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Standing hundreds of feet above ground, wind turbines — like tall trees, buildings, and telephone poles — are easy targets for lightning. Just by virtue of their height, they will get struck.

Lightning protection systems exist for conventional wind turbine blades. But protection was needed for blades made from a new type of material—thermoplastic resin composites — and manufactured using an innovative thermal (heat-based) welding process developed by scientists at the National Renewable Energy Laboratory (NREL).

Thermoplastic materials, like plastic bottles, can be more easily recycled than the thermoset materials commonly used to make wind turbine blades today. While thermoset materials need to be heated to cure, thermoplastics cure at room temperature, which reduces both blade manufacturing times and costs.

NREL’s patent-pending thermal welding process for thermoplastic blades allows for these benefits and even adds to them by replacing the adhesives currently used to bond blade components. The use of welding instead of adhesives eliminates the downsides of added weight and cracking potential.

While thermal welding offers benefits, it also requires adding within the blade a metal heating element — which can attract lightning. As a result, a team of NREL researchers led by Robynne Murray and supported by General Electric (GE) and LM Wind Power (a GE subsidiary) invented a new lightning protection system to keep the novel thermoplastic materials safe.

Thermal Welding Goes for the Patent

In 2018, Robynne Murray, an NREL engineer who specializes in advanced manufacturing methods and materials for wind turbine blades, received a two-year NREL Laboratory Directed Research and Development award to research thermal welding of thermoplastic wind turbine blades.

To make one of these new blades, a vacuum pulls liquid thermoplastic resin into the fiberglass material that is placed in a mold for each blade half. To weld the blade halves together, scientists sandwich a conductive material — such as an expanded metal foil or carbon fiber — between the two blade components and attach a wire to a power source. This creates the heating element. As current flows through this element, the thermoplastic materials melt. Once they are melted, the current is switched off and the bond cools under pressure.

Murray’s research demonstrated that thermal welding can effectively bond thermoplastic wind turbine blade segments. She submitted a patent application on the process in 2018.

A Pathway for Lightning

Thermal welding works. But it leaves the conductive heating element, which can attract lightning, within the blade.

“Thermal welding is an important step in the progression of commercializing thermoplastic materials for wind blades, but what happens when lightning strikes a thermal-welded blade? That was an unanswered question and a big concern,” Murray said. “For thermal welding of thermoplastic blades to become commercially viable, it is critical that the conductive bond lines be protected from a lightning strike.”

Partnering with GE and LM Wind Power, Murray submitted a research proposal to the U.S. Department of Energy’s (DOE’s) Technology Commercialization Fund (TCF). TCF awards are designed to advance technology developed at national laboratories toward commercialization while encouraging lab-industry partnerships.

“With our partnership with GE, a company that can take the thermal welding process to commercialization, our TCF was a strong proposal,” Murray said. “Together, we wanted to determine whether we can protect these blades from lightning strikes and eliminate a big reason to stop us from using the technology.”

In 2019, the team received $150,000 in TCF funding; GE matched that amount.

The research partners set up shop in NREL’s Composites Manufacturing Education and Technology (CoMET) Facility to demonstrate that thermoplastic blades sealed using thermal welding can be protected from lightning strikes.

The team infused an expanded aluminum foil into the blade skin to divert lightning current away from the metal heating elements. They then completed experiments using a simulation that showed that a lightning strike would not cause blade failure with the lightning protection system in place.

Lightning protection To build a lightning shield for their innovative wind turbine blade design, the research team added an expanded aluminum foil layer (left) and a carbon-fiber heating element at the bond lines (right) to enable thermal welding of the blade parts. Photos by NREL

Lightning strike.  Researchers used a lightning simulation technique to see where lightning might strike the blade and found that, typically, electricity hit the tip of the blade or one of the edges—but not inside the blade or welded seams where it could cause excessive damage. Photo by NREL

Physical damage tests — which subject the blades to high currents of electricity — demonstrated that about 80% of the electric current went into the expanded aluminum foil layer for lightning protection and not into the blade skin. The carbon fiber beneath the damaged area of the tip was also unscathed.

The research confirmed the design can protect wind turbine blades against failure caused by lightning strikes.

“LM Wind Power and GE Research were excited to work with NREL on the development of this technology and appreciated the support by DOE’s Technology Commercialization Fund. Thermal welding technology for thermoplastic, recyclable wind blades offers a significant opportunity to impact the sustainability and carbon footprint of wind blade structures,” said James Martin, director of blade platform deployment for LM Wind Power. “NREL’s focus on mitigating the lightning damage risks associated with the electrically conductive elements in the welded bond is a key challenge to be overcome, and their work has helped mature the technology toward potential commercialization.”

Still More Questions To Answer

The project has already delivered two strikes against lightning. Murray’s work developing a market-ready thermal welding system, however, is still at bat.

