Development and Characterisation of High Thermal Conductivity Insulation Systems for Offshore Wind Generator Windings

About the Project

Offshore wind turbine generators are increasingly constrained by thermal limitations in stator windings, where conventional electrical insulation materials with comparatively lower thermal conductivity can accelerate thermal ageing and limit overall generator performance. As system demands grow, improving heat dissipation within insulation systems becomes critical to enhancing efficiency, reliability, and operational lifetime in harsh offshore environments.

This PhD project aims to develop and characterise advanced insulation systems with enhanced thermal conductivity, specifically designed to improve heat transfer within generator windings while maintaining electrical, mechanical, and environmental performance. By targeting the root causes of thermal bottlenecks, the project aims to enable higher current-carrying capabilities and slow the insulation degradation due to thermal ageing, ultimately enhancing generator reliability and lifespan.

The research will begin with a systematic investigation of existing insulation systems to identify key thermal limitations and their impact on winding performance. This will involve literature review, industrial benchmarking, and baseline experimental characterisation of conventional insulation materials. Particular emphasis will be placed on understanding the relationship between thermal conductivity, temperature distribution, and ageing behaviour under representative operating conditions.

Building on this foundation, the core of the project will focus on the design and development of novel thermally enhanced insulation materials. Potential approaches include incorporating thermally conductive fillers, developing advanced polymer composites, and optimising resin systems compatible with established manufacturing processes, such as vacuum pressure impregnation. A key challenge will be achieving significant improvements in thermal conductivity without compromising dielectric strength, partial discharge resistance, or mechanical integrity of the insulation systems.

Comprehensive multi-physics characterisation will be conducted to evaluate the developed materials. Thermal conductivity measurements will directly correlate with heat dissipation capability, while electrical testing will ensure robust insulation performance under high-voltage stress. Mechanical properties, including resistance to vibration and thermal cycling, will also be assessed to ensure suitability for demanding offshore operating conditions. Environmental stability, including resistance to humidity, salt exposure, and temperature variations, will form an integral part of the evaluation.

A major component of the project will focus on accelerated ageing studies under combined thermal and electrical stress. These experiments will replicate realistic offshore operating conditions and provide insight into the mechanisms of insulation degradation. By linking improved thermal properties to reduced ageing rates, the research will establish a clear relationship between material innovation and enhanced reliability.

In the final phase, experimental results will be integrated with thermal and system-level modelling of offshore wind generators. This will enable quantitative assessment of performance improvements, including increased allowable current density, reduced hotspot temperatures, improved efficiency, and extended service lifetime. These outcomes will provide design-relevant insights into how advanced insulation systems can be implemented in practical generator designs.

The impact of this research is significant. By improving thermal management at the material level, the project directly contributes to the development of more efficient, reliable, and durable offshore wind turbine generators. This will support higher energy yields, reduced maintenance requirements, and lower lifetime costs, ultimately strengthening the role of offshore wind in delivering a sustainable and resilient low carbon energy future.

Eligibility

Applicants should hold a first-class (or equivalent) degree in a relevant discipline (upper second class may be considered depending on the bachelor's/master's dissertation project). The candidate is expected to have regular meetings with Siemens Gamesa Renewable Energy R&D team and also undertake an industry placement as part of the PhD programme.

Funding

This 3.5 year PhD studentship partially funded by Siemens Gamesa Renewable Energy is open to Home (UK) applicants. The successful candidate will receive an annual tax-free stipend set at the UKRI rate (£20,780 for 2025/26; subject to annual uplift).

The start date is October 2026.

We recommend that you apply early as the advert may be removed before the deadline.