WeldCast

Objective:
WeldCast aims to develop a game changing welding technology that will enable assembly welding and repair welding of large-scale cast iron components in wind turbines. Developing industrialized weld methods for large cast iron components will be supported by state-of-the art characterization and modelling, aiming at the development of new procedures for welding specifications and a common quality control industry standard and a common repair catalogue industry standard. These will be converted into technical specifications with the aim of developing an industry standard, making the outcome available for all interested parties.

Expected outcome:
The long-term results of the project will allow for joining of large cast iron components for modular construction, as well as repairing casting imperfections in components otherwise due for scrapping. Facilitating assembly welding will introduce smaller foundries to the supply chain that are otherwise barred due production facility size restrictions, especially as turbines grow ever larger.

Overall, the project results are estimated to reduce the price by 10-15% of large cast iron components. In total, implementing the results from this project is estimated to cause a 0.5-1% reduction of cost for manufacturing WTs, with Danish OEM’s benefitting from the cost reductions. There will be further savings in maintenance by using up-tower repair welding, avoiding full exchange of the WT nacelle and rotor, as well as a reduction in cost and complexity of bulk transport. 

This project began April 2021 and runs for 3 years.

Total project budget: 29.553 mio. DKK.

Contact

Søren Fæster
Senior Researcher
DTU Wind
+45 46 77 57 62

FUNDING

THE PROJECT IS FUNDED BY