Limitations of Standard Rain Erosion Tests for Wind Turbine Leading Edge Protection Evaluation

Blade leading edge erosion (LEE) is a persistent challenge in the wind industry, resulting in reduced aerodynamic efficiency and increased maintenance costs, with an estimated total expense of GBP 1.3M over a 25-year turbine lifetime. To mitigate these effects, leading edge protection (LEP) systems are widely used, but their real-world performance often falls short of predictions based on the standard rain erosion test (RET). This study investigates the limitations of current RET practices, which are designed to accelerate testing but fail to replicate the diverse environmental conditions experienced by wind turbines. Two LEPs with contrasting viscoelastic properties were tested using a novel design of experiments (DoEs) approach. The study explored the droplet impact frequency, combination and sequencing of high or low rainfall intensities, recovery during the inspection period and droplet size effects on erosion behaviour, to uncover significant differences in material performance compared to standard RET conditions. Results, supported by dynamic mechanical analysis (DMA), indicated that the chosen LEPs undergo a transition between elastic and brittle failure modes at a critical impact frequency, influenced by the viscoelastic properties of the material. Importantly, the findings emphasise the need for revised testing protocols across a range of parameters that incorporate realistic environmental conditions to improve the predictability of LEP performance.