New Welding Technology Innovates Repair of Cast Iron Components in Wind Turbines

Partners including Siemens Gamesa, Vestas and others unite to tackle common issues in wind turbine maintenance, resulting in a new welding method with promising results.

A new welding method has been developed, enabling the repair and also later assembly of large cast iron components in wind turbines. This innovation has the potential to reduce time, costs, and CO2 emissions across the wind energy industry.

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.

The project is supported by Innovation Fund Denmark and facilitated by Energy Cluster Denmark.

Joint solutions for common challenges

The challenge for the industry is that large cast iron components in wind turbines are not only expensive but also difficult to repair if defects arise during casting. Consequently, many cast parts are scrapped.

As turbine sizes increase, many foundries struggle to keep up with the demand, making welding a viable alternative to reduce costs and expand the supplier base.

Therefore the project developed a welding method aimed at repairing defective wind turbine components.

Hans-Frieder Vogt, Team Lead Structural Analysis at Siemens Gamesa, remarks on the cooperative effort:

“We saw that we can discuss details openly without compromising our competition laws or competitive position. I think we’ve found solutions together because we share common challenges.”

The collaboration helped the partners address technical difficulties and create a solution that benefits the wider industry.

Identify, categorize and repair iron components

A key outcome of the WeldCast project is a technique that makes it easier to repair larger cast iron components. This method simplifies the repair process, reducing both waste and production downtime.

“We now have a better understanding of how to identify and categorize defects, and how to repair them.”, says Anders Vedel, Chief Science Advisor at Vestas.

Kaare Jensen, Senior Welding Technician at FORCE Technology, explains:

“We’ve developed a buttering layer that adapts to changes in the weld and fills it with another material, allowing us to create welds without cracks or defects.”

This innovation could lead to more resource efficient turbine maintenance, reducing costs and time associated with repairing large components. While the results are promising, there is still work to be done before the method can be commercialized.

Looking ahead – a big perspective

If the technology is successfully implemented, it could change how the wind energy sector manages repairs, potentially reducing the need to scrap large components

“These solutions allow us to repair indications directly on the production line, avoiding the need to stop the production. This enables us to conduct quick repairs instead of scrapping parts,” says Kaare Jensen from FORCE Technology about the practical benefits.

Looking to the future, Anders Vedel from Vestas says:

“With implementation and rollout, which I hope could take place in three to four years, we will have something that makes a meaningful difference for the industry—both for sub-suppliers and OEMs.”

Facts about WeldCast

The WeldCast project began in 2021 with the partners Siemens Gamesa Renewable Energy A/S, Vestas Wind Systems, BEATTR, FORCE Technology, DTU – Danmarks Tekniske Universitet and Energy Cluster Denmark. The project is funded by Innovation Fund Denmark.

Would you like more information about WeldCast? Contact Christian Boysen, COO, Energy Cluster Denmark: +45 61 71 86 63 / chb@energycluster.dk.

Read more about WeldCast or check out the project video here: https://www.energycluster.dk/en/projects/weldcast/