The cost study for large wind turbine blades reviewed three blades of 30 meters, 50 meters, and 70 meters in length. Blade extreme wind design loads were estimated in accordance with IEC Class I recommendations. Structural analyses of three blade sizes were performed at representative spanwise stations assuming a stressed shell design approach and E-glass/vinylester laminate. A bill of materials was prepared for each of the three blade sizes using the laminate requirements prepared during the structural analysis effort. The labor requirements were prepared for twelve major manufacturing tasks. TPI Composites developed a conceptual design of the manufacturing facility for each of the three blade sizes, which was used for determining the cost of labor and overhead (capital equipment and facilities). Each of the three potential manufacturing facilities was sized to provide a constant annual rated power production (MW per year) of the blades it produced. The cost of the production tooling and overland transportation was also estimated. The results indicate that as blades get larger, materials become a greater proportion of total cost, while the percentage of labor cost is decreased. Transportation costs decreased as a percentage of total cost. The study also suggests that blade cost reduction efforts should focus on reducing material cost and lowering manufacturing labor, because cost reductions in those areas will have the strongest impact on overall blade cost.
An effort is underway at Sandia National Laboratories to develop a library of algorithms to search for potential interactions between surfaces represented by analytic and discretized topological entities. This effort is also developing algorithms to determine forces due to these interactions for transient dynamics applications. This document describes the Application Programming Interface (API) for the ACME (Algorithms for Contact in a Multiphysics Environment) library.
This report summarizes the purchasing and transportation activities of the Procurement and Logistics Management Center for Fiscal Year 2002. Activities for both the New Mexico and California locations are included.
The autonomic healing ability of an epoxy adhesive containing micro-encapsulated dicyclopentadiene (DCPD) was evaluated. The epoxy resin used was Epon 828 cured with either Versamid 140 or diethylenetriamine (DETA). Variables included total weight percent of microcapsules (MCs) and catalyst, as well as the catalyst to DCPD ratio. The degree of healing was determined by the fracture toughness before and after ''healing'' using double-cantilever beam analysis. It was found that the degree of self-healing was most directly related to the contact area (i.e. crack width) during healing. Temperature also played a significant role. Observed differences between the results of this study and those in literature are discussed.
A test method, the Tensile Brazil Nut Sandwich (TBNS) specimen, was developed to measure mixed-mode interfacial toughness of bonded materials. Interfacial toughness measured by this technique is compared to the interfacial toughness of thin film adhesive coatings using a nanoindentation technique. The interfacial toughness of solvent-cast and melt-spun adhesive thin films is compared and found to be similar. Finally, the Johnson-Kendall-Roberts (JKR) technique is used to evaluate the cleanliness of aluminum substrates.
Since initiating research on integration of distributed energy resources (DER) in 1999, the Consortium for Electric Reliability Technology Solutions (CERTS) has been actively assessing and reviewing existing DER test facilities for possible demonstrations of advanced DER system integration concepts. This report is a compendium of information collected by the CERTS team on DER test facilities during this period.
The ability for scientific simulation software to detect and recover from errors and failures of supporting hardware and software layers is becoming more important due to the pressure to shift from large, specialized multi-million dollar ASCI computing platforms to smaller, less expensive interconnected machines consisting of off-the-shelf hardware. As evidenced by the CPlant{trademark} experiences, fault tolerance can be necessary even on such a homogeneous system and may also prove useful in the next generation of ASCI platforms. This report describes a research effort intended to study, implement, and test the feasibility of various fault tolerance mechanisms controlled at the simulation code level. Errors and failures would be detected by underlying software layers, communicated to the application through a convenient interface, and then handled by the simulation code itself. Targeted faults included corrupt communication messages, processor node dropouts, and unacceptable slowdown of service from processing nodes. Recovery techniques such as re-sending communication messages and dynamic reallocation of failing processor nodes were considered. However, most fault tolerance mechanisms rely on underlying software layers which were discovered to be lacking to such a degree that mechanisms at the application level could not be implemented. This research effort has been postponed and shifted to these supporting layers.
A continuously operating prototype chemical weapons sensor system based on the {mu}ChemLab{trademark} technology was installed in the San Francisco International Airport in late June 2002. This prototype was assembled in a National Electric Manufacturers Association (NEMA) enclosure and controlled by a personal computer collocated with it. Data from the prototype was downloaded regularly and periodic calibration tests were performed through modem-operated control. The instrument was installed just downstream of the return air fans in the return air plenum of a high-use area of a boarding area. A CW Sentry, manufactured by Microsensor Systems, was installed alongside the {mu}ChemLab unit and results from its operation are reported elsewhere. Tests began on June 26, 2002 and concluded on October 16, 2002. This report will discuss the performance of the prototype during the continuous testing period. Over 70,000 test cycles were performed during this period. Data from this first field emplacement have indicated several areas where engineering improvements can be made for future field emplacement.
When several kA pulses are passed through single, fine 25 {micro}m diameter wires, the wire material heats, melts, vaporizes and expands. Initially the voltage across--and current through--a wire increases until an abrupt voltage collapse occurs. After this collapse the voltage remains at a relative small value while the current continues to increase. In order to understand how this early time behavior may affect the subsequent implosion, small-scale experiments at Cornell University's Laboratory of Plasma Studies concentrated on diagnosing expanding single wire dynamics. X-ray backlighting, interferometry and Schlieren imaging as well as current and voltage measurements have been employed. The voltage collapse has been attributed to the formation of plasma around the wire and a transfer of current to this highly conducting coronal plasma. Interferometry has confirmed the plasma formation, but the current transfer has only been postulated. Subsequent experiments on the Z-Facility at Sandia National Laboratories have produced impressive x-ray yields etc.
The research discussed in this report was conceived during our earlier attempts to simulate breakdown across a dielectric surface using a Monte Carlo approach. While cataloguing the various ways that a dielectric surface could affect the breakdown process, we found that one obvious effect--photoemission from the surface--had been ignored. Initially, we felt that inclusion of this effect could have a major impact on how an ionization front propagates across a surface because of the following argument chain: (1) The photon energy required to release electrons from a surface via photoemission is less than the photon energy required to ionize gas molecules directly. (2) The mean free path of a photon in gas is longer for low-energy photons than for high-energy photons. (3) Photoionization is a major effect in advancing the ionization front for breakdown in gas without a surface, therefore, we know that even high-energy photons can be released from the head of a streamer and propagate some distance through the gas. Our hypothesis, therefore, was that photons with energies near the threshold of photoemission could travel further in front of the streamer before being absorbed than higher-energy photons needed for photoionization, yet the lower-energy photons, with the help of the surface, could still create seed electrons for new avalanches. Thus, the streamer would advance more rapidly next to a surface than in gas alone. Additionally, the photoemission from the surface would add to the electrons in the avalanche and cause the avalanche to grow faster. After some study, however, we are forced to conclude that although photoemission does contribute to avalanche growth at fields near breakdown threshold, secondary electron emission causes electrons to stick to the surface and cancels out the growth due to photoemission. This conclusion assumes a discharge that occurs over a short period of time so that charging of the surface, which could alter its secondary electron emission characteristics, does not occur. This report documents the numerical work we did on investigating this effect and the experimental work we did on pre-breakdown phenomena in gas.