scholarly journals Materials and Additive Manufacturing for Energy Efficiency in Wind Turbine and Aircraft Industries

2016 ◽  
Author(s):  
Panos G Datskos ◽  
Georgios Polyzos ◽  
Art Clemons ◽  
Paul Bolton ◽  
Aaron Hollander
Keyword(s):  
Energy Efficiency ◽  
Additive Manufacturing ◽  
Wind Turbine

scholarly journals Large-Scale Additive Manufacturing for Low Cost Small-Scale Wind Turbine Manufacturing

2020 ◽  
Author(s):  
Brian Post ◽  
Phillip Chesser ◽  
Alex Roschli ◽  
Lonnie Love ◽  
Katherine Gaul
Keyword(s):  
Additive Manufacturing ◽  
Wind Turbine ◽  
Large Scale ◽  
Low Cost ◽  
Small Scale

Hybrid Polymer Additive Manufacturing of a Darrieus Type Vertical Axis Wind Turbine Design to Improve Power Generation Efficiency

2016 ◽  
Author(s):  
Sourabh Deshpande ◽  
Nithin Rao ◽  
Nitin Pradhan ◽  
John L. Irwin
Keyword(s):  
Power Generation ◽  
Additive Manufacturing ◽  
3D Printing ◽  
Wind Turbine ◽  
Turbine Blades ◽  
Vertical Axis ◽  
Blade Design ◽  
Vertical Axis Wind Turbine ◽  
Wind Turbine Blades ◽  
3D Printed

Utilizing the advantages of additive manufacturing methods, redesigning, building and testing of an existing integral Savonius / Darrieus “Lenz2 Wing” style vertical axis wind turbine is predicted to improve power generation efficiency. The current wind turbine blades and supports made from aluminum plate and sheet are limiting the power generation due to the overall weight. The new design is predicted to increase power generation when compared to the current design due to the lightweight spiral Darrieus shaped hollow blade made possible by 3D printing, along with an internal Savonius blade made from aluminum sheet and traditional manufacturing techniques. The design constraints include 3D printing the turbine blades in a 0.4 × 0.4 × 0.3 m work envelope while using a Stratasys Fortus 400mc and thus the wind turbine blades are split into multiple parts with dovetail joint features, when bonded together result in a 1.2 m tall working prototype. Appropriate allowance in the mating dovetail joints are considered to facilitate the fit and bonding, as well as angle, size and placement of the dovetail to maximize strength. The spiral shape and Darrieus style cross section of the blade that provides the required lift enabling it to rotate from the static condition are oriented laterally for 3D printing to maximize strength. The bonding of the dovetail joints is carried out effectively using an acetone solution dip. The auxiliary components of the wind turbine which include the center support pole, top and bottom support, and center Savonius blades are manufactured using lightweight aluminum. Design features are included in the 3D printed blade parts so that they can be assembled with the aluminum parts in bolted connections. Analysis of the 3D CAD models show that the hybrid aluminum and hollow 3D printed blade construction provides a 50% cost savings over a 3D printed fully solid blade design while minimizing weight and maximizing the strength where necessary. Analysis of the redesign includes a detailed weight comparison, structural strength and the cost of production. Results include linear static finite element analysis for the strength in dovetail joint bonding and the aluminum to 3D printed connections. Additional data reported are the time frame for the design and manufacturing of the system, budget, and an operational analysis of the wind turbine with concern for safety. Results are analyzed to determine the advantages in utilizing a hybrid additive manufacturing and aluminum construction for producing a more efficient vertical axis wind turbine. Techniques used in the production of this type of wind turbine blade are planned to be utilized in similar applications such as a lightweight hovercraft propeller blade design to be tested in future research projects.

Powder-Binder Jetting Large-Scale, Metal Direct-Drive Generators: Selecting the Powder, Binder, and Process Parameters

2019 ◽  
Author(s):  
Austin C. Hayes ◽  
Gregory L. Whiting
Keyword(s):  
Additive Manufacturing ◽  
Wind Turbine ◽  
Large Scale ◽  
Material Selection ◽  
Direct Drive ◽  
Turbine Generators ◽  
Wind Turbine Generators ◽  
Complex Parts ◽  
Printing Parameters ◽  
Binder Jetting

