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.
EV and battery supply chain research specialists Benchmark Mineral Intelligence reports that 2.0 million electric vehicles were sold globally in November 2025, bringing global EV sales to 18.5 million units year-to-date. That’s a 21% increase compared to the same period in 2024.
Europe was the clear growth leader in November, while North America continued to lag following the expiration of US EV tax credits. China, meanwhile, remains the world’s largest EV market by a wide margin.
Europe leads global growth
Europe’s EV market jumped 36% year-over-year in November 2025, with BEV sales up 35% and plug-in hybrid (PHEV) sales rising 39%. That brings Europe’s total EV sales to 3.8 million units for the year so far, up 33% compared to January–November 2024.
France finally returned to year-to-date growth in November, edging up 1% after spending most of 2025 in the red following earlier subsidy cuts. The rebound was led by OEMs such as the Volkswagen Group and Renault, a wider selection of EV models, and France’s “leasing social” program, aimed at helping lower-income households switch to EVs.
Italy also posted a standout month, logging record EV sales of just under 25,000 units in November. The surge followed the launch of a new incentive program designed to replace older ICE vehicles. The program earmarks €597.3 million (about $700 million) in funding for the replacement of around 39,000 gas cars.
The UK expanded access to its full £3,750 ($4,400) EV subsidy by adding five more eligible models: the Nissan Leaf (built in Sunderland, with deliveries starting in early 2026), the MINI Countryman, Renault 4, Renault 5, and Alpine A290.
US market slows after federal tax credit’s premature death
In North America, EV sales in the US did tick up month-over-month in November, following a sharp October drop after federal tax credits expired on September 30, 2025. Brands including Kia (up 30%), Hyundai (up 20%), Honda (up 11%), and Subaru (232 Solterra sales versus just 13 the month before) all saw gains, but overall volumes remain below levels when the federal tax credit was still available.
Policy changes aren’t helping. In early December, Trump formally “reset” US Corporate Average Fuel Economy (CAFE) standards, lowering the required fleetwide average to about 34.5 mpg by 2031. That’s a steep drop from the roughly 50.4 mpg target under the previous rule. Automakers can now meet the standard largely through gas vehicles, reducing pressure to scale BEVs and PHEVs.
Those loosened rules are already reflected in investment decisions, such as Stellantis’ $13 billion plan to expand US production by 50%, with a heavy focus on ICE vehicles. Earlier this year, Trump’s big bill set fines for missing CAFE targets to $0, further weakening the incentive for OEMs to electrify.
That’s some foolish policymaking, considering the world reached peak gas car sales in 2017. The US under Trump will be left behind, just as it will be with its attempts to revive the coal industry.
China still dominates, exports surge
China remains the backbone of global EV sales, even as growth slows. The Chinese market grew 3% year-over-year and 4% month-over-month in November. Year-to-date, EV sales in China are up 19%, with 11.6 million units sold.
One of the biggest headlines out of China is exports. BYD reported a record 131,935 EV exports in November, blowing past its previous high of around 90,000 units set in June. BYD sales in Europe have jumped more than fourfold this year to around 200,000 vehicles, doubled in Southeast Asia, and climbed by more than 50% in South America.
Global snapshot
Global EV sales from January to November 2025 vs January to November 2024, YTD %:
- Global: 18.5 million, +21%
- China: 11.6 million, +19%
- Europe: 3.8 million, +33%
- North America: 1.7 million, -1%
- Rest of World: 1.5 million, +48%
The takeaway: EV demand continues to grow worldwide, but policy support – or the lack thereof – is increasingly shaping where this growth shows up.
“Overall, EV demand remains resilient, supported by expanding model ranges and sustained policy incentives worldwide,” said Rho Motion data manager Charles Lester.
Read more: EV sales *still* have not fallen, cooled, slowed or slumped. Media is lying to you.
If you’re looking to replace your old HVAC equipment, it’s always a good idea to get quotes from a few installers. To make sure you’re finding a trusted, reliable HVAC installer near you that offers competitive pricing on heat pumps, check out EnergySage. EnergySage is a free service that makes it easy for you to get a heat pump. They have pre-vetted heat pump installers competing for your business, ensuring you get high quality solutions. Plus, it’s free to use!
Your personalized heat pump quotes are easy to compare online and you’ll get access to unbiased Energy Advisors to help you every step of the way. Get started here. – *ad
FTC: We use income earning auto affiliate links. More.
The Elexio is Hyundai’s first electric SUV custom-tailored for the Chinese market, but now it’s headed overseas.
Hyundai is bringing the Elexio electric SUV overseas
Hyundai’s midsize electric SUV was spotted on a carrier truck in Melbourne, Australia, alongside a few of its other vehicles.
Although the Elexio is built by Hyundai’s joint venture with BAIC Motor, Beijing-Hyundai, “tailor-made for Chinese consumers,” we had a feeling it would be sold overseas.
A few months ago, Don Romano, CEO of Hyundai Australia, hinted that the midsize electric SUV could arrive in The Land Down Under. Romano told journalists during an IONIQ 9 launch event that the Elexio’s launch in Australia was “under evaluation,” calling it “a promising vehicle.”
Hyundai confirmed the rumors shortly after, saying the new midsize electric SUV would launch in Australia in early 2026.
According to CarsGuide, the Elexio was caught on a car carrier in Melbourne on Wednesday morning ahead of its official launch.
Powered by an 88.1 kWh battery, the Elexio delivers up to nearly 450 miles (722 km) CLTC range. It’s based on the E-GMP platform, which underpins all IONIQ models and Kia’s EV lineup, with single and dual-motor (AWD) powertrain options. The electric SUV can also recharge from 30% to 80% in about 27 minutes.
