Escuela Superior de Enseñanzas Técnicas

Leading edge protection (LEP) coating systems are applied to protect turbine blade edges from rain erosion. The performance of a LEP system is assessed in an accelerated rain erosion test (RET) as a metric for industrial application, but these tests are expensive. Modelling methods are available to predict erosion, based on fundamental material properties, but there is a lack of validation. The Springer model (1976) is analysed in this work to assess it as a tool for using material fundamental properties to predict the time to failure in a rain erosion test. It has been applied, referenced and industry validated with important partial considerations. The method has been applied successfully for erosion damage by wear performance prediction when combined with prior material data from rain erosion test (RET), instead of obtaining it directly from fundamental properties measured separately as Springer proposed. The method also offers accurate predictions when coupled with modified numerical parameters obtained from experimental RET testing data. This research aims to understand the differences between the experimental data used by Springer and the current industry approach to rain erosion testing, and to determine how it may introduce inaccuracies into lifetime predictions of current LEP systems, since they are very different to those tested in the historic modelling validation. In this work, a review of the modelling is presented, allowing for the understanding of key issues of its computational implementation and the required experimental material characterisation. Modelling results are discussed for different original application issues and industry-related LEP configuration cases, offering the reader to interpret the limits of the performance prediction when considering the variation in material fundamental properties involved.

Achieving European climate neutrality by 2050 requires further efforts not only from the industry and society, but also from policymakers. The use of high-efficiency cogeneration facilities will help to reduce both primary energy consumption and CO2 emissions because of the increase in overall efficiency. Fuel cell-based cogeneration technologies are relevant solutions to these points for small- and microscale units. In this research, an innovative and new fuel cell-based cogeneration plant is studied, and its performance is compared with other cogeneration technologies to evaluate the potential reduction degree in energy consumption and CO2 emissions. Four energy consumption profile datasets have been generated from real consumption data of different dwellings located in the Mediterranean coast of Spain to perform numerical simulations in different energy scenarios according to the fuel used in the cogeneration. Results show that the fuel cell-based cogeneration systems reduce primary energy consumption and CO2 emissions in buildings, to a degree that depends on the heat-to-power ratio of the consumer. Primary energy consumption varies from 40% to 90% of the original primary energy consumption, when hydrogen is produced from natural gas reforming process, and from 5% to 40% of the original primary energy consumption if the cogeneration is fueled with hydrogen obtained from renewable energy sources. Similar reduction degrees are achieved in CO2 emissions.

Under droplet impingement, surface leading edge protection (LEP) coating materials for wind turbine blades develop high-rate transient pressure build-up and a subsequent relaxation in a range of strain rates. The stress-strain coating LEP behavior at a working frequency range depends on the specific LEP and on the material and operational conditions, as described in this research in a previous work. Wear fatigue failure analysis, based on the Springer model, requires coating and substrate speed of sound measurements as constant input material parameters. It considers a linear elastic response of the polymer subjected to drop impact loads, but does not account for the frequency dependent viscoelastic e ects for the materials involved. The model has been widely used and validated in the literature for di erent liquid impact erosion problems. In this work, it is shown the appropriate definition of the viscoelastic materials properties with ultrasonic techniques. It is broadly used for developing precise measurements of the speed of sound in thin coatings and laminates. It also allows accurately evaluating elastic moduli and assessing mechanical properties at the high frequencies of interest. In the current work, an investigation into various LEP coating application cases have been undertaken and related with the rain erosion durability factors due to suitable material impedance definition. The proposed numerical procedures to predict wear surface erosion have been evaluated in comparison with the rain erosion testing, in order to identify suitable coating and composite substrate combinations. LEP erosion performance at rain erosion testing (RET) technique is used widely in the wind industry as the key metric, in an e ort to assess the response of the varying material and operational parameters involved.

