Effects and Damage Mechanisms of Polytetrafluoroethylene on Wear and Rain Erosion Resistance of Polyurethane Coatings for Wind Turbine Blades

doi:10.11902/1005.4537.2024.228

Journal of Chinese Society for Corrosion and protection

2025, Vol. 45

Issue (4): 881-893 DOI: 10.11902/1005.4537.2024.228

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Effects and Damage Mechanisms of Polytetrafluoroethylene on Wear and Rain Erosion Resistance of Polyurethane Coatings for Wind Turbine Blades

ZHENG Zilong¹, SUN Haijing¹(

), XUE Weihai², CHEN Guoliang¹, ZHOU Xin¹, WANG Jinjun³, DUAN Deli², SUN Jie¹

1 School of Environmental and Chemical Engineering, Shenyang Ligong University, Shenyang 110159, China
2 Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China
3 Avic Shenyang Aircraft Corporation, Shenyang 110034, China

Cite this article:

ZHENG Zilong, SUN Haijing, XUE Weihai, CHEN Guoliang, ZHOU Xin, WANG Jinjun, DUAN Deli, SUN Jie. Effects and Damage Mechanisms of Polytetrafluoroethylene on Wear and Rain Erosion Resistance of Polyurethane Coatings for Wind Turbine Blades. Journal of Chinese Society for Corrosion and protection, 2025, 45(4): 881-893.

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Abstract

Under actual operating conditions of wind turbine blades, rain erosion causes extremely severe damage to the coatings on wind turbine blades. Polytetrafluoroethylene (PTFE) is often used to enhance the wear resistance, hydrophobicity, anti-icing, and anti-sand erosion properties of coatings. However, research on the impact of PTFE on the rain erosion resistance of coatings is lacking. Therefore, this study investigates the impact of PTFE on the wear resistance and rain erosion resistance of polyurethane (PU) protective coatings on wind turbine blades, as well as the damage mechanisms of these coatings. This study prepared PU coatings with different PTFE contents, tested the basic properties of the PU coatings. Additionally, the study explored the impact of varying amounts of PTFE on the erosion resistance of PU coatings under two different erosion conditions using a high-speed liquid drop erosion device. The study used a profilometer to characterize the macroscopic morphology of the coatings and measure the volume loss. It employed scanning electron microscopy (SEM) to observe the microstructure of the coatings, and combined with energy-dispersive X-ray spectroscopy (EDS) to analyze how PTFE influences the wear resistance and rain erosion resistance of the coatings. The wear resistance tests showed that the coating's wear resistance improved with increasing PTFE content, with the best performance observed at a mass fraction of 5%. The liquid drop erosion tests revealed that, compared to coatings without PTFE, coatings with 1%-2%PTFE exhibited little change in erosion resistance. However, coatings with 3%-5%PTFE experienced a sharp decrease in erosion resistance. SEM and EDS analysis indicated that fluorine (F) elements accumulated at specific locations on the coating surface, leading to the formation of defects such as pinholes, peeling, and delamination pits. Moreover, higher PTFE content in the coating correlated with an increased presence of surface defects.

Key words: PTFE PU coating rain erosion resistance wear resistance fluorine aggregation

Received: 27 July 2024 32134.14.1005.4537.2024.228

ZTFLH:

TG174

Fund: Basic Scientific Research Project of Department of Education of Liaoning Province(LJKMZ20220598);Special Funds for Basic Research Business Expenses of Provincial Undergraduate Universities in Liaoning Province(SYLUGXRC26)

Corresponding Authors: SUN Haijing, E-mail: hjsun@sylu.edu.cn

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	ZHENG Zilong
	SUN Haijing
	XUE Weihai
	CHEN Guoliang
	ZHOU Xin
	WANG Jinjun
	DUAN Deli
	SUN Jie

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https://www.jcscp.org/EN/10.11902/1005.4537.2024.228 OR https://www.jcscp.org/EN/Y2025/V45/I4/881

Table 1 Basic formulation of PU coating for wind turbine blades

Fig.1 Sample preparation and testing procedure

Fig.2 Schematic diagram of high-speed droplet erosion device

Fig.3 Three-dimensional actual shapes and corresponding erosion schematics of atomizing nozzle (a) and jet nozzle (b)

Table 2 Requirements and test standards of basic performances of wind turbine blade coatings

Table 3 Performance test results of PU coatings with different contents of PTFE

Fig.4 Macroscopic morphologies of PU coatings containing 0 (a), 1% (b), 2% (c), 3% (d) and 5% (e) PTFE

Fig.5 Variations of mass losses of PU coatings containing different contents of PTFE with wear cycle

Fig.6 Volume loss changes of PU coatings containing different contents of PTFE during atomization erosion at 8.3 MPa for 2 h

Fig.7 Surface morphologies of PU coatings containing 0 (a), 1% (b), 2% (c), 3% (d) and 5% (e) PTFE after atomization erosion for 60 min (a1-e1), 90 min (a2-e2) and 120 min (a3-e3) test time

Fig.8 Volume losses of PU coatings containing different contents of PTFE after atomization erosion for 30 min at pipeline pressures of 8.3 MPa and 10.3 MPa

Fig.9 Surface morphologies of PU coatings containing 0 (a), 1% (b), 2% (c), 3% (d) and 5% (e) PTFE after atomization erosion for 30 min at pipeline pressures of 8.3 MPa (a1-e1) and 10.3 MPa (a2-e2)

Fig.10 Volume loss variations of PU coatings containing different contents of PTFE during jet erosion for 30 min at 6.9 MPa and 30° attack angle

Fig.11 Surface morphologies of PU coatings containing 0 (a), 1% (b), 2% (c), 3% (d) and 5% (e) PTFE after jet erosion at 6.9 MPa and 30° attack angle for 5 min (a1-e1), 20 min (a2-e2) and 30 min (a3-e3) test time

Fig.12 Surface morphology of PU-5% coating (a), and enlarged image of the marked region in Fig.12a and corresponding EDS analysis results (b)

Fig.13 Damage mechanisms of PU-PTFE coatings under the conditions of atomization erosion (a), jet erosion (b) and wear test (c)

Table 4 Chemical compositions of PU coatings with different contents of PTFE (mass fraction / %)

Fig.14 SEM images and EDS analysis results of original PU coatings with different contents of PTFE: (a) PU-0, (b) PU-1%, (c) PU-2%, (d) PU-3%, (e) PU-5%

Fig.15 SEM images and EDS element mappings of PU coatings with different contents of PTFE after atomization erosion for 2 h: (a) PU-0, (b) PU-1%, (c) PU-2%, (d) PU-3%, (e) PU-5%

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