Non‐destructive and contactless defect detection inside leading edge coatings for wind turbine blades using mid‐infrared optical coherence tomography

Abstract

Abstract Leading edge erosion of wind turbine blades is one of the most critical issues in wind energy production, resulting in lower efficiency, as well as increased maintenance costs and downtime. Erosion is initiated by impacts from rain droplets and other atmospheric particles, so to protect the blades, special protective coatings are applied to increase their lifetime without adding significantly to the weight or friction of the blade. These coatings should ideally absorb and distribute the force away from the point of impact; however, microscopic defects, such as bubbles, reduce the mechanical performance of the coating, leading to cracks and eventually erosion. In this work, mid‐infrared (MIR) Optical Coherence Tomography (OCT) is investigated for non‐destructive, contactless inspection of coated glass‐fiber composite samples to identify subsurface coating defects. The samples were tested using rubber projectiles to simulate rain droplet and particle impacts. The samples were subsequently imaged using OCT, optical microscopy, and X‐ray tomography. OCT scanning revealed both bubbles and cracks below the surface, which would not have been detected using ultrasonic or similar non‐destructive methods. In this way, OCT can complement the existing quality control in turbine blade manufacturing, help improve the blade lifetime, and reduce the environmental impact from erosion.

Keywords

• coating
• erosion
• leading edge
• non‐destructive testing
• optical coherence tomography