is delaminated and cures the resin. Curing of the composite can be performed prior to the stitching and the tensioning of the one or more tows and can be performed by the tensioning of the one or more tows. Optionally, one or more additional plies can be applied to the repaired area and/or a portion of the one or more tows that extends above a surface the plies can be removed.

Abstract: A rotor blade section and a method for assembling a rotor blade for a wind turbine are disclosed. The rotor blade section includes a plurality of ribs each extending in a generally chord-wise direction. Each of the plurality of ribs includes an outer surface. The outer surface has a generally aerodynamic contour. The rotor blade section further includes at least one cross-member extending between adjacent ribs of the plurality of ribs, and an outer body mounted to the plurality of ribs. The outer body has an aerodynamic contour generally corresponding to the aerodynamic contour of the plurality of ribs.

Abstract: The invention relates to a method for producing a blade tip plating (20) on a blade (10) for a turbomachine, in particular on a high-pressure rotating compressor blade for a gas turbine, comprising the following steps: —producing a particle composite material (24) having embedded hard material particles (18); —placing the panicle composite material (24) on a solder (30) applied to the blade tip (16); and—healing the solder (30).

Abstract: A turbine engine blade made of composite material including fiber reinforcement obtained by weaving a first plurality of yarns with a second plurality of yarns, the yarns of the first plurality of yarns being arranged in successive layers and extending in a longitudinal direction of the fiber blank corresponding to a longitudinal direction of the blade, the reinforcement being densified by a matrix. The blade includes one or more internal channels extending in the longitudinal direction of the blade.

Abstract: A method for producing a metal insert for protecting a leading or trailing edge of a compressor vane of an aeronautical machine made of a composite material, by stamping sheets and diffusion bonding between the sheets. The method includes: initially shaping the sheets by stamping to approximate the sheets to a shape of a suction side and pressure side of the insert; producing a core shaped inner cavity of the metal insert to be manufactured, one of the surfaces thereof reproducing an inner shape of the suction side of the insert and the other surface reproducing an inner shape of the pressure side of the insert; positioning the sheets around the core and securing the assembly; applying a vacuum and sealing the assembly by bonding; assembling the assembly by hot isostatic compression; cutting the assembly to extract the core and separate the insert; producing an outer profile of the insert by a final machining.

Abstract: A mold for a centrifugal impeller for a turbomachine is provided. The mold comprises at least one annular insert, wherein the annular insert comprises a plurality of aerodynamic vane inserts configured to reproduce an annular assembly of aerodynamic vanes of a finished centrifugal impeller.

Abstract: A turbine blade having a root and a tip and an airfoil with a core section made of composite material and a protective sheath or layer joined to the composite core at a location or locations exposed to erosion is described with the composite core of the airfoil being continuous from a location in vicinity of the root to a location in vicinity of the tip of the blade and including a section which widens with distance from the rotational axis along the length of the airfoil and which ends at the location in vicinity of the tip of the blade. The protective sheath or layer is secured by interference fit with widening section of the core.

Abstract: A turbine rotor blade made from the spar and shell construction in which the shell formed from a plurality of shell segments each being a thin wall shell segment made from a high temperature resistant material that is formed by a wire EDM process, and where the shell segments are each secured to the spar separately using a retainer that is poured into retainer occupying spaces formed in the shell segments and the spar, and then hardened to form a rigid retainer to secure each shell segment to the spar individually. The spar includes a number of radial extending projections each with a row of cavities that form the retainer occupying spaces in order to spread the loads around. The retainer can be a bicast material, a transient liquid phase bonding material, or a sintered metal. An old shell can be easily removed and replaced with a new shell by removing parts of the retainer and re-pouring a new retainer with a new shell in place.

Abstract: A method for making a metal reinforcement for the leading edge or trailing edge of the blade of a turbine engine that includes making a metal insert defining the base of the metal reinforcement; positioning the metal insert at the end of a blank of a shaping tool, the blank repeating the shape of the turbine-engine blade; shaping a planar metal sheet on the metal insert and the blank of the shaping tool using a superplastic hot-shaping method.

Abstract: The invention relates to a method for wiring suctions ((i), (i+1)) of a blade (1) for a blade row of a turbomachine. According to said method, a first central component (formula (II)) of a second section ((i+1)) is selected according to at least one central component ((formula (IV)), xCG(i), rCG(i)) of a first section ((i)), especially according to a formula (I) where: (i) is a variable of the first section; (i+1) is a variable of the second section; (formula (III)) is a central component of a section in the peripheral direction, preferably in the angular or radian measure; xCG is a central component of a section in the axial direction; rCG is a central component of a section in the radial direction; ? is a graduated angle of a section; and (formula (V)) is a peripheral incline, preferably in the angular or radian measure.

