Exploring new ways to extend the life of wind-turbine main shafts

Pushing the boundaries of what’s possible in wind-power drivetrain maintenance is part of our everyday work at Gamesa Gearbox. Recently, our After