Structural Evaluation of a Horizontal Axis Wind Turbine Composite Blade Using a Monitored Testing Bench

Articles in Press

Document Type : Research Article

Authors

1 LRPSI, Polydisciplinary Faculty, Sultan Moulay Slimane University, Beni Mellal, Morocco

2 EMISys Research Team, E3S Research Center, Mohammadia School of Engineers, Mohammed V University in Rabat, Morocco

3 Multidisciplinary Laboratory of Exact and Applied Sciences, Superior School of Technology, Fkih Ben Saleh, Morocco

4 Alkhalil Center, Private laboratory of Engineering Energy, Beni Mellal, Morocco

Abstract

This study presents a comprehensive evaluation of the mechanical performance of a segmented 3D-printed composite prototype blade. To assess its stiffness characteristics, the blade was subjected to systematically applied load levels in the flapwise direction. The experimental campaign enabled detailed characterization of the blade's stiffness and the initiation and evolution of damage as a function of applied loading and the number of fatigue cycles. A statistical analysis was performed to quantify the uncertainty and repeatability of the measured results.



A specialized test bench was designed and constructed to accommodate fatigue testing of blades measuring 712~mm in length. The blade was subjected to controlled cyclic loading while its mechanical response was continuously monitored using a high-resolution imaging system. The collected data revealed a significant increase in total deformation energy of 77.5\%, particularly near the root (point~1), and a corresponding decrease in stiffness of 77\% after cyclic loading in the flapwise direction.



These results provide critical insights into the blade's structural health and dynamic response during service and have informed improvements in the manufacturing process to ensure that the final products meet stringent reliability and safety standards under severe operating conditions. Uncertainty and repeatability were further evaluated by testing two blades with identical geometry and material properties, demonstrating that the derived results were accurate within an error margin not exceeding 10%.

Keywords

Main Subjects

Mechanics of Advanced Composite Structures

Articles in Press, Accepted Manuscript
Available Online from 22 April 2026

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