Abstract: A wind turbine for generating electrical energy may include a wind turbine blade including a plurality of vortex generators integrally formed in the outer surface of the blade. The vortex generator includes a first component that defines a portion of the outer surface of the blade and a second component defining the shape of the vortex generator and at least partially surrounded by the first component. A method of manufacturing the wind turbine blade includes disposing a first plurality of layers of structural material over a mold main body and a removable insert member with a shaped cavity. A shaped plug is then pressed into the shaped cavity, and a second plurality of layers of structural material is disposed over the plug and the mold main body to complete manufacture of a wind turbine blade with a vortex generator.

Abstract: A blade assembly includes a blade body and at least one sheath assembly located at a leading edge of the blade assembly. The at least one sheath assembly is retained to the blade body in a chordwise direction via an interlocking arrangement between the at least one sheath assembly and the blade body. A tip cap is located at a tip portion of the blade and secured to the blade body thus securing the at least one sheath assembly to the blade body in a spanwise direction. A method of assembling an airfoil includes securing at least one sheath assembly to a leading edge of a blade body via an interlocking arrangement between the at least one sheath assembly and the blade body, and assembling a tip cap to the blade body, thereby retaining the at least one sheath assembly to the blade body in a spanwise direction.

Abstract: Blade insert arranged inside the blade walls so that the joint between the insert and composite (1) is a double shear joint. The insert is made up of two defined parts, the head (3, 3?) and the body, which are joined together by joint elements (5) that define a double wall body (6, 6?). The joint between the insert and pultruded material (2) is made with an adhesive chemical joint (9). After making the joint, the assembly made up by the inserts and pultrusion profiles (2) is fitted into the blade walls during its manufacturing process and material curing.

Abstract: A method of manufacturing an aerofoil for a gas turbine engine (10). The method comprises the steps of providing first and second panels (16, 18), providing a web (30) between the first and second panels, deforming the panels and the web by applying internal pressure between the panels so as to form a series of internal cavities partitioned by the web. The method further includes the step of either cutting the web (30) across its entire width or causing the web to fail across its entire width so as to define an aerofoil having first and second panels with at least one protrusion extending from the first panel partially across the space between the first and second panels.

Abstract: An elongate web is attached to the root end of a spar of a wind turbine rotor blade to provide additional support along the width of the blade. The root end is formed by a winding operation, and a recess is then cut into the surface of the spar. The recess is defined by a relatively large first, cylindrical surface, which is coaxial with the longitudinal axis of the root end, and a relatively small second, conical surface. A tapered end of the elongate web is attached within the recess of the root end using a layer of suitable adhesive and an array of pins. Resilient spacer elements are arranged within the recess so as to surround the pins. The large area of the cylindrical surface causes the tensile and compressive stresses which arise along the elongate web in use to be transmitted to the spar as shear stresses.

Abstract: A wind turbine blade transversely divided in an inboard module (13) and an outboard module (33) provided on their end sections with connecting means, comprising, respectively, an inboard spar (15), an inboard upper shell (17) and an inboard lower shell (19); an outboard spar (35), an outboard upper shell (37) and an outboard lower shell (39); and arranged so that the aerodynamic profile of said inboard and outboard modules (13, 33) is defined by said upper and lower shells (17, 19; 37, 39), in which the inboard spar (15) is composed of two cap prefabricated panels (21, 23) and two web prefabricated panels (25, 27), and the outboard spar (35) is composed of first and second prefabricated panels (41, 43) integrating its caps (45, 47) and webs (49, 51). The invention also refers to a method of fabricating said wind turbine blade.

Abstract: A method of manufacturing a rotor blade for a wind turbine and a rotor blade manufactured in accordance with such method are disclosed. The method generally comprises providing a blade blank formed at least partially from a filler material, shaping the blade blank to form a profile of the rotor blade and positioning a skin around an outer perimeter of the shaped blade blank.

Abstract: A wind turbine blade includes a multilayer composite structure including a first reflective layer, and a second layer including a plurality of resistive circuit analogue (CA) elements. The CA elements are tuned so as to interact with said first layer to provide absorption of electromagnetic (EM) energy over a desired frequency range. The parameters of the CA elements can be varied to provide for frequency tuning and to maintain absorption at a specific frequency range despite varying layer separation, while at the same time ensuring that the mechanical properties of the CA layer are compatible with integration into the turbine blade.

