Technical development path of wind turbine blade material
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Wind turbine blades are at the heart of wind energy technology, and their material choices have evolved significantly over the years. According to Bob Bellemare, president of UtiliPoint, a global consulting firm, carbon fiber is becoming an increasingly important material in blade manufacturing. For smaller blades—such as those around 22 meters long—E-glass fiber reinforced plastics (GFRP) are commonly used due to their cost-effectiveness. These blades typically use unsaturated polyester resins, though vinyl ester or epoxy can also be employed. When it comes to larger blades, such as those exceeding 42 meters in length, carbon fiber reinforced polymers (CFRP) or hybrid composites combining carbon and glass fibers are preferred, with epoxy resin as the primary matrix.
Ramesh Gopalakrishnan, global manager of wind energy blade engineering at GE, highlights that carbon fiber has become a key choice for designers aiming to achieve lightweight yet high-strength blades. As a result, both glass fiber and carbon fiber remain the two most critical materials in modern blade production.
The blade itself is one of the most vital components in a wind turbine. Its design, quality, and performance directly impact the turbine’s reliability and efficiency. Blades must endure harsh conditions, including strong winds, storms, and fluctuating loads, while maintaining structural integrity and fatigue resistance. They must also exhibit proper flexibility and vibration characteristics to ensure stable power transmission to the system. Additionally, they need to resist corrosion, UV damage, and lightning strikes, all while keeping operational and maintenance costs low.
To enhance the economic viability of wind turbines, blade size has increased dramatically. In 1980, the average blade length was just 4.5 meters, producing only 55 kW of power. Today, blades can reach 61.5 meters in length and generate up to 5 MW. In the 1970s, steel, aluminum, and wood were common materials, but today, E-glass fiber reinforced plastics (GFRP) dominate. Carbon fiber composites are now being used more widely, reflecting the ongoing trend toward larger, lighter, and more efficient blades.
While wood is still used in some micro- and small-scale wind turbines, it's rarely found in large or medium-sized models. Wooden blades often incorporate strong wooden beams as longitudinal supports to handle the forces during operation. Steel-based blades, on the other hand, use D-shaped steel beams and rib structures, with foamed plastic cores wrapped in fiberglass. The steel sections are gradually tapered along the blade to reduce weight while maintaining strength.
Aluminum alloy extruded blades offer advantages in terms of ease of manufacturing and continuous production. However, they are limited in their ability to taper from root to tip due to current extrusion technology constraints. Fiberglass blades, made from glass fiber-reinforced plastics, provide a good balance of strength, lightness, and durability. Surface treatments like sizing and coatings further improve their performance.
Carbon fiber composites are gaining traction due to their superior stiffness—up to three times that of traditional FRP blades. Despite this, their high cost remains a barrier to widespread adoption. Companies worldwide are investing in research to reduce production costs through better materials, advanced manufacturing techniques, and improved quality control.
From wood and metal in the past, to fiberglass today, and possibly carbon fiber tomorrow, the evolution of blade materials continues to drive innovation in wind energy. What lies ahead? Perhaps even nanomaterials. The future of wind turbine technology is bright, and the journey of blade development is far from over.