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Net Shape Fabricated Low Cost MHK Pass-Through the Hub Turbine Blades with Integrated Health Management Technology

Published by ARL Penn State | Department of Energy | Metadata Last Checked: January 27, 2026 | Last Modified: 2021-05-17T16:25:03Z
The primary objective of this project is to develop a three-blade MHK rotor with low manufacturing and maintenance costs. The proposed program will design, fabricate and test a novel half-scale low cost, net shape fabricated single piece three-blade MHK rotor with integrated health management technology to demonstrate significant Capital Expenditures (CAPEX) and Operational Expenditures (OPEX) cost reductions due to the novel design and manufacturing process. The proposed project is divided into three major tasks: Task 1: Single Piece Three-blade Kinetic Hydropower System (KHPS) Rotor Full-Scale and Half-Scale Design; Task 2: Composite Manufacturing Trials and Half-Scale Prototype Rotor Fabrication; and Task 3: Material Characterization and Half-Scale Prototype Test and Evaluation. These three tasks include design and analysis of full-scale and half-scale three-blade rotor prototypes using computational fluid dynamics (CFD) and finite-element analysis (FEA), demonstration of a novel half-scale net shape fabrication process, determination of a fatigue threshold composite strain allowable, three-blade rotor mold design, manufacture of half-scale rotor clam shell mold, three-blade rotor test fixture design and fabrication, development of final manufacturing and test plans, manufacture of the half-scale net shape composite single blade and three-blade prototypes, and test and evaluation of the half-scale rotor.

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Complete Metadata
@type dcat:Dataset
accessLevel public
bureauCode 
                                            [
  "019:20"
]
contactPoint 
                                            {
  "fn": "Kevin Koudela",
  "@type": "vcard:Contact",
  "hasEmail": "mailto:klk121@arl.psu.edu"
}
dataQuality 
                                            true
description The primary objective of this project is to develop a three-blade MHK rotor with low manufacturing and maintenance costs. The proposed program will design, fabricate and test a novel half-scale low cost, net shape fabricated single piece three-blade MHK rotor with integrated health management technology to demonstrate significant Capital Expenditures (CAPEX) and Operational Expenditures (OPEX) cost reductions due to the novel design and manufacturing process. The proposed project is divided into three major tasks: Task 1: Single Piece Three-blade Kinetic Hydropower System (KHPS) Rotor Full-Scale and Half-Scale Design; Task 2: Composite Manufacturing Trials and Half-Scale Prototype Rotor Fabrication; and Task 3: Material Characterization and Half-Scale Prototype Test and Evaluation. These three tasks include design and analysis of full-scale and half-scale three-blade rotor prototypes using computational fluid dynamics (CFD) and finite-element analysis (FEA), demonstration of a novel half-scale net shape fabrication process, determination of a fatigue threshold composite strain allowable, three-blade rotor mold design, manufacture of half-scale rotor clam shell mold, three-blade rotor test fixture design and fabrication, development of final manufacturing and test plans, manufacture of the half-scale net shape composite single blade and three-blade prototypes, and test and evaluation of the half-scale rotor.
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DOI 10.15473/1643941
identifier https://data.openei.org/submissions/7978
issued 2016-02-09T07:00:00Z
keyword 
                                            [
  "ADV",
  "CAD",
  "CAPEX",
  "CEC",
  "CFD",
  "Composite Materials",
  "FAST",
  "FEA",
  "Gen5d",
  "Hydrokinetic",
  "KHPS",
  "Kinetic Hydropower System",
  "Net Shape Fabrication",
  "OPEX",
  "OVER-REL",
  "RITE",
  "Test and Evaluation",
  "Threshold Fatigue",
  "VP",
  "Verdant Power",
  "as-fabricated",
  "axial flow turbine",
  "economics",
  "fabrication",
  "fatigue test",
  "flow",
  "health management",
  "modeling",
  "rotor",
  "simulation",
  "steady-state",
  "strain",
  "stress",
  "three-blade",
  "transient",
  "visualization"
]
landingPage https://mhkdr.openei.org/submissions/324
license https://creativecommons.org/licenses/by/4.0/
modified 2021-05-17T16:25:03Z
programCode 
                                            [
  "019:009"
]
projectLead Yana Shininger
projectNumber EE0007176
projectTitle EE0007176.000 Net Shape Fabricated Low Cost MHK Pass-Through the Hub Turbine Blades with Integrated Health Management Technology
publisher 
                                            {
  "name": "ARL Penn State",
  "@type": "org:Organization"
}
spatial 
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title Net Shape Fabricated Low Cost MHK Pass-Through the Hub Turbine Blades with Integrated Health Management Technology

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