On-site Wind Turbine repair with Titomic D523 Cold Spray

1. Wind energy and the challenges of turbine maintenance

Wind energy is one of the most important renewable energy sources today, contributing significantly to reducing our dependence on fossil fuels and decreasing carbon emissions that contribute to the greenhouse effect.

  • Decreasing carbon emissions: By converting wind energy into electricity, we significantly reduce the burning of fossil fuels such as coal, oil, and natural gas, thereby decreasing CO2 emissions and other pollutants in the atmosphere.
  • Scale and significance: Wind farms have been constructed worldwide, from coastal to inland areas. The scale of wind farms is growing, providing a clean and stable energy source for many countries.

Challenges in wind turbine maintenance and repair

Despite its many advantages, operating and maintaining wind turbines also face numerous challenges in maintenance and repair, especially in harsh environments like Fire Island Wind, Alaska

On-site Wind Turbine repair with Titomic D523 Cold Spray

Harsh conditions: Wind turbines are often installed in windy and harsh environments such as coastal areas, where they are exposed to salt, acid rain, and extreme temperature changes. This leads to rapid corrosion and damage to turbine components. 

Common issues include:

  • Corrosion: Metal components of the turbine, especially those in direct contact with the environment, are susceptible to corrosion, leading to reduced strength and performance
  • Material degradation: Composite and polymer materials used for blades and other components can be damaged by UV radiation, bird strikes, or foreign object damage
  • Replacement costs: Replacing damaged turbine components can be very expensive, including the costs of materials, transportation, and installation, especially for turbines in remote locations

In order to address these issues, engineers have turned to Titomic D523 cold spray technology, which applies a thin layer of metal to damaged components. In the case of wind turbines, aluminum coatings are commonly used to protect components from corrosion

2. Case Study: Wind Turbine Maintenance at Fire Island Wind with Titomic D523

2.1. Overview of Fire Island Wind

Fire Island Wind: This wind farm is located in a remote area of Alaska, where harsh weather conditions such as strong winds, high humidity, and extreme temperature fluctuations pose significant challenges for wind turbine operation and maintenance

On-site Wind Turbine repair with Titomic D523 Cold Spray

The heat exchanger of one of the wind turbines at Fire Island Wind has suffered severe corrosion due to constant exposure to the marine environment and other natural elements. This has significantly reduced the turbine's efficiency and poses a risk of complete failure.

Challenges

  • High replacement cost: Replacing the heat exchanger at a remote location like Fire Island Wind is extremely costly, with transportation and installation expenses estimated at up to $80,000
  • Downtime: The lengthy process of disassembling the old component and installing the new one will result in significant downtime for the turbine, impacting the overall power generation of the wind farm
  • Logistics complexity: Transporting a large and heavy component to a remote location like Fire Island Wind requires a complex and costly logistics plan.

2.2. Repair process using Titomic D523 Cold Spray Technology

On-site Wind Turbine repair with Titomic D523 Cold Spray

Titomic D523 cold spray technology is employed to blast away corroded material and subsequently apply a layer of aluminum to the affected areas. Over time, the aluminum forms an oxide layer, shielding the underlying surface from further corrosion for years to come.

D523 utilizes a solid-state deposition process known as cold spray, thus avoiding the melting of metals and enabling the combination of various metals, including aluminum and steel. With a basic maintenance procedure:

2.2.1: Preparation of the repair area

  • Location identification: The technical team pinpoints the damaged area of the heat exchanger by [method of identification].
  • Surface cleaning: The corroded surface is thoroughly cleaned to remove rust, dirt, and other contaminants, ensuring optimal adhesion for the new coating.

On-site Wind Turbine repair with Titomic D523 Cold Spray

2.2.2: Applying an aluminum coating using cold spray technology

  • Operation of the D523 system: The D523 system uses compressed air to create a stream of supersonic aluminum particles, which are then sprayed onto the surface to be protected.
  • Creating mechanical bonds: The aluminum particles collide with the surface at high speed, creating strong mechanical bonds, forming a uniform and durable coating.
  • Advantages of cold spray:
    • No deformation: The cold spray process occurs at low temperatures, not deforming or weakening the underlying material structure.
    • High speed: The coating process is fast, saving time.
    • High adhesion: The aluminum coating adheres firmly to the metal surface, creating an effective protective layer.