The interior is packed with advanced Chinese tech, including Huawei’s advanced driver-assistance systems (ADAS) and a Qualcomm Snapdragon 8295 chip that powers the massive 27″ 4K widescreen display.
The Elexio is 4,615 mm long, 1,875 mm wide, and 1,698 mm tall, with a wheelbase of 2,750 mm, which is a bit shorter than the Tesla Model Y. It’s closer in size to the BYD Yuan Plus, sold overseas as the Atto 3.
Hyundai’s midsize electric SUV is expected to compete with some of Australia’s top-selling EVs, including the Tesla Model Y and Geely EX5.
Prices have yet to be announced, but given the IONIQ 5 starts at $76,200 (AUD), before on-road costs, the Elexio should be slightly cheaper.
In China, the Elexio is available in three trims: Fun, Smart, or Tech, with pre-sale prices starting at RMB 119,800 ($16,900).
Although the electric SUV is launching in Australia and possibly other overseas markets like New Zealand, it’s not expected to be a true global vehicle. Hyundai designed it specifically for Chinese buyers, leveraging local tech and design elements.
For those in the US, if you’re looking for a midsize electric SUV, the IONIQ 5 is worth a look with 300+ miles of range, fast charging, and a spacious, tech-filled interior. With leases starting at just $189 a month, the IONIQ 5 is cheaper than most gas-powered cars in its class. You can use our link to find the Hyundai IONIQ 5 models closest to you.
FTC: We use income earning auto affiliate links. More.
Iron-sodium battery makers Inlyte Energy just crossed an important line from lab to grid reality. The company has completed a factory acceptance test of its first field-ready iron-sodium battery energy storage system with reps from a major US utility in attendance.
Iron-sodium battery storage
The test took place at Inlyte’s facility near Derby in the UK, and was witnessed by representatives from Southern Company, one of the largest electric utilities in the US. The goal was to prove the performance and integration readiness of the whole system, which combines sodium metal chloride battery cells with inverters and control electronics. By Inlyte’s account, the system performed as expected and is ready for field deployment.
The energy storage market is growing fast, and utilities are looking beyond lithium‑ion. Iron-sodium battery storage systems are emerging as a compelling alternative to lithium-ion batteries for grid-scale use, as they rely on abundant, low-cost materials and offer strong safety and long-duration performance.
While lithium-ion batteries excel at fast response and short-to-medium-duration storage, iron-sodium systems are better suited for multi-hour to multi-day grid applications where cost, thermal stability, and long service life matter more than energy density.
The global energy storage market is projected to grow from approximately $70 billion in 2025 to over $150 billion by 2030. The US Department of Energy estimates the grid will need more than 225 gigawatts of long‑duration energy storage by 2050.
Inlyte is betting that iron‑sodium batteries can help fill that gap. The system tested in the UK utilizes what the company claims are the world’s largest sodium metal chloride battery cells and modules ever built, each capable of storing more than 300 kilowatt-hours of energy. The chemistry is designed to be lower-cost, safer, and longer-lasting than lithium-ion – key traits for grid-scale storage.
During the factory test, Inlyte’s battery system hit 83% round‑trip efficiency, including auxiliary loads. That puts it in the same range as high-performance lithium-ion systems and well above the roughly 40% to 70% efficiency typical of many other long-duration energy storage technologies. Southern Company’s R&D team observed the test in person, a step that helps clear the way for real‑world deployment.
The commercial plan
Next up: the field. Inlyte says its first energy storage systems will be installed at Southern Company’s Energy Storage Test Site in Wilsonville, Alabama, in early 2026. Those deployments will allow the utility to study how the iron‑sodium batteries perform under real grid conditions.
With technical readiness now demonstrated, Inlyte is turning its focus to US manufacturing. The company plans to finalize a site for its first domestic factory in 2026. To help speed that process, Inlyte has partnered with HORIEN Salt Battery Solutions, the world’s largest producer of sodium metal chloride batteries. HORIEN brings over 25 years of commercial experience across applications like critical power, remote industrial sites, and battery energy storage.
The plan is to combine HORIEN’s manufacturing know‑how with Inlyte’s system integration work to bring sodium‑based grid batteries to the US market. If all goes according to plan, Inlyte expects commercial deliveries of domestically produced systems to begin in 2027.
If you’re looking to replace your old HVAC equipment, it’s always a good idea to get quotes from a few installers. To make sure you’re finding a trusted, reliable HVAC installer near you that offers competitive pricing on heat pumps, check out EnergySage. EnergySage is a free service that makes it easy for you to get a heat pump. They have pre-vetted heat pump installers competing for your business, ensuring you get high quality solutions. Plus, it’s free to use!
Your personalized heat pump quotes are easy to compare online and you’ll get access to unbiased Energy Advisors to help you every step of the way. Get started here. – *ad
FTC: We use income earning auto affiliate links. More.
-
Sports2 years agoStory injured on diving stop, exits Red Sox game
-
Sports3 years ago‘Storybook stuff’: Inside the night Bryce Harper sent the Phillies to the World Series
-
Sports2 years agoGame 1 of WS least-watched in recorded history
-
Sports3 years agoButton battles heat exhaustion in NASCAR debut
-
Sports3 years agoMLB Rank 2023: Ranking baseball’s top 100 players
-
Sports4 years ago
Team Europe easily wins 4th straight Laver Cup
-
Environment3 years agoJapan and South Korea have a lot at stake in a free and open South China Sea
-
Environment1 year agoHere are the best electric bikes you can buy at every price level in October 2024