Appendix 1.D - Open Source Airfoils Candidates.pdf

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Attached to
Fundamental Aerodynamics for Large Wind Turbine Performance and Reliability Federal contract opportunity
Solicitation number
RFX-2025-10021
Issued by
Department of Energy Office of Science

About this file

This is an appendix document describing two Open-Source Offshore (OSO) airfoils developed by Sandia National Laboratories and NREL for research purposes in offshore wind turbines. The airfoils (OSO-21-WT1 and OSO-30-WT1) are designed to meet modern turbine requirements while being free of proprietary constraints, targeting the IEA 22 MW wind turbine project.

The document provides detailed technical specifications and performance metrics for both airfoils, including thickness ratios (21% and 30%), Reynolds numbers (Re=12e6 and Re=18e6), and lift coefficients (1.4 and 1.5). The airfoils mostly meet design criteria with two exceptions: the OSO-21-WT1 exceeds the L/D Roughness Loss metric (43% vs 40% target), and both airfoils exceed the desired lift coefficient margin (0.5 and 0.4 vs 0.3 target). The airfoil coordinates will be publicly available on SNL's Github repositories. The development involved collaboration between Sandia National Laboratories, California State Long Beach University, NREL, and was supported by the DOE Wind Energy Technologies Office.

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APPENDIX 1-D. Open-Source Airfoil Candidates

Description and Characteristics of the Open-Source Airfoils designed at SNL/NREL

The Open-Source Offshore (OSO) airfoils have been developed for research purposes for offshore wind turbines, offering a set of airfoils that captures modern turbine design requirements and industry design practices without the proprietary constraints on research use. The eventual airfoil family will target the IEA 22 MW wind turbine [Zahle et al. 2024], which was originally developed with the FFA airfoils. The two airfoils summarized in Table 1 (OSO-21-WT1 and OSO-30-WT1) started development as part of a family of airfoils being developed targeting the IEA 22 MW wind turbine.

The criteria used to design these airfoils are re-iterated from the SOW in Table 1, aim to encapsulate requirements of modern airfoils for offshore wind turbine applications, and were developed with feedback form industry and research experts. The airfoils were designed using XFOIL and candidate airfoils were then analyzed in RFOIL, which is considered more accurate than XFoil for high lift predictions of thicker airfoils. The design process for a preliminary family of airfoils is available for a more detailed explanation of the design requirements and metrics [Karcher et al. 2025].

Most of the design criteria are met for these two airfoils, with two exceptions. For the OSO-21-WT1 airfoil, the L/D Roughness Loss metric is exceeded (43% > 40% goal); for both airfoils the desired lift coefficient travel beyond design value (“CL_Margin”) was moderately exceeded (0.5 > 0.3) while smooth-stall (computed) were achieved. Note that all of the metrics are computed using RFOIL, and like other new airfoils, these will need to be experimented validated before high-Reynolds number testing. The airfoil coordinates will be shared publicly on SNL’s public Github repositories:

(https://github.com/sandialabs/released-oso-airfoils).

Table 1. Open-Source Offshore airfoil design criteria and performance summary (computed metrics)

Design Criteria

Modern Airfoil tip region Modern Airfoil mid-span

OSO-21-WT1

Airfoil, tip region

OSO-30-WT1

Airfoil, mid-span Thickness - t/c 21% 30% 21% 30% Reynolds Number, Chordwise, design target Re=12e6+ Re=15e6+ Re=12e6 Re=18e6 CL_Design 1.2-1.6 1.2-1.6 1.4 1.5 L/D clean >200 >160 206 172 L/D rough >115 >95 117 102 L/D Roughness Loss % <40% <40% 43% 40% Stall Margin - Clean >3 deg. 7.0 6 Stall Margin - Rough >3 deg. 7.0 4.2 CL Margin Cl_Max - Cl_Des < 0.3 0.5 0.4

Post Stall Slope - Clean (dCL/dAlpha < -0.17/deg. over 2 deg.

post stall) -0.132

-0.076

Post stall slope - Rough (dCL/dAlpha < -0.17/deg. over 2 deg.

post stall) -0.135

-0.085 https://github.com/sandialabs/released-oso-airfoils

L/D robustness - Clean +/- 15% from peak L/D at +/- 15% from design AoA -5.7% -1.5%

L/D robustness - Rough +/- 15% from peak L/D at +/- 15% from design AoA -3.3% -2.5%

CM Magnitude ~Equal or less than existing open airfoils

(FFA , S-series) -0.15 -0.135

Structures - TE angle Last 2% of chord must have a wedge angle of at least 10 degrees ü ü Structures - Leading Edge Curvature - Shaped for robust performance, manufacturing, and erosion resistance

LE Radius > 0.01 LE Radius > 0.04 ü ü

Structures - Aft section upper surface curvature

Limit concave curvature on aft airfoil upper surface for buckling resistance ü ü

Structures - Spar location and thickness

Maximum thickness of airfoil measured perpendicular to chord line and located aft of 25% normalized chord ü ü

Structures - Bending Stiffness

Quantify that structural performance is at least as good as existing open airfoils, for example by comparing area moment of inertia. ü ü

The Open-Source Offshore (OSO) airfoils have been developed by Sandia National Laboratories in collaboration with the university of California State Long Beach, the National Renewable Energy laboratory, as well as through the advisement of many experts and the support of the DOE Wind Energy Technologies Office.

References Zahle, F., Barlas, A., Loenbaek, K., Bortolotti, P., Zalkind, D., Wang, L., Labuschagne, C., Sethuraman, L., and Barter, G., “Definition of the IEA Wind 22-Megawatt Offshore Reference Wind Turbine,” Technical University of Denmark, 2024.

https://doi.org/10.11581/dtu.00000317.

Cody J. Karcher, David C. Maniaci, Chris Kelley, Alan Hsieh, Nathaniel deVelder and Anurag Gupta. "Design of a Preliminary Family of Airfoils for High Reynolds Number Wind Turbine Applications," AIAA 2025-0840. AIAA SCITECH 2025 Forum.

January 202 https://doi.org/10.11581/dtu.00000317 https://arc.aiaa.org/doi/10.2514/6.2025-0840 https://arc.aiaa.org/doi/10.2514/6.2025-0840

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