The invention relates to a heavy-duty upgrading method for rotor blades of existing wind turbines and to a plastic membrane used in the method according to the invention, wherein the rotor blades are covered and/or extended in that at least one fibre-reinforced or fabric-reinforced plastic membrane is fitted onto an outer surface of the original aerodynamic profile of the rotor blade being upgraded and the original contour of the rotor blade being upgraded is then joined to the upgraded rotor blade.

Methods for repairing composite cylindrical components are provided. One exemplary method for repairing a cylindrical component defining an axial direction, a radial direction, and a circumferential direction includes removing a damaged region of the cylindrical component. A flange extending from a cylindrical body of the cylindrical component is included in the damaged region. One or more arc segments that extend along the circumferential direction are connected with the existing cylindrical component. At least one of the arc segments includes a prefabricated flange. One or more plies are laid up to connect the arc segments with the existing cylindrical component to repair the damaged region of the cylindrical body and the prefabricated flange formed integrally with one of the arc segments replaces the damaged portion of the flange. Repaired cylindrical components are also provided.

In one embodiment, a method may comprise coupling a plurality of reinforcement fibers to a plurality of spherical components; inserting the plurality of spherical components into an enclosure; and heating the enclosure to cause the plurality of spherical components to expand, wherein the plurality of spherical components expands to form a geodesic structure, wherein the geodesic structure comprises a plurality of polyhedron components configured in a geodesic arrangement.

In one embodiment, a method may comprise coupling a plurality of reinforcement fibers to a plurality of spherical components; inserting the plurality of spherical components into an enclosure; and heating the enclosure to cause the plurality of spherical components to expand, wherein the plurality of spherical components expands to form a geodesic structure, wherein the geodesic structure comprises a plurality of polyhedron components configured in a geodesic arrangement.

Methods for repairing composite components are provided. For instance, one exemplary method includes machining an interlocking feature into an existing component. A replacement material or core having an interlocking feature complementary to the interlocking feature of the existing component is then joined with the component. The interlocking features interlock to form a joint. The joint is then overlaid with one or more plies to rebuild the outer surface of the component and seal the joint. A bonding process can be used to chemically bond the newly joined parts together. Repaired composite components are also provided.

In a first aspect, there is a method of making a rotor blade, including designing at least one of an upper skin, a lower skin, a support network, and components therefor; and forming at least one of the upper skin, the lower skin, a support network, and components therefor using an additive manufacturing process. In a second aspect, there is an airfoil member having a root end, a tip end, a leading edge, and a trailing edge, the airfoil member including an upper skin; a lower skin; and a support network having a plurality of interconnected support members in a lattice arrangement and/or a reticulated arrangement, the support network being configured to provide tailored characteristics of the airfoil member. Also provided are methods and systems for repairing an airfoil member.

In a first aspect, there is a method of making a rotor blade, including designing at least one of an upper skin, a lower skin, a support network, and components therefor; and forming at least one of the upper skin, the lower skin, a support network, and components therefor using an additive manufacturing process. In a second aspect, there is an airfoil member having a root end, a tip end, a leading edge, and a trailing edge, the airfoil member including an upper skin; a lower skin; and a support network having a plurality of interconnected support members in a lattice arrangement and/or a reticulated arrangement, the support network being configured to provide tailored characteristics of the airfoil member. Also provided are methods and systems for repairing an airfoil member.

A method and device for connecting and repairing a shear web includes the method steps of dry-fitting a shear web insert in a rotor blade assembly to establish a perimeter gap at an angled perimeter interface between the shear web insert and the rotor blade assembly, the angled perimeter interface positioned between the shear web insert and at least one adjacent surface of a first shear web, a second shear web, a first side of the rotor blade assembly, and a second side of the rotor blade assembly, and then injecting a bonding paste into the perimeter gap. The rotor blade assembly can include a connecting device having at least one pre-fabricated clip.

A method for repairing a target member including a ceramic matrix composite reinforced by ceramic fiber includes: a removal step of removing at least a part of a surface of the target member; an arrangement step of arranging a green body for repair which includes the ceramic fiber on a portion where the surface is removed in the removal step; an impregnation step of impregnating at least the portion of the target member where the green body for repair is disposed with slurry; and a sintering step of sintering the target member on which the green body for repair is disposed, after the impregnation step.

A method for repairing a target member including a ceramic matrix composite reinforced by ceramic fiber includes: a removal step of removing at least a part of a surface of the target member; an arrangement step of arranging a green body for repair which includes the ceramic fiber on a portion where the surface is removed in the removal step; an impregnation step of impregnating at least the portion of the target member where the green body for repair is disposed with slurry; and a sintering step of sintering the target member on which the green body for repair is disposed, after the impregnation step.