Abstract: Methods for making near net shape airfoil metal leading edge protective strips including providing a high temperature additive manufacturing device; providing a tooling system having a mandrel; a metallic cladding applied to the mandrel; and at least one cooling channel associated with the mandrel applying a metallic deposit to the mandrel having the metallic cladding using the high temperature additive manufacturing device; and concurrently removing heat from the mandrel using the at least one cooling channel to produce the near net shape airfoil metal leading edge protective strip.

Abstract: The invention relates to a method for producing a rotor or stator blade (1a) of a gas turbine, in particular an aircraft gas turbine (2), comprising forming a airfoil (8a) made of at least one first material and attaching a blade root (4a) made of at least one second material to the airfoil (8a) by means of a thermal spraying method. The invention further relates to a rotor or stator blade (1a) produced according to such a method.

Abstract: A method of repairing a vane cluster for a gas turbine engine includes attaching a first registration block to a salvageable airfoil segment of the vane cluster, machining a face of the first registration block relative to datum surfaces of the vane cluster, removing a damaged airfoil segment from the vane cluster, adding new material to the salvageable airfoil segment, joining a replacement airfoil segment having a second registration block to the salvageable airfoil segment to replace the damaged airfoil segment, removing the first registration block, and removing the second registration block. The respective first and second registration blocks of the salvageable airfoil segment and the replacement airfoil segment are aligned in a configuration substantially identical to a configuration of the vane cluster prior to undergoing repair.

Abstract: A method and system for assembling large wind turbine blades that includes providing a plurality of wind turbine blade segments. An adhesive distribution arrangement is disposed on a surface of at least one of the plurality of the wind turbine blade segments. The adhesive distribution arrangement includes a bonding grid having a plurality of adhesive distribution openings. The wind turbine blade segments are directed together and sufficient adhesive is provided to the bonding grid to substantially fill an area between the wind turbine segments. The adhesive is then cured to form a bonded joint, the bonding grid being incorporated into the bonded joint. A bonding grid for use with the method and system and a segmented wind turbine blade are also disclosed.

Abstract: A wind turbine rotor blade and a wind turbine incorporating the rotor blade include a first and second composite skin. A first and a second spar pultrusion having a base and a plurality of integral ribs generally normal to base are attached to the inside surface of the first and second composite skins and extend the span of the rotor blade. At least one shear web connects a rib of the first spar pultrusion to a corresponding rib of the second spar pultrusion. The width of the spar pultrusions decreases in a step-wise fashion along the span of the rotor blade from the root to the tip. The leading or trailing edge of the rotor blade may be selectably opened for inspection and repair.

Abstract: One embodiment of the present invention is a unique method for producing a turbomachine airfoil. Other embodiments include unique methods for manufacturing an airfoil for a gas turbine engine. Still other embodiments include apparatuses, systems, devices, hardware, methods, and combinations for airfoils for gas turbine engines and other turbomachinery. Further embodiments, forms, features, aspects, benefits, and advantages of the present application will become apparent from the description and figures provided herewith.

Abstract: A core for forming a cooling microcircuit has at least one row of metering/tripping features configured to form at least one row of protrusions in the cooling microcircuit, a plurality of teardrop features configured to form forming a plurality of fluid passageways in the cooling microcircuit, and a terminal edge. The plurality of teardrop features includes a central teardrop feature having a trailing edge which is spaced from the terminal edge and a first teardrop feature located on a first side of and spaced from the central teardrop feature. The first teardrop feature has a longitudinal axis and is non-symmetrical about the longitudinal axis. A process of using the core and a turbine engine component formed thereby are described.

Abstract: A method of optimizing performance of a wind turbine electric generator (WTG) comprises the steps of measuring the performance of a wind turbine electric generator, defining an area on a blade of the WTG, placing stall flags within said defined area, monitoring the behavior of the stall flags when the WTG is operating, determining a stall line based upon the stall flags during operation, installing vortex generators on the blade adjacent to and upwind of said stall line, monitoring the behavior of said stall flags during operation with vortex generators installed on all blades, and measuring the performance of the WTG to detect improved performance. If there is little or no improvement, repeating the steps on a second WTG using different placement within the defined area for the vortex generators.

Abstract: Disclosed is a field repairable coated airfoil such as a wing or a rotor blade having a leading edge protected by a spray applied or prefabricated variable thickness, multilayer coating system composed a primer or adhesive layer, a basecoat layer and a topcoat where the coating is continuously tapering having a thicker cross section at the leading edge and a thinner cross section at the trailing edge of the airfoil.

Abstract: A method for replacing a blade (12) of a rotor (2) having integral blades, wherein a new blade (22) is joined to a base (34) arranged on a separation surface (28) on the main rotor body, and to a rotor repaired or mended according to said method.

