Although the wind turbine market is projected to grow tremendously as the industry takes an increasingly leading role in the global energy supply, corrosion threatens this growth since it can often go unseen and hinder power generation, operation, and uptime. The corrosion is typically found in locations such as wind turbine AC/DC motors and DC generators, hydraulic and lubricating systems, switchgears, control cabinets, and electrical enclosures.
Consequently, effective corrosion maintenance plays a key role in the efficient, profitable operation of wind turbines. The challenge is that traditional methods of removing corrosion can be messy, laborious, time consuming, and can even pose serious health hazards.
Today, one of the easiest to use, most effective alternatives in the war against corrosion is the increasingly important category of industrial-grade, clean technology lasers. With this approach, precision laser-based systems are used to remove corrosion, contaminants, paint, and residues with a high-energy laser beam that leaves the substrate unaffected. Preparation and cleanup time are minimal, and the low-maintenance equipment can last decades. The technology minimizes operator exposure to potential environmental health hazards. In addition, no consumables are necessary.
In the wind power industry, it is necessary to remove corrosion, residue, oil, grease, or paint before coating components or infrastructure to improve coating adhesion. Toward this end, laser-based systems have significant advantages over traditional methods, starting with ease of use.
“With laser-based systems, an operator simply points and clicks a high-energy laser beam at the surface. The substrate is not affected by the laser, and the systems do not create any mess or byproducts. The approach is eco-friendly, energy-efficient, and completes the job in approximately half the time of traditional methods when preparation and cleanup are considered. Also, no consumables are required,” says Wayne Tupuola, CEO, Orlando, Florida-based Laser Photonics, a leading provider of patented industrial grade CleanTech® lasers for cleaning and surface conditioning. The company’s systems function either as mobile standalone units or can be integrated into production lines.
In the case of Laser Photonics, the laser systems are available in portable and stationary models ranging from 50 to 3,000-watts (a 4,000-watt version is in development) with chamber sizes from 3’ x 3’ in size to 6’ x 12’. The systems can also be installed in manufacturing lines in cabinets or operated by a robotic arm.
The CleanTech lasers are used to refurbish wind turbine components and infrastructure, such as when removing a previous coating along with any corrosion to facilitate the new coating’s adhesion to the surface. The laser pre-treatment of metal surfaces can also be used to streamline various manufacturing processes by removing any rust from components.
Another common laser application involves pre-weld treatment to remove corrosion, mill scale, residue, and any impurities on the surface of the base material that would compromise the weld’s effectiveness. It is essential to avoid any such contamination on a weld’s surface, which could otherwise lead to a weakening of the weld’s mechanical properties, requiring rework.
Laser treatment is also used for post-weld cleaning to increase the life expectancy and corrosion resistance of a welded joint. Post-weld cleaning is important for stainless steel as well. The strength of stainless steel allows wind turbines to be built taller and more efficiently while providing corrosion resistance.
For more information on laser cleaning solutions for surface preparation, contact Laser Photonics at (407) 804-1000 or visit www.laserphotonics.com.