“We answered the question about lightning. But there are more questions to answer and more work to be done,” Murray said. “The next step for us is to do structural validation of thermally welded blade bond lines and blade tip segments. I hope we can do this in the next year or so.”

Read more about this project in Wind Engineering.

Article courtesy of NREL.



 


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Fintechs like Block and PayPal are battling like never before to be your all-in-one online bank

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Fintechs like Block and PayPal are battling like never before to be your all-in-one online bank

Jack Dorsey, co-founder of Twitter Inc., speaks during the Bitcoin 2021 conference in Miami, Florida, U.S., on Friday, June 4, 2021.

Eva Marie Uzcategui | Bloomberg | Getty Images

Jack Dorsey’s Block got started as Square, offering small businesses a simple way to accept payments via smartphone. Affirm began as an online lender, giving consumers more affordable credit options for retail purchases. PayPal upended finance more than 25 years ago by letting businesses accept online payments.

The three fintechs, which were each launched by tech luminaries in different eras of Silicon Valley history, are increasingly converging as they seek to become virtual all-in-one banks. In their latest earnings reports this month, their lofty ambitions became more clear than ever.

Block was the last of the three to report, and the high-level numbers were troubling. Earnings and revenue missed estimates, sending the stock down 18%, its steepest drop in five years. But to hear Dorsey discuss the results, Block is successfully implementing a strategy of offering consumers the ability to pay businesses by smartphone, send money to friends through Cash App, and access credit and debit services while also getting more ways to invest in bitcoin.

In 2024, we expanded Square from a payments tool into a full commerce platform, enhanced Cash App’s financial services offerings, and restructured our organization,” Dorsey said on Block’s earnings call on Thursday after the bell.

Block and an expanding roster of fintech rivals have all come to see that their moats aren’t strong enough in their core markets to keep the competition away, and that the path to growth is through a diverse set of financial services traditionally offered by banks. They’re playing to an audience of digital-first consumers who either didn’t grow up using a brick-and-mortar bank or realized at an early age that they had no need to ever set foot in a physical branch, or to meet with a loan officer or customer service rep.

“Longer term, we see a significant opportunity to grow actives, particularly among that digital-native audience like Millennial and Gen Z,” Block CFO Amrita Ahuja said on the earnings call.

Block shares drop after reporting earnings and revenue miss

As part of its expansion, Block has encroached on Affirm’s turf, with an increasing focus on buy now, pay later (BNPL) offerings that it picked up in its $29 billion purchase of Afterpay, which closed in early 2022. Block’s market share in BNPL increased by one point to 19%, while Affirm held its position at 17%, according to a recent report from Mizuho. Both companies are outperforming Klarna in BNPL, the report said.

Block’s BNPL play is now tied into Cash App, with an integration activated this week that gives users another way to make purchases through a single app. With Cash App monthly active users stagnating at 57 million for the last few quarters, the company is focused on engagement rather than rapid user acquisition.

“We think that there is significant opportunity for growth longer term, but there are some deliberate decisions we’ve made as part of our banker-based strategy in the near term” that have kept user numbers from increasing, Ahuja said. “This is a part of our continuous enhancements to drive healthy customer engagement as we bank our base.”

Compared to Block, Wall Street had a very different reaction to Affirm’s earnings earlier this month, pushing the stock up 22% after the company’s results sailed past estimates.

Affirm founder and CEO Max Levchin, who was previously a co-founder of PayPal, built his company with the promise of giving consumers lower-cost and easy-to-tap intstallment loans for purchases like electronics, jewelry and travel.

The BNPL battlefront

Watch CNBC's full interview with PayPal CEO Alex Chriss

Under the leadership of CEO Alex Chriss, who took over the company in September 2023, PayPal is in the midst of a turnaround that involves working to better monetize products like Braintree and Venmo and joining the world of physical commerce with a debit card inside its mobile app.

Investors responded positively in 2024, pushing the stock up almost 40% after a brutal few years. But the stock dropped 13% after its earnings report, even as profit and revenue were better than expected. PayPal’s total payment volume for the quarter hit $437.8 billion, slightly below projections, while transaction margins rose to 47% from 45.8% — a sign of improving profitability.

One of Chriss’ big pushes is to get more out of Venmo, which has long been a popular way for friends to pay each other but hasn’t been a big hit with businesses. Venmo’s total payment volume in the quarter rose 10% year-over-year, with increased adoption at DoorDash, Starbucks, and Ticketmaster.

PayPal is also promoting Venmo’s debit card and “Pay With Venmo,” which saw 30% and 20% monthly active growth in 2024, respectively. The company is introducing new services to improve merchant retention, including its Fastlane one-click checkout feature, designed to compete with Apple Pay and Shopify’s Shop Pay.

Last year, the company launched PayPal Everywhere, a cashback-driven initiative designed to boost engagement within its mobile app. Chriss said on the earnings call that it’s “driving significant increases in debit card adoption and opening new categories of spend.”

