A new welding method has been developed, enabling the repair and subsequent assembly of large cast iron components in wind turbines. This technique is the result of the WeldCast innovation project, which brought together partners including Siemens Gamesa Renewable Energy, Vestas Wind Systems, FORCE Technology, DTU, and Baettr.
A key outcome of the WeldCast project is a technique that simplifies the repair of larger cast iron components. This method reduces both waste and production downtime by streamlining the repair process. The project has enhanced the understanding of how to identify and categorise defects and how to repair them. It has led to the development of a buttering layer that adapts to changes in the weld, filling it with another material, thus allowing the creation of welds without cracks or defects.
This innovation could lead to more resource-efficient turbine maintenance, reducing the costs and time associated with repairing large components. While the results are promising, further work is needed before the method can be commercialised.
The project is supported by Innovation Fund Denmark and facilitated by Energy Cluster Denmark.
