Plasma treatment of giant wind power rotors—efficient, automatic, reproducible
Wind power systems convert the kinetic energy of the wind directly into electrical energy. In windy locations, these systems make a significant contribution to energy production. Besides the construction shape, the efficiency of such a wind power system also depends in particular on its size. Current systems are built for production of up to 10 megawatts and with blade profile lengths of up to 90 meters.
The technology required for manufacturing and constructing a wind power system is similar in many ways to that of aircraft construction. The cross section and the mechanical stability, as well as the air flow around the blade profile, are based on the design of aircraft wings. The circumferential speeds, which are especially high at the blade tips, create extreme materials stress—like air turbulence in the ultrasound range or an accumulation of ice—just as in air travel.
Special requirements for the construction of modern wind turbine rotors
The design and manufacture of new-generation wind turbine rotors impose extremely high technical requirements, which are essential to ensure aerodynamic efficiency, durability, and operational safety:
- Lightweight materials to reduce rotating masses
- High structural strength, even under extreme dynamic loads
- Smooth, turbulence-free surfaces to optimize airflow
- High surface quality and stability for consistent performance over time
These requirements can only be met by using fiber-reinforced composite materials such as GRP (Glass Reinforced Plastic) and CRP/CFRP (Carbon Reinforced Plastic). Similar to the aeronautical industry, atmospheric plasma treatment is also a highly effective process solution in the wind power sector, allowing for reliable, repeatable surface preparation that can be perfectly integrated into modern rotor production processes.
Painting rotor blades for wind turbines: Secure paint bonding on CRP after plasma activation
The state of the art in surface pretreatment for CRP rotor blades is mechanical roughening and cleaning with solvents. This process leads to results that are far from uniform, it is environmentally hazardous, and it requires a lot of manual effort.
Typical for CRP components is the different heat conductivity between the fibers themselves and the fiber matrix. Treatments that apply higher temperatures, such as in flaming or laser treatment, can destroy the characteristics of the composite surface.
With Openair-Plasma® technology, plasma treatment of even large-scale components is possible without problems. This opens up new possibilities for manufacturing rotor blades made of CRP for wind turbines.
An Openair-Plasma® treatment, especially with the plasma jet RD2005, provides uniform surface activation without the application of heat. The result of such plasma activation is improved paint adhesion with uniform paint flow for friction-free and high-efficiency use of the rotor blades.
PT-Release plasma coating: demolding of fiber composite components without release agents (CRP and GRP)
Generally, rotor blades are manufactured as half shells in a laminating process with CRP and GRP mixed construction. Application of a separating layer in the mold is indispensable so the finished component can later be removed from the mold. Conventionally, this is achieved with chemical release agents and has to be applied again after each demolding. In the demolding process, traces of this separating layer are transferred to the component. These must be removed without residue before the subsequent painting.
Simple and efficient extraction of CRP and GRP composites with PT-Release plasma coating
PT-Release plasma coating significantly optimizes the extraction processes of elements in CRP and GRP reinforced plastic materials, improving efficiency, surface quality, and sustainability of the production process:
- Coating of molds prior to lamination using the PlasmaPlus® process, applied automatically and robotically.
- Precise control of the thickness of the polymer coating for uniform and repeatable coverage across the entire surface of the mold.
- High functional resistance: with a single plasma coating, up to approximately 50 molding cycles can be performed, reducing operating times and costs.
- Final cleaning with Openair-Plasma®: after component extraction and before painting, any residues are completely broken down and removed, ensuring clean surfaces ready for subsequent processes.
Thanks to these features, the PT-Release system developed by Plasmatreat enables more reliable, automated, and environmentally friendly production of composite components, ideal for the wind energy sector and high-performance industrial applications.
PlasmaPlus® functional coating of rotor blades: corrosion protection and better aerodynamics for more yield
The laws of aerodynamics apply just as much to the efficiency of rotor blades in wind power systems as they do to aircraft, where air friction on the surface of the wings and on the fuselage determines the efficiency of the aircraft. Microstructuring and the application of very hydrophobic and textured surfaces reduce the friction resistance. One model for this is the way the dolphin moves in water (dolphin skin).
