Wind turbine component having a lightweight structure

Abstract

A wind turbine component having a lightweight structure is provided and includes a metallic matrix defining a cavity, metallic foam enclosed within the cavity and a solidification metallurgical bond formed at an entire interface between the metallic matrix and the metallic foam.

1 . A wind turbine component configured to have a lightweight structure, the wind turbine component comprising:
 a metallic matrix defining a cavity;   metallic foam enclosed within the cavity; and   a solidification metallurgical bond formed at an entire interface between the metallic matrix and the metallic foam.   
     
     
         2 . The wind turbine component according to  claim 1 , for use as a wind turbine casing, gearbox housing or bedplate. 
     
     
         3 . The wind turbine component according to  claim 1 , for use as a multi-ton component of wind turbine. 
     
     
         4 . The wind turbine component according to  claim 1 , for use as a cast housing torque arm of a gearbox. 
     
     
         5 . The wind turbine component according to  claim 1 , wherein the metallic matrix comprises at least one or more of aluminum, magnesium, iron, nickel, titanium, cobalt, copper, chromium and alloys thereof 
     
     
         6 . The wind turbine component according to  claim 1 , wherein the metallic foam comprises at least one or more of aluminum, magnesium, iron, nickel, titanium, cobalt, copper, chromium and alloys thereof. 
     
     
         7 . The wind turbine component according to  claim 1 , wherein the solidification metallurgical bond comprises an interface region in which eutectic precipitates are formed. 
     
     
         8 . A method to form a wind turbine component configured to have a lightweight structure, the method comprising:
 shaping a mold cavity between metallic foam and an exterior mold;   filling a molten metallic matrix into the mold cavity to enclose the metallic foam; and,   as the molten metallic matrix cools, forming a solidification metallurgical bond at an entire interface between the metallic matrix and the metallic foam.   
     
     
         9 . The method according to  claim 8 , further comprising controlling a distribution of metallic material in the metallic foam. 
     
     
         10 . The method according to  claim 8 , wherein the shaping comprises at least one or more of cleaning a surface of the metallic foam and pre-heating the metallic foam. 
     
     
         11 . The method according to  claim 8 , further comprising forming a sacrificial layer about a surface of the metallic foam. 
     
     
         12 . The method according to  claim 8 , further comprising defining core regions in the mold cavity. 
     
     
         13 . The method according to  claim 8 , further comprising conducting a heat treatment to improve the solidification metallurgical bond. 
     
     
         14 . The method according to  claim 8 , wherein the shaping comprises:
 building an expendable foam pattern in the mold cavity;   coating a surface of the expendable foam pattern; and   burning out the expendable foam pattern around preformed metallic foam inserts during the filling.   
     
     
         15 . A method to form a wind turbine component configured to have a lightweight structure, the method comprising:
 shaping a mold cavity within a metallic matrix having an opening;   filling the mold cavity with molten metallic material and a foaming agent;   closing the opening such that the metallic matrix encloses the mold cavity; and,   as the molten metallic material cools and foams within the mold cavity, forming a solidification metallurgical bond at an entire interface between the metallic matrix and the metallic foam.   
     
     
         16 . The method according to  claim 15 , further comprising controlling a distribution of the metallic material in the mold cavity. 
     
     
         17 . The method according to  claim 15 , wherein the shaping comprises at least one or more of cleaning a surface of the metallic matrix and pre-heating the metallic matrix. 
     
     
         18 . The method according to  claim 15 , further comprising forming a sacrificial layer about a surface of the metallic matrix. 
     
     
         19 . The method according to  claim 15 , further comprising defining core regions in the mold cavity. 
     
     
         20 . The method according to  claim 15 , further comprising conducting a heat treatment to improve the solidification metallurgical bond.