Processing Window for High‐Performance Glass‐Fiber/Nylon‐6 Pultruded Shear Webs in Wind Turbine Blades

The shear web in wind turbine blades is traditionally manufactured from thermoset glass‐fiber composites, but its irreversible curing chemistry severely limits repair, remanufacturing and recycling. Decommissioned blades typically end up in landfills, making the non‐recyclability a critical bottleneck to the sustainable development of the wind industry. Continuous‐fiber thermoplastic composites offer a recyclable alternative; however, the processing window for thick shear‐web profiles, particularly for glass‐fiber/nylon‐6 systems, remains unclear. To address this issue, continuous glass‐fiber‐reinforced nylon‐6 (GF/PA6) thermoplastic composites are investigated. A pultrusion mold suitable for thick‐section shear webs is designed. The effects of four process parameters are systematically examined: the number of prepreg strips (13–17), die temperatures (preheating 160°C–200°C, heating 230°C–270°C, cooling 40°C–120°C), pultrusion speed (115–315 mm min −1 ) and fiber mass fraction (44–67 wt%). Their influences on shear web density, porosity, flexural strength and compressive strength are analyzed. A shear web with excellent mechanical properties is successfully fabricated, achieving a radial flexural strength of 670 MPa, an axial compressive strength of 289 MPa and a radial compressive strength of 176 MPa. These results delineate a practical processing window for thick‐section wind turbine blade shear web that suppresses voids while avoiding resin starvation and thermal degradation.