Strain self-sensing capability of a tidal turbine blade fabricated of PU-foam/glass fiber/epoxy composites using MWCNTs

A novel marine composite structure (experimental tidal turbine blade) made up of a polyurethane (PU) foam/glass fiber/epoxy resin composite with multiwall carbon nanotubes (MWCNTs) is proposed herein to self-sense its strain under a structural test scenario. To achieve this, MWCNTs were deposited onto glass fiber fabric by spray-coating technique in order to form an effective electrical percolation network onto the external skin surface of the tidal turbine blade which enables piezoresistive capability. After MWCNT deposition, the blade was manufactured by means of one-shot resin transfer molding (RTM) in a closed and heated metallic mold specially designed with a blade geometry of 67 cm length. The results confirm that the spray coating technique is a viable method to deposit MWCNTs onto glass fiber surface and form electrical networks into the blade at a relatively low MWCNT concentration. Finite element analysis (FEA) predicted a suitable structural blade design with a maximum failure index value of 0.9 attained in the blade shear web. The measured longitudinal strains of the tidal turbine blade were in good agreement with the numerical strain values predicted with FEA. Electromechanical tests carried out on a structural test rig designed and instrumented for tidal turbine blades showed that the electrical resistance change response of carbon nanotube (CNT) network integrated into the blade was capable of following the mechanical curve response up to the blade limit load, confirming its ability to self-sense its strain in real time.