Top coating are usually moulded, painted or sprayed onto the wind blade Leading-Edge surface to prevent rain erosion due to transverse repeated droplet impacts. Wear fatigue failure analysis based on Springer model has been widely referenced and validated to quantitatively predict damage initiation. The model requires liquid, coating and substrate speed of sound measurements as constant input parameters to define analytically the shockwave progression due to their relative vibro-acoustic properties. The modelling assumes a pure elastic material behavior during the impact event. Recent coating technologies applied to prevent erosion are based on viscoelastic materials and develop high-rate transient pressure build-up and a subsequent relaxation in a range of strain rates. In order to analyze the erosion performance by using Springer model, appropriate impedance characterization for such viscoelastic materials is then required and represents the main objective of this work to avoid lack of accuracy. In the first part of this research, it is proposed a modelling methodology that allows one to evaluate the frequency dependent strain-stress behavior of the multilayer coating system under single droplet impingement. The computational tool ponders the operational conditions (impact velocity, droplet size, layer thickness, etc.) with the appropriate variable working frequency range for the speed of sound measurements. The second part of this research defines in a complementary paper, the ultrasonic testing characterization of di erent viscoelastic coatings and the methodology validation. The modelling framework is then used to identify suitable coating and substrate combinations due to their acoustic matching optimization and to analyze the anti-erosion performance of the coating protection system.

This work evaluates the use of structural aspects in the manufacture of drum shells based on their modal behavior. The drum shells are made of composite carbon fiber-reinforced epoxy (CFRE) due to the structural variables commonly used in the industry for the manufacture of these musical instruments. Musicians consider the shell of a membranophone to be responsible for the diferences in timbre between di erent instruments. Normally, this variation focuses attention on the mechanical characteristics of the material and on the overall thickness of the cylinder that forms the shell. Some manufacturers, especially those that use metals and composites, resort to low thicknesses, below 2 mm, which forces them to use structural reinforcements at the edges of the cylindrical shell to avoid deformations due to the tension generated by the membranes. As shown in this research work, these structural elements have great relevance within the acoustic behavior of the drum shell. Comparisons are made among the frequencies obtained for the di erent vibrational modes by using finite element simulations, establishing the length of the structural solution previously mentioned and the number of plies of composite laminate as design variables, starting from the characteristics of a real case constructed with CFRE and concluding with experimental validation. The range of study is limited to the values of the frequencies generated by the membranes. The results demonstrate that the use of di erent manufacturing variables can lead to savings in production costs without compromising the modal behavior of the shell.

Phase change materials (PCMs) can be used in refrigeration systems to redistribute the thermal load. The main advantages of the overall system are a more stable energy performance, energy savings, and the use of the off-peak electric tariff. This paper proposes, models, tests, and analyzes an experimental water vapor compression chiller connected to a PCM thermal energy storage (TES) tank that acts as an alternative heat sink. First, the transient model of the chiller-PCM system is proposed and validated through experimental data directly measured from a test bench where the PCM TES tank is connected to a vapor compression-based chiller. A maximum deviation of 1.2 C has been obtained between the numerical and experimental values of the PCM tank water outlet temperature. Then, the validated chiller-PCM system model is used to quantify (using the coeffcient of performance, COP) and to analyze its energy performance and its dependence on the ambient temperature. Moreover, electrical energy saving curves are calculated for different ambient temperature profiles, reaching values between 5% and 15% taking the experimental system without PCM as a baseline. Finally, the COP of the chiller-PCM system is calculated for di erent temperatures and use scenarios, and it is compared with the COP of a conventional aerothermal chiller to determine the switch ambient temperature values for which the former provides energy savings over the latter.

Composite materials are presented in a wide variety of industrial sectors as an alternative to traditionally used materials. In recent years, a new sector has increasingly used these kinds of materials: the manufacture of musical instruments. Resonances of di erent elements that make up the geometries of musical instruments are commonly used with the aim of enhancing aspects of the timbre. These are sensitive to the mechanical characteristics of the material, so it is important to guarantee the properties of the composite. To do this, it is not uncommon to use pre-impregnated fibers (prepregs) which allow fine control of final volumetric fractions of the composite. Autoclaving is a high-quality process used to guarantee the desired mechanical properties in a composite, reducing porosity and avoiding delamination, but significantly raising production costs. On the contrary, manufacture without autoclaving increases competitiveness by eliminating the costs associated with autoclave production. In this paper, di erences in dynamic behavior are evaluated under free conditions of di erent Carbon Fiber Reinforced Epoxy (CFRE) prepreg boards, processed by autoclave and out-of-autoclave. The results of the complex module are presented according to the frequency, quantifying the variations in the vibratory behavior of the material due to the change of processing.