Improving tribocorrosion protection of offshore structures using electrodeposited Multilayer Metal Matrix Nano Composite (MMMNC) coatings

The leading edge of offshore wind turbines is currently protected by soft elastomer tapes, due to their low cost and ease of application during blade manufacture. However, the life span of these tapes is around 10 years and therefore need replacing within the 25 year lifetime of the turbine. There is also significant value lost in-service, as blade erosion can result in up to a 5% power loss each year, according to industry experts. Replacing such tapes, offshore, on assembled turbines is inherently problematic. Industry desires a full-life solution to protecting wind turbine blades from leading edge erosion. Such a solution needs to be erosion resistant, corrosion resistant and damp vibrations resulting from the water hammer effect from impinging spray.

Metal matrix nanocomposite can be produced by electrodeposition of metals from plating baths containing a dispersion of inert nanoparticles. A novel method, pulse reverse plating (PRP), has been developed at Leicester to produce these. To date this method has been successfully applied to produce Metal Matrix Nano Composite (MMNC) coatings. The proposed project will extend this technique to allow the production of Multilayer-MMNC coatings that may be applied to offshore structures such as wind turbine blades.

Long-term (full-life) protection of wind turbines and offshore structures remains a key development priority, due to the current costs involved with maintenance and refurbishment of offshore systems. The proposed project represents an opportunity to develop a proof of concept for a unique coating system and coating process that would resolve these problems and therefore deliver significant economic benefits to industry. The researcher will additionally benefit from engaging with the industrial research partner, TWI Ltd.