As with virtually all financial services products, the new offerings from Block, Affirm and PayPal are designed to produce growth but not at the expense of profit. Banks operate at low margins, in large part because there’s so much competition for lower-priced loans and better cash-back options. There’s also all the costs associated with underwriting and compliance.

That’s the environment in which fintechs have to operate, though without the costs of running a network of physical branches.

Levchin talks about helping customers spend less, not more. And Block acknowledges the need for hefty investments to reach the company’s desired outcome.

“This is a part of our continuous enhancements to drive healthy customer engagement as we bank our base,” Ahuja said. “We’ve made investments in critical areas like compliance, support and risk. And as we’ve done that, we’ve progressed more of our actives through our identity verification process, which in turn, unlocks greater access to those actives to our full suite of financial tools.”

WATCH: CNBC’s full interview with PayPal CEO Alex Chriss

Watch CNBC's full interview with PayPal CEO Alex Chriss

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Trump to shut down all 8,000 EV charging ports at federal govt buildings

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Trump to shut down all 8,000 EV charging ports at federal govt buildings

The Trump administration is shutting down EV chargers at all federal government buildings and is also expected to sell off the General Services Administration‘s (GSA) newly bought EVs.

GSA, which manages all federal government-owned buildings, also operates the federal buildings’ EV chargers. Federally owned EVs and federal employee-owned personal EVs are charged on those 8,000 charging ports.

The Verge reports it’s been told by a source that plans will be officially announced internally next week, and it’s seen an email that GSA has already sent to regional offices about the plans:

“As GSA has worked to align with the current administration, we have received direction that all GSA-owned charging stations are not mission-critical.”

The GSA is working on the timing of canceling current network contracts that keep the EV chargers operational. Once those contracts are canceled, the stations will be taken out of service and “turned off at the breaker,” the email reads. Other chargers will be turned off starting next week.

“Neither Government Owned Vehicles nor Privately Owned Vehicles will be able to charge at these charging stations once they’re out of service.” 

Colorado Public Radio first reported yesterday that it had seen the email that was sent to the Denver Federal Center, which has 22 EV charging stations at 11 locations.

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The Trump/Elon Musk administration has taken the GSA’s fleet electrification webpage offline entirely. (An archived version is available here.)

The Verge‘s source also said that the GSA will offload the EVs it bought during the Biden administration, although it’s unknown whether they’ll be sold or stored.

Read more: Trump just canceled the federal NEVI EV charger program


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Hackers steal $1.5 billion from exchange Bybit in biggest-ever crypto heist

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Hackers steal .5 billion from exchange Bybit in biggest-ever crypto heist

Ben Zhou, chief executive officer of ByBit, during the Token2049 conference in Singapore, on Thursday, Sept. 14, 2023. 

Joseph Nair | Bloomberg | Getty Images

Bybit, a major cryptocurrency exchange, has been hacked to the tune of $1.5 billion in digital assets, in what’s estimated to be the largest crypto heist in history.

The attack compromised Bybit’s cold wallet, an offline storage system designed for security. The stolen funds, primarily in ether, were quickly transferred across multiple wallets and liquidated through various platforms.

“Please rest assured that all other cold wallets are secure,” Ben Zhou, CEO of Bybit, posted on X. “All withdrawals are NORMAL.”

Blockchain analysis firms, including Elliptic and Arkham Intelligence, traced the stolen crypto as it was moved to various accounts and swiftly offloaded. The hack far surpasses previous thefts in the sector, according to Elliptic. That includes the $611 million stolen from Poly Network in 2021 and the $570 million drained from Binance in 2022.

Analysts at Elliptic later linked the attack to North Korea’s Lazarus Group, a state-sponsored hacking collective notorious for siphoning billions of dollars from the cryptocurrency industry. The group is known for exploiting security vulnerabilities to finance North Korea’s regime, often using sophisticated laundering methods to obscure the flow of funds.

“We’ve labelled the thief’s addresses in our software, to help to prevent these funds from being cashed-out through any other exchanges,” said Tom Robinson, chief scientist at Elliptic, in an email.

The breach immediately triggered a rush of withdrawals from Bybit as users feared potential insolvency. Zhou said outflows had stabilized. To reassure customers, he announced that Bybit had secured a bridge loan from undisclosed partners to cover any unrecoverable losses and maintain operations.

The Lazarus Group’s history of targeting crypto platforms dates back to 2017, when the group infiltrated four South Korean exchanges and stole $200 million worth of bitcoin. As law enforcement agencies and crypto tracking firms work to trace the stolen assets, industry experts warn that large-scale thefts remain a fundamental risk.

“The more difficult we make it to benefit from crimes such as this, the less frequently they will take place,” Elliptic’s Robinson wrote in a post.

WATCH: Crypto stocks plunge

Crypto stocks plunge despite SEC dropping suit against Coinbase

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