Fatigue damage mechanics approach to predict the end of incubation and breakthrough of leading edge protection coatings for wind turbine blades

The state of the surface of the leading edge of wind turbine blades is important for optimal aerodynamic performance. Rain erosion leads to damage and roughness on the leading edge. In this study, we present an approach to predict the level of roughness of the leading edge based on fatigue damage accumulation due to impacts of rain droplets. Impact simulations of droplets on the protective coating layer are coupled with rain erosion test data and fatigue S-N curves. Fatigue damage values are then related to surface roughness levels. An approach to extract S-N curve parameters from a rain erosion test and then make predictions for other coatings based only on the output of impact simulations is presented and tested against test data. Both the end of incubation and coating breakthrough times are predicted with this approach. Stress, strain and energy density values were used as fatigue damage indicators and the respective predictions were compared to each other. It was found that the maximum principal strain gave the best predictions and matched the experimental trends. • Surface damage levels of protective coatings are predicted with a fatigue model. • Simulations and test data were used to obtain S-N curves for relevant strain rates. • The incubation and breakthrough times were predicted for other coatings. • The peak maximum principal strains were found to provide the best predictions.