Wind turbines are a popular source of power, complete with gearboxes that can last up to 20 years before needing a replacement. However, whether it’s due to the elements or a lack of lubrication, they can develop premature wear that requires immediate chrome plating repairs. Here’s a closer look at the most common issues and the indicators that reveal a need for service. 

How to Know a Wind Turbine Gearbox Requires Repairs

1. False Brinelling & Fretting

The moving parts in a gearbox rely on lubrication to prevent metal from grinding up against metal and preserve the condition of each piece. Those that lack lubrication or have years of service could experience false brinelling and fretting, which are indentations that develop within the gearbox itself. These can inhibit its operation and cause vibrations and ultimately catastrophic failure. Providing regular lubrication and maintenance is essential for preventing wear of this type. 

2. Micropitting

The turbine’s height exposes the gearbox to some of the harshest winds and weather conditions. Over time, this can cause corrosion within the bearings and bearing surfaces. It increases the risk of rust and jeopardizes the performance and reliability of the gearbox. 

Chrome plating repairs are one of the few ways to extend the life span of your turbine's gearbox. 

3. Microstructural Alteration

Even if the bearings are new, there’s a chance that they could sustain a microstructural alteration. This is when white etching area (WEA) cracks appear within the subsurface of the material and can result in axial damage. 

It could be that the lubricant is reaching the end of its life span and is unable to provide the appropriate amount of protection. Replacing it with a newer product and securing the necessary repairs is the only way to ensure continued functionality.

If your turbines require chrome plating repairs, reach out to R. A. Heller Co. of Cincinnati, OH. They have over 70 years of experience and provide a variety of machining services within their 20,000-square-foot facility. Complete with a 10-ton crane, they work with an assortment of materials and are a member of the Tri-State Tooling & Manufacturing Association. Call (513) 771-6100 to place an order or visit their website for additional information on their chrome plating techniques.