Abstract: The invention relates to a compressible and expandable blade for the rotor of a fluid pump having at least two lamellae which are disposed adjacently, are pivotable respectively relative to an axis of rotation of the rotor and moveable relative to each other, and abut against each other in the expanded state of the blade such that they form together a continuous blade surface.

Abstract: A wind turbine rotor blade and a wind turbine incorporating the rotor blade include a first and second composite skin. A first and a second spar pultrusion having a base and a plurality of integral ribs generally normal to the base are attached to the inside surface of the first and second composite skins and extend the span of the rotor blade. At least one shear web connects a rib of the first spar pultrusion to a corresponding rib of the second spar pultrusion. The width of the spar pultrusions decreases in a step-wise fashion along the span of the rotor blade from the root to the tip. The leading or trailing edge of the rotor blade may be selectably opened for inspection and repair.

Abstract: A method is provided for manufacturing a wind turbine rotor blade in which the blade is formed as a laminated structure by laying a composite material of fiber reinforcement material and/or core material in a mold defining the shape of the blade; evacuating the mold after laying the composite material; introducing a liquid polymer into the evacuated mold and wetting the composite material; curing the liquid polymer after the composite material has been wetted; and removing the mold after curing the liquid. At least one lightning conductor is integrated into the composite material before wetting it with the liquid polymer. Moreover, a wind turbine rotor blade made from a single laminated structure is provided with at least one lightning conductor is integrated into the laminated structure.

Abstract: A wind turbine rotor blade assembly includes a rotor blade having a pressure side, a suction side, a leading edge, and a trailing edge extending in a generally span-wise direction between a tip and a root. An edge extension is attached along the trailing edge and includes a first strip member having a span-wise attachment section attached to pressure side, and a second strip member having a span-wise attachment section attached to the suction side. Each of the first and second strip members has an outboard edge and an extension section that projects chord-wise beyond the trailing edge. The extension sections are adhesively attached to each other outboard of the trailing edge along a span-wise length of the first and second strip members and define an adhesively bonded closure edge of the edge extension. A method is also provided for forming an edge extension on a wind turbine rotor blade.

Abstract: In one aspect, a method for assembling an outlet guide vane is provided. The method includes providing an outlet guide vane frame having a first side and a second side. The outlet guide vane includes a radially inward flange coupled to a radially outward flange by a leading edge. A trailing edge is coupled to the radially inward flange and the radially outward flange aft of the leading edge. A cavity is defined between the radially inward flange, the radially outward flange, the leading edge, and the trailing edge. A first and a second mating surface circumscribe the cavity on the first and second sides respectively. The method further includes coupling a filler portion within the cavity wherein the filler portion includes a third side and a fourth side, coupling a first skin to the third side and the first mating surface, and coupling a second skin to the fourth side and the second mating surface, wherein at least one of the first skin and the second skin are fabricated from a composite material.

Abstract: A leading edge for use as a leading edge reinforcement on a blade or air foil part. The leading edge has a main body that includes two leg sections. A metal deposition layer is applied to the main body to form the outer end portion of the leading edge. The main body can be formed of one or more pieces.

Abstract: A rotor blade (10) of a wind power plant, wherein the rotor blade (10) has a longitudinal extension (11), which extends from a rotor blade root (12) substantially to a rotor blade tip (13), wherein, at least in one region of the rotor blade (10), an aerodynamic cross-sectional profile (15) is provided, which has a leading edge (16) (nose) and a trailing edge (17), which are connected via a suction side (18) and a pressure side (19) of the cross-sectional profile (15). The rotor blade is characterized in that the rotor blade (10) is subdivided at least in a longitudinally extended section (20) into a front rotor blade section (21) with the leading edge (16) and a rear rotor blade section (22) with the trailing edge (17), wherein the rear region (23) of the front rotor blade section (21) and the adjacent front region (24) of the rear rotor blade section (22) are connected through an I-beam (25).

Abstract: A blade of a wind turbine is provided. The blade includes at least one vortex-generator, which is positioned at the blade-surface. The vortex-generator is constructed and arranged in a way that it contributes to the aerodynamic characteristics of the blade. The vortex-generator includes a platform and an extension-part. The blade also includes a recess, which is constructed and arranged to receive at least a part of the platform of the vortex-generator. The platform is fixed at least partly within the recess.