Abstract Additive manufacturing enables the production of complex geometries extremely difficult to create with conventional subtractive methods. While good at producing complex parts, its limitations can be seen through its penetration into everyday manufacturing markets. Throughput limitations, poor surface roughness, limited material selection, and repeatability concerns hinder additive manufacturing from revolutionizing all but the low-volume, high-value markets. This work characterizes combining powder-binder jetting with traditional casting techniques to create large, complex metal parts. Specifically, we extend this technology to wind turbine generators and provide initial feasibility of producing complex direct-drive generator rotor and stator designs. In this process, thermal inkjet printer heads selectively deposit binder on hydroperm casting powder. This powder is selectively solidified and baked to remove moisture before being cast through traditional methods. This work identifies a scalable manufacturing process to print large-scale wind turbine direct drive generators. As direct-drive generators are substantially larger than their synchronous counterparts, a printing process must be able to be scaled for a 2–5 MW 2–6m machine. For this study, research on the powder, binder, and printing parameters is conducted and evaluated for scalability.

Recycling of fiberglass wind turbine blades into reinforced filaments for use in Additive Manufacturing

2019 ◽  
Vol 175 ◽  
pp. 107101 ◽  
Author(s):  
Amirmohammad Rahimizadeh ◽  
Jordan Kalman ◽  
Kazem Fayazbakhsh ◽  
Larry Lessard
Keyword(s):  
Additive Manufacturing ◽  
Wind Turbine ◽  
Turbine Blades ◽  
Wind Turbine Blades

scholarly journals Additive Manufacturing of Wind Turbine Molds

2017 ◽  
Author(s):  
Brian Post ◽  
Bradley Richardson ◽  
Peter Lloyd ◽  
Lonnie Love ◽  
Stephen Nolet ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Wind Turbine

Evaluation and Assessment of Additive Manufacturing Processes Based on the Least Energy Demand in Application for Sustainable Production

2017 ◽  
Vol 871 ◽  
pp. 153-160
Author(s):  
Sven Kreitlein ◽  
Viktor Gerter ◽  
Nikolaus Urban ◽  
Jörg Franke
Keyword(s):  
Energy Efficiency ◽  
Additive Manufacturing ◽  
Reference Values ◽  
Energy Demand ◽  
Energy Savings ◽  
Reference Value ◽  
Melting Process ◽  
Relative Energy ◽  
Production Processes ◽  
Least Energy

This paper presents the Least Energy Demand as an independent reference value for evaluating energy efficiency of additive manufacturing (AM) processes. Nowadays an essential challenge is represented by a proper evaluation and calculation of the energy efficiency of production processes. The reason for this is the lack of appropriate reference values. A comprehensive comparison of the energy efficiency is not possible without consistent reference values. However, this comparison serves as a first step towards the goal in order to reveal the actual energy savings potential of additive manufacturing procedures and to take actions on this basis. Therefore, the first step is to define the general concept, which is used for the calculation of the Least Energy Demand. Moreover, the unit operation-specific Least Energy Demand EGM is introduced based on unit operations. In conclusion, the importance of EGM as a reference value for evaluating the energy efficiency of production processes, defined in DIN 8580, is explained. Within the scope of an application of the illustrated concept the Least Energy Demand and the Relative Energy Efficiency (REE) are calculated using the example of a selective laser melting process.

BAAM Additive Manufacturing of Magnetically Levitated Wind Turbine

2018 ◽  
Author(s):  
Bradley S. Richardson ◽  
Mark W. Noakes ◽  
Alex C. Roschli
Keyword(s):  
Additive Manufacturing ◽  
Wind Turbine ◽  
Magnetically Levitated

Economic and Ecologic Analysis of Wind Energy as Steps in Starting a New Business

2017 ◽  
pp. 133-159
Keyword(s):  
Energy Efficiency ◽  
Renewable Energy ◽  
Kinetic Energy ◽  
Environmental Impact ◽  
Wind Energy ◽  
Wind Turbine ◽  
Technological Development ◽  
Electric Energy ◽  
Energy Capacity ◽  
New Business

Wind energy has a long history but in the last decades the technological development and the increasing energy efficiency push this business on a top position for the installed renewable energy capacity worldwide. For a better understanding of the economic and ecologic analysis of the business into the wind energy sector, in this chapter, are presented the main principles and energy concepts related to renewable energy, especially for wind energy. The analysis is focused on the importance of the main elements of a wind turbine and its costs structure. The wind turbine is analyzed also along its lifecycle in order to identify the environmental impact from the row material extraction to the end of lifetime. The main objective of this chapter is to understand the importance of wind energy as a renewable energy and how to use the kinetic energy of wind in order to generate electric energy taking into account its efficiency and also its impact on the environment.

Sign in / Sign up

Export Citation Format

Share Document