Silent behemoths supporting 60 meter blades that rotate at up to 300 km/h, industrial wind turbines are modern engineering miracles. These sentinels of electric power stand up to 152 meters tall and must withstand decades of harsh environmental conditions found offshore, in coastal regions and on mountaintops.
Industrial wind turbines cost roughly $1.2 to $2.6 million to build, and installation costs increase the average investment to approximately $3.5 million per turbine. Turbine manufacturers and owners are constantly looking for ways to reduce manufacturing and maintenance costs and increase profitability by shortening production cycles, increasing production volume, and simplifying maintenance requirements.
Adhesives, sealants, lubricants and surface treatments play critical roles in the life, health and financial soundness of wind turbines. These materials are used during every phase of manufacturing, installation and day-to-day operation.
Turbine Manufacturing and Assembly
For blade and nacelle production, gigantic molds are first treated with semi-permanent mold release agents that allow large-scale composite parts to be easily removed from the mold. Blade halves and nacelle body components are bonded together and sealed using structural adhesives such as two-part polyurethanes that prevent crack propagation, micro-cracking and fatigue, and ensure the long-term integrity of the structure. Two-part polyurethanes also fill voids found on the molded assemblies.
Two component polyurethane adhesives and MS polymer sealants are used to permanently bond components such as access doors, rain deflectors and gurney flaps to the blades. Color-matching, weather-resistant MS polymers and high performance sealants protect and seal the blade and nacelle interior and exterior from moisture and environmental contaminants.
