Lightning No Match for Wind Turbine Blade Protection System
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.
Environment
Podcast: Xiaomi shocks with YU7, Tesla Robotaxi launch, Rivian brings back tank mode, and more
In the Electrek Podcast, we discuss the most popular news in the world of sustainable transport and energy. In this week’s episode, we discuss Xiaomi shocking the industry with YU7, Tesla’s Robotaxi launch, Rivian bringing back tank mode, and more.
The show is live every Friday at 4 p.m. ET on Electrek’s YouTube channel.
Today, the episode is live at 12:15 a.m instead due to Fred’s travels in China and Seth’s in.
As a reminder, we’ll have an accompanying post, like this one, on the site with an embedded link to the live stream. Head to the YouTube channel to get your questions and comments in.
After the show ends at around 5 p.m. ET, the video will be archived on YouTube and the audio on all your favorite podcast apps:
We now have a Patreon if you want to help us avoid more ads and invest more in our content. We have some awesome gifts for our Patreons and more coming.
Here are a few of the articles that we will discuss during the podcast:
Here’s the live stream for today’s episode starting at 12:15 a.m. ET (or the video after 1 a.m. ET):
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Solar provided over 10% of total US electrical generation in April, wind and solar produced almost one-quarter, and the mix of all renewable energy generated nearly a third, according to data just released by the US Energy Information Administration (EIA).
Solar set new records in April and the first third of 2025
EIA’s latest monthly “Electric Power Monthly” report (with data through April 30, 2025), which was reviewed by the SUN DAY Campaign, confirms that solar continues to be the fastest-growing source of US electricity.
In April alone, electrical generation by utility-scale solar (>1 MW) increased by 39.3% while “estimated” small-scale (e.g., rooftop) solar PV increased by 11.8%. Combined, they grew by 31.3% and provided 10.7% of US electrical output.
Utility-scale solar thermal and PV expanded by 42.4% while that from small-scale systems rose by 11.4% during the first third of 2025 compared to the same period in 2024. The combination of utility-scale and small-scale solar increased by 32.9% and was almost 7.7% of total US electrical generation for January-April, up from 6.1% a year earlier.
As a result, solar-generated electricity easily surpassed hydropower output, at 6.0%. In fact, solar is now producing more electricity than hydropower, biomass, and geothermal combined.
Wind is still the renewable energy leader
Wind turbines produced 12.6% of US electricity in the first four months of 2025. Their output was 5.9% greater than the year before.
In April alone, wind provided 13.9% of US electricity supply, essentially equal to the share provided by coal.
Wind and solar now outproduce coal and nuclear
During the first third of 2025, electrical generation by wind plus utility-scale and small-scale solar provided 20.3% of the US total, up from 18.5% during the first four months of 2024. In just the month of April, solar plus wind accounted for 24.6% of US electrical output.
During the first four months of this year, the combination of wind and solar provided 20.2% more electricity than did coal, and 13.8% more than US nuclear power plants. In April alone, the disparity increased significantly when solar + wind outproduced coal and nuclear power by 77.1% and 40.2%, respectively.
Renewables are closing in on natural gas
The mix of all renewables (wind and solar plus hydropower, biomass, and geothermal) produced 10.3% more electricity in January-April than they did a year ago (9.7% more in April alone) and provided 27.7% of total US electricity production compared to 26.3% 12 months earlier.
Electrical generation by the combination of all renewables in April alone reached a new record and provided 32.8% of total US electrical generation. Moreover, renewables are now approaching the share provided by natural gas (35.1%), whose electrical output actually dropped by 4.4% during the month.
For perspective, five years ago, in April 2020, the mix of renewables provided 24.4% of total electrical generation while natural gas accounted for 38.8%.
Consequently, the mix of renewables has further strengthened its position as the second largest source of electrical generation, behind only natural gas, with the gap closing rapidly.
Ken Bossong, the SUN DAY Campaign’s executive director, noted:
Solar is now the fastest-growing major source of electricity and is generating more than hydropower, biomass, and geothermal combined, while wind plus solar provides more electricity than either coal or nuclear power, and the mix of all renewables is nearly matching the output of natural gas.
Yet, the Trump administration and the Republican Congress are seeking to pull the rug out from underneath renewables in favor of dirtier and more expensive fossil fuel and nuclear technologies. What are they thinking?
Read more: $15.5B in EV, renewable projects vanish as Senate eyes rollbacks
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![Here's a look at the Kia EV4 GT before you're supposed to see it [Video]](https://i0.wp.com/electrek.co/wp-content/uploads/sites/3/2025/06/Kia-EV4-GT-US.jpeg?resize=1200,628&quality=82&strip=all&ssl=1)
Kia’s upcoming EV4 GT is gunning for the Tesla Model 3 Performance, but it’s expected to undercut the price. Could this be the affordable electric sports car we’ve been waiting for? A new video shows the Kia EV4 GT driving on US streets ahead of its debut.
Kia EV4 GT is testing in the US ahead of its debut
After launching it in Korea in April, some are already calling Kia’s first electric sedan “a box office hit.” The EV4 was the best-selling domestic electric sedan in Korea in May, its second month on the market.
Kia’s electric sedan starts at just 41.92 million won, or around $30,000 in Korea. When it arrives in the US and Europe, the entry-level EV is expected to start at about $35,000 to $40,000 (€35,000).
With its sleek, fastback silhouette, the EV4 already looks like a sports car, making it an ideal candidate for a high-performance upgrade. All the EV4 needs is a little added power. Don’t worry, Kia plans to turn up the heat very soon.
We caught our first glimpse of the interior earlier this month after a prototype was spotted outside of a Kia facility in Korea.
A new video is giving us a closer look at the Kia EV4 GT being tested in the US for the first time. The video from the folks at KindelAuto reveals a few design elements you can expect to see, like Kia’s vertical LED headlights with its signature Star Map lighting.
Although it’s still covered, you can expect to see Kia’s new Tiger Face grille design, which aligns with its latest electric models, including the EV9 and EV3.
We will have to wait until closer to launch for final prices and specs, but like Kia’s other GT vehicles, the EV4 GT is expected to feature an AWD dual-motor powertrain.
It will sit under the EV6 GT, which boasts 576 hp, enabling a 0 to 60 mph sprint time of 3.4 seconds. Will the smaller EV4 GT top it? With recent advancements in battery and powertrain technology, it wouldn’t be a surprise.
Kia will launch the EV4 in the US later this year with an EPA-estimated driving range of up to 330 miles. Additionally, it will feature a built-in NACS port, allowing it to recharge at Tesla Superchargers. With the base model expected to start at around $35,000, the high-performance GT variant could cost around $50,000 to $55,000.
In comparison, the Tesla Model 3 Performance starts at $54,990 with an EPA-est range of 298 miles. It can also accelerate from 0 to 60 mph in just 2.9 seconds.
Would you pick the Kia EV4 GT for around $50,000, or are you sticking with the Tesla Model 3 Performance? Got a better option in mind? Drop us a comment below.
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