Wind turbines rise into the sky on enormous feet. To ensure these giants can reliably generate electricity for many years to come, the iron processing industry must manufacture their massive components in a stable, resource-saving and yet cost-effective way. However, material inclusions such as dross are often unavoidable while casting. Fraunhofer researchers are currently working to detect and analyze such material defects.
Wind turbines should be environmentally friendly, highly efficient, cost-effective, and able to function reliably for at least 20 years. However, as turbines become increasingly powerful, the demands on the components used are growing, and so is the risk of material fatigue. Material defects such as inclusions from slag, known as dross, are considered undesirable because they greatly reduce the load-bearing capacity of cast iron components with spheroidal graphite. This special kind of cast iron is also used to make a wind turbine’s mainframe and rotor hubs. Manufacturing such components is difficult due to the build-up of dross that often occurs despite tricks in casting techniques.
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