Session: 01-04 Multifunctional Composites/Nanocomposites

Paper Number: 171904

171904 - Production and Characterization of Electrically Conductive Adhesives Based on Carbon-Based Fillers for Use in the Wind Energy Sector 

Wind energy has a crucial role to play in the energy transition and the reduction of CO₂ emissions. One challenge in the operation of wind turbines is carrying out regular maintenance and inspections. A key aspect of these inspections are the rotor blades, which are exposed to high wind, weather and dynamic loads. This can lead to material fatigue and cracking in the adhesive joints. Damage often occurs at the trailing edge of the blade, which impairs the stability of the rotor blades and, in the worst case, can lead to the failure of the entire turbine. Current inspection methods include visual inspections by industrial climbers, but these are associated with considerable costs, logistical effort and safety risks. In addition, most methods detect external damage, while internal defects are rarely recognized at an early stage. As a result, damage is only recognized at a late stage, which leads to delayed repairs, long downtimes and high follow-up costs.

In order to increase the reliability and cost-effectiveness of wind turbines, there is increasing interest in new methods for early damage detection, particularly in the area of rotor blade adhesive joints. Materials science in particular plays a central role here, as the properties of the materials used contribute significantly to the stability and durability of the rotor blades. Modern adhesive systems must not only withstand mechanical and climatic stresses, but also ensure the best possible processing and adhesion to the rotor blades. The development of innovative solutions for the early detection of damage, such as particle-reinforced adhesive systems with integrated sensor properties, could enable continuous monitoring of the rotor blade structure and thus bring about a decisive improvement in the operational safety and cost-effectiveness of wind turbines.

Reaching this goal, a particle-reinforced, electrically conductive adhesive system based on a two-component epoxy resin was developed. Electrical conductivity was realized by adding carbon-based fillers such as carbon black and multi-walled carbon nanotubes. In addition, mechanical and rheological properties were also optimized to meet the requirements for application in the wind energy sector. A targeted selection and adjustment of the filler concentrations led to a balance between electrical conductivity, mechanical properties and processability.

The results focus on the development and characterization of the adhesive system and the experimental investigation of its electrical, mechanical and rheological properties. Long-term investigations, life cycle analyses or the construction of a full-scale rotor blade model are not considered. A wind power adhesive already established in the industry serves as a reference material.

Presenting Author: Sebastian Geier German Aerospace Center

Presenting Author Biography: 2001-2008 Technical University Berlin
2008 M.Sc. Aerospace Engineering
2008-today German Aerospace Center (DLR)
2009-2013 University of fine Arts Braunschweig
2013 M.A. Transportation Design
2019 P.h.D completed