Related Resource:

D523 BOOST PRODUCTIVITY IN METAL REPAIR AND MANUFACTURING

On-site Wind Turbine repair with Titomic D523 Cold Spray

2.2.3: Inspection and evaluation of maintenance results

  • Visual inspection: The technical team conducts a visual inspection to assess the quality of the coating, ensuring there are no defects such as holes or delamination.
  • Thickness measurement: Specialized measuring equipment is used to check the coating thickness, ensuring it meets technical standards.
  • Non-destructive testing: Non-destructive tests such as ultrasonic or eddy current testing can be performed to evaluate the adhesion and integrity of the coating.

2.3: Results achieved

  • Significant cost reduction: Repair costs using Titomic D523 technology are only a fraction of the cost of replacing a new heat exchanger, estimated at less than $500.
  • Time savings: The repair process is completed within 2 hours, reducing turbine downtime and increasing power output.
  • Component protection: Repaired components do not exceed 140 degrees Fahrenheit (60 °C), meaning the heat exchanger can be repaired in place without draining, with no risk of deformation or affecting the grain structure of the metal.
  • Increased lifespan: The aluminum coating protects the heat exchanger from corrosion, extending the life of the equipment and reducing future maintenance costs.
  • Environmental protection: Minimizing the replacement of large components helps reduce waste and protect the environment.

On-site Wind Turbine repair with Titomic D523 Cold Spray

Learn more:

METAL 3D PRINTING POWER TURBINE - A BREAKTHROUGH IN ENERGY PRODUCTION

3. Titomic D523 Cold Spray Technology: A Breakthrough Innovation

The cold spray technology of the D523 system operates based on the principle of spraying metal particles (such as aluminum) at high speed onto the surface to be repaired. Upon impact, these metal particles adhere to the surface and bond together to form a new coating. The D523 system has provided an effective and flexible solution for the maintenance and repair of industrial equipment, especially in the wind energy sector.

  • No metal melting: The unique feature of this technology is that the metal particles are not melted during the spraying process. This preserves the structure of the base material, avoiding deformation or weakening the material properties.
  • Flexible combination of different metals: The D523 system can use various types of metal particles, allowing the combination of different metals with different properties to create coatings with desired characteristics. For example, coating steel with aluminum increases corrosion and abrasion resistance.
  • No need to disassemble or transport large equipment: Instead of disassembling the entire damaged component and transporting it to a repair shop, cold spray technology allows for on-site repairs. This saves time and costs.
  • Protecting and restoring materials with high durability: The coating formed by the cold spray process has high adhesion, creating a durable protective layer, extending the life of components and enhancing resistance to corrosion, abrasion, and wear.

On-site Wind Turbine repair with Titomic D523 Cold Spray

Explore the Titomic D523

Due to its significant advantages compared to conventional methods, this technology is gaining widespread adoption and driving sustainable development in the energy, aerospace, mechanical, and automotive sectors

Aerospace industry

  • Repairing engine components: Aircraft engine components such as turbine blades, crankshafts, and cylinders are often subjected to high loads and temperatures, leading to wear, corrosion, and damage
  • Repairing aircraft fuselage: Cracks and holes in the aircraft fuselage can be quickly and effectively repaired by cold spraying composite or metal coatings
  • Manufacturing new components: Cold spray technology can be used to create new components with complex shapes and small sizes, meeting the specific requirements of the aviation industry

Automotive industry

On-site Wind Turbine repair with Titomic D523 Cold Spray

  • Repairing engine components: Automotive engine components like pistons, cylinders, and camshafts can be repaired using cold spray technology
  • Repairing vehicle bodies: Scratches and dents on vehicle bodies can be repaired by cold spraying materials with similar color and texture
  • Creating molds: Cold spray technology can be used to rapidly create accurate molds for casting automotive parts

Machinery industry

  • Repairing thermal power equipment: Thermal power equipment components, such as steam turbines, boilers, and compressors, are often subjected to high temperatures and pressures
  • Repairing hydroelectric equipment: Hydroelectric equipment components, such as turbine blades and shafts, can experience wear and corrosion due to exposure to water and corrosive substances

Learn more:

Cold Spray Technology – Application in Aerosapce Repair and Maintenance

This is definitely an effective and flexible solution for maintenance and repair of industrial equipment. It saves both labor costs and maintenance time

Source: Revolutionizing wind energy maintenance: Cold spray delivers long-lasting repairs


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