Abstract: Wind turbine systems and methods are disclosed herein. A representative system includes a wind turbine blade having an inner region that has an internal load-bearing truss structure, and an outer region that has an internal, non-truss, load-bearing structure. In particular embodiments, the truss structure can include a triangular arrangement of spars, and/or can include truss attachment members that connect components of the truss without the use of holes in the spars. Spars can be produced from a plurality of pultruded composite members laminated together in longitudinally extending portions. The longitudinally extending portions can be connected at joints that interleave projections and recesses of each of the spar portions. The blades can include fan-shaped transitions at a hub attachment portion, formed by laminated layers and/or a combination of laminated layers and transition plates.

Abstract: Wind turbine systems and methods are disclosed herein. A representative system includes a wind turbine blade having an inner region that has an internal load-bearing truss structure, and an outer region that has an internal, non-truss, load-bearing structure. In particular embodiments, the truss structure can include a triangular arrangement of spars, and/or can include truss attachment members that connect components of the truss without the use of holes in the spars. Spars can be produced from a plurality of pultruded composite members laminated together in longitudinally extending portions. The longitudinally extending portions can be connected at joints that interleave projections and recesses of each of the spar portions. The blades can include fan-shaped transitions at a hub attachment portion, formed by laminated layers and/or a combination of laminated layers and transition plates.

Abstract: A method of replacing a portion of a composite airfoil in a turbine. The method comprises the steps of providing a turbine with a plurality of composite airfoils mounted on a wheel. At least one of the composite airfoils has a core made of a non-plastic material and a plastic airfoil portion to envelope at least a portion of the core. A composite airfoil having an airfoil portion in need of replacement is accessed. The plastic airfoil portion is removed to expose the core while the core is mounted on the wheel. A plastic airfoil portion is molded to envelope the core while the core is mounted on the wheel.

Abstract: A jet vane for use in streams of hot gas, comprising a wing having a core area and a cover skin area surrounding the core area, is proposed. The cover skin area is made of a fiber-reinforced material, and the fibers in the cover skin area are oriented substantially parallel to the wing surface, and/or the cover skin area is made of a fiber-reinforced material that is reinforced with short fibers.

Abstract: A method for assembling a rotor blade for use with a wind turbine. The method includes providing a blade sidewall at least partially defining a cavity extending from a blade root towards a blade tip of the rotor blade, the blade sidewall having a leading edge and a trailing edge. A structural support assembly is positioned at least partially within the cavity and extends from the blade root towards the blade tip. The structural support assembly includes a root end and an opposing tip end. At least one support member is coupled to the blade sidewall and to the structural support assembly.

Abstract: A dual-core blade and method for manufacturing a dual-core blade are disclosed. The blade is formed with a first core portion and a second core portion comprising an epoxy having a plurality of expanded microspheres. The method of forming the two foams generally comprises sizing a foam core to form a first core portion and providing and preparing an epoxy mixture to form a second core portion. The first core portion and the second core portion of the epoxy mixture are placed into a preform, and the preform is heated slightly so as to cause the epoxy mixture to flow into the shape of the preform and around the first core portion. The first core portion and the second core portion are then bonded in a molding operation. The formed structure can form part of a hockey stick blade.

Abstract: A rotor blade or rotor blade segment for a wind turbine has at least one cable for the fixation of the rotor blade or rotor blade segment on a rotor hub or on the further rotor blade segment. A connecting surface, in the mounted state, faces the rotor hub or further rotor blade segment and from this connecting surface, a free end of the at least one cable protrudes for fixation on the rotor hub or further rotor blade segment. The at least one cable is anchored inside a connecting region of the rotor blade or rotor blade segment and extends only over a longitudinal section of the rotor blade or rotor blade segment which adjoins the connecting surface.

Abstract: The present invention proposes a lightning protection device of a windmill blade, comprising a tip receptor assembly having receptors which are mounted, in particular to, the tip end part of the blade where the blade profile becomes smaller, and having a simple structure so as to be readily assembled, and an intermediate receptor assembly having a receptor which is set at the outer surface of the blade so as to exhibit an effective countermeasure against increasing of the air pressure in the blade upon a lightning striking upon the blade, a lightening current being discharged to the ground from the receptors through connection equipment such as lead wires laid through the inside of the blade the windmill body and bypass brushes, characterized in that a base plate made of an electrically conductive material and connected thereto with the lead wires is embedded in the blade, and the receptors are secured and supported to the base plate, being exposed at the outer surface of the blade.

Abstract: A method for assembling a modular wind turbine rotor blade, includes aligning a first blade module and a second blade module such that a first receptacle of the first blade module and a second receptacle of the second blade module are co-axial; and forming a detachable mechanical connection between a first inlay of the first blade module and a second inlay of the second blade module using a threaded fastener that extends into the first receptacle and into the second receptacle.