Resin uptake plays a critical role in the stiffness‐to‐weight ratio of wind turbine blades in which sandwich composites are used extensively. This work examines the flexural properties of nominally half‐inch thick sandwich composites made with polyvinyl chloride (PVC) foam cores (H60 and H80; PSC and GPC) at several resin uptakes. We found that the specific flexural strength and modulus for the H80 GPC sandwich composites increase from 82.04 to 90.70 kN · m/kg and 6.03 to 7.13 MN · m/kg, respectively, with 11.0% resin uptake reduction, which stands out among the four core sandwich composites. Considering reaching a high stiffness‐to‐weight ratio while preventing resin starvation, 32% to 38% and 40% to 45% resin uptakes are adequate ranges for the H80 PSC and GPC sandwich composites, respectively. The H60 GPC sandwich composites have lower debonding toughness than H60 PSC due to stress concentration in the smooth side skin‐core interphase region. The ailure mode of the sandwich composites depends on the core stiffness and surface texture. The H60 GPC sandwich composites exhibit core shearing and bottom skin‐core debonding failure, while the H80 GPC and PSC sandwich composites show top skin cracking and core crushing failure. The findings indicate that an appropriate range of resin uptake exists for each type of core sandwich composite, and that within the range, a low‐resin uptake leads to lighter blades and thus lower cyclic gravitational loads, beneficial for long blades.

This paper presents the development of a multi‐fidelity digital twin structural model (virtual model) of an as‐built wind turbine blade. The goal is to develop and demonstrate an approach to produce an accurate and detailed model of the as‐built blade for use in verifying the performance of the operating two‐bladed, downwind rotor. The digital twin model development methodology, presented herein, involves a novel calibration process to integrate a wide range of information including design specifications, manufacturing information, and structural testing data (modal and static) to produce a multi‐fidelity digital twin structural model: a detailed high‐fidelity model (i.e., 3D finite element analysis [FEA]) and consistent beam‐type models for aeroelastic simulation. A key element is that the multi‐fidelity structural digital twin method follows the rotor from the stages of design, to manufacturing, then to the ground testing and field operation. The result of this comprehensive approach is an accurate multi‐fidelity digital twin structural model for the geometric, structural, and structural dynamic properties of the as‐built blade within a 1% match in mass properties, 3.2% in blade frequencies, and 6% in deflection. The different stages of processing this information within the methodology are discussed. The rotor examined is the SUMR‐Demonstrator (SUMR‐D), which was installed on the Controls Advanced Research Testbed (CART‐2) wind turbine at the National Wind Technology Center. The digital twin model developed here was utilized to design controllers to safely operate SUMR‐D in field tests, which are providing additional data for further evaluation and development of the multi‐fidelity digital twin structural model.

The quest for reduced levelized cost of energy has driven significant growth in wind turbine size; however, larger rotors face significant technical and logistical challenges. The largest published rotor design is 25 MW, and here we consider an even larger 50 MW design with blade length over 250 m. This paper shows that a 50 MW design is indeed possible from a detailed engineering perspective and presents a series of aero-structural blade designs, and critical assessment of technology pathways and challenges for extreme-scale rotors. The 50 MW rotor design begins with Monte Carlo simulations focused on optimizing carbon spar cap and root design. A baseline design resulted in a 250-m blade with mass of 502 tonnes. Subsequently, an aero-structural design and optimization were performed to reduce the blade mass/cost with more than 25% mass reduction and 30% cost reduction by determining optimal blade chord and airfoil thickness for best aero-structural performance.