A large-scale rotor test platform for atmospheric icing simulation and passive ice protection evaluation

Ice accumulation on the leading edges of wind turbines significantly reduces energy output, aerodynamic efficiency, and structural integrity. In recent years, research into ice protection systems has intensified, driven by the growing deployment of turbines and rotorcraft in cold climates. However, the development and validation of these systems are hindered by the rarity and unpredictability of natural icing events, making field-testing impractical. To address this, there is a pressing need for large-scale laboratory platforms that can reliably replicate atmospheric icing conditions. This study presents the design and implementation of a horizontal axis rotating-blade test stand installed within a cold room, enabling controlled simulation of representative icing scenarios. Unlike most existing setups, the platform reproduces realistic icing through a complete accumulation-pause-shedding sequence, allowing precise characterization of ice morphology prior to detachment. The procedure leverages centrifugal ice adhesion measurements and is validated using a metallic substrate to ensure repeatability and comparability with prior studies and small-scale tests for two specific ice types problematic for wind turbines. The configuration captures both adhesive and cohesive failure mechanisms at a meaningful scale, reflecting fracture behaviors typically observed on full-sized turbine blades. The validation tests show results in accordance with other similar test benches with ice adhesion strength measured at 0,25 MPa at -12 °C and 0,15 MPa at -5 °C. The cohesive strength of the ice, required for the evaluation of ice adhesion strength in partial detachment cases, is measured specifically for this test bench as well using a dedicated apparatus. The setup is particularly suited for evaluating passive ice protection strategies, such as icephobic surface coatings, under realistic and reproducible conditions. Consequently, it provides a robust foundation for future studies by bridging the gap between small-scale laboratory methods and full-scale field behavior.