From lab to blade: Scalable validation of a durable silicone-epoxy icephobic coating for wind turbine blades

Ice accumulation on large rotor blades poses a major operational challenge by reducing energy output and threatening structural integrity. Active de-icing systems are effective but limited by high energy demand, delayed response, and elevated costs. Passive solutions, particularly silicone–epoxy icephobic coatings, offer advantages such as low surface energy, durability, and reduced ice adhesion, enabling earlier shedding. However, most studies remain confined to laboratory scale without validation under realistic conditions. This study addresses this gap by evaluating a durable commercial silicone–epoxy coating at both laboratory and large scales. Laboratory characterization following ISO/TS 19392 standards showed a water contact angle of 100° ± 2.2°, mechanical abrasion resistance of 72 ± 2.1 mg/1000, and ice adhesion strength below 20 kPa even after 50 icing/de-icing cycles, confirming strong icephobic performance. Push-off and CAT tests with short ice specimens predominantly exhibited adhesion-dominated detachment, favorable for anti-icing. In contrast, spinning rotor blade and field trials with more realistic accretions often resulted in cohesive or mixed failures, leaving residual ice. These results indicate that adhesion-focused behavior observed in small-scale tests correlates with the more complex detachment dynamics at larger scales, demonstrating how laboratory measurements can predict expected performance and benefits under operational conditions. Overall, the study demonstrates the value of integrating quantitative material properties with multi-scale adhesion testing to guide the design of ice-mitigation coatings. In practice, the coating’s role is best understood as part of broader ice protection strategies, where variables such as rotation speed during accretion strongly influence shedding. • Comprehensive multi-scale evaluation of an icephobic silicone–epoxy coating, from laboratory tests to larger-scale spinning rotor blade validation. • Demonstrates anti-icing performance under realistic operating conditions. • Investigates the critical influence of chemical composition on ice adhesion and coating effectiveness. • Reveals interfacial mechanics and scale effects as key factors in ice adhesion behavior. • Provides guidance for designing and validating other practical anti-icing coatings for real rotor blades.