Self-Repairing Polyurethane–Urea Coating for Wind Turbine Blades: Modeling and Analysis

This study investigates a UDETA-modified polyurethane–urea (PUU) self-healing coating for wind turbine blades, focusing on its ability to autonomously repair surface erosion damage under realistic environmental conditions. A multiphysics finite element model was developed to couple temperature, moisture, and stress effects on crack healing, and a Gaussian process regression (GPR) model was trained on 35 experimental data points to predict the mobile fraction and healing thresholds with high accuracy (R2 = 0.79, MAE = 0.059). The diffusion coefficient of water in the PUU matrix was determined as 11.03 × 10−7 mm2/s, and stress-driven moisture accumulation at crack tips was shown to accelerate crack healing. Erichsen cupping test simulations were conducted to reproduce experimental crack patterns, demonstrating brittle behavior in dehydrated coatings with a Young’s modulus of 50 MPa and critical principal strains of 0.48. An exponential healing function was incorporated into the computational model and validated against experiments, predicting significant crack healing within 24 h of humidity exposure. These findings provide quantitative design criteria for self-healing coatings, enabling the selection of UDETA content, thickness, and curing strategies to extend wind turbine blade service life while reducing maintenance costs.