Experimental analysis of alternative thermoplastic resins for manufacturing thick-section composite laminates in tidal turbine blades

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Smith, Ione L. M. and Lykkeberg, Anna and Garden, Jennifer A. and McCarthy, Edward D. and Thies, Philipp R. and Oterkus, Selda and Obande, Winifred (2025) Experimental analysis of alternative thermoplastic resins for manufacturing thick-section composite laminates in tidal turbine blades. Journal of Thermoplastic Composite Materials. ISSN 1530-7980 (https://doi.org/10.1177/08927057251359537)

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Abstract

Tidal turbine blades require thick-sections (10 - 100 mm) to withstand challenging operating conditions and high loads. The growing demand for sustainable materials is driving interest in recyclable liquid thermoplastic resins. These room-temperature processable resins may, in time, rival thermosets as the material of choice for blade manufacturing. Like other liquid resins, their use in thick-laminate production proves challenging as heat generated during polymerisation must be controlled to avoid boiling and defects. Although innovative low-exotherm grades are now available, their behaviour in thick-laminate manufacturing remains poorly understood. This study provides novel insights into the exothermic polymerisation profiles of two low-exotherm grades (Elium ® 188 XO and Elium ® 191 XO/SA). Industry-relevant findings on process times are also reported to guide their implementation. Five thermocouples embedded in each 10-ply laminate tracked temperature evolution over 12 hours. Elium ® 188 XO reached a higher exothermic peak temperature (86.5°C) than Elium ® 191 XO/SA (63.2°C). Nonetheless, both maximum temperatures remained below their respective boiling points, indicating minimised risk of exotherm-induced defects. A delayed exothermic reaction in Elium ® 191 XO/SA extended its process time, implying a slower manufacturing rate. The enhanced understanding of the polymerisation behaviour of liquid thermoplastic resins in thick-section laminates will allow researchers and practitioners to establish their suitability for tidal turbine blades.

ORCID iDs

Smith, Ione L. M., Lykkeberg, Anna, Garden, Jennifer A., McCarthy, Edward D., Thies, Philipp R., Oterkus, Selda ORCID logoORCID: https://orcid.org/0000-0003-0474-0279 and Obande, Winifred;
CORE (COnnecting REpositories)