Enhancing wind turbine blade protection: Solid particle erosion resistant ceramic oxides-reinforced epoxy coatings

In recent days, it is crucial for the globe to shift fossil fuel energies to renewable energies such as hydroelectric, wind, solar, tidal, geothermal, etc. to mitigate global warming issues. Wind energy has been regarded as one of the renewable energy sources to rely on in the future. In this aspect, wind turbine blade maintenance is quite a challenge in tropical areas like India. One of the main reasons why wind turbine blades get damaged and produce less energy is solid particle erosion. In the present work, epoxy nanocomposite coatings reinforced with Al2O3, ZrO2, and CeO2 nanoparticle fillers have been applied on glass fiber reinforced polymer (GFRP) substrates using a simple spray coating method. These nanoparticles have been prepared in-house by solution combustion synthesis (SCS) route using urea, glycine, and oxalyl dihydrazide fuels, respectively. X-ray diffraction, field emission scanning electron microscopy, Fourier transform infrared spectroscopy, and X-ray photoelectron spectroscopy have been used to characterize the materials and coatings. Epoxy coatings with different Al2O3, ZrO2, and CeO2 nanoparticle concentrations have been subjected to solid particle erosion resistance tests at impinging angles of 30 degrees, 60 degrees, and 90 degrees. ZrO2 and CeO2 nanoparticle-reinforced epoxy coatings show much better resistance to solid particle erosion than Al2O3-reinforced coatings. Estimated average erosion rates are 17 and 11.3 x 10-3 mm3 g- 1 , respectively, for epoxy coatings with 20 and 40 wt% ZrO2 nanoparticles. However, GFRP substrate and neat epoxy (EP) coating show much higher erosion rates with respect to nanoparticles-reinforced epoxy coatings. To ascertain a correlation between H3/E2 and the solid particle erosion rates of the coatings, nanoindentation tests have been carried out. Tensile strength and initial modulus of all the coatings are found to be directly proportional to the average erosion rates, whereas, elongation at break shows an inverse relationship with the average erosion rate. This correlation of mechanical properties with solid particle erosion performance can play a critical role in the development of realistic simulation of protective coatings for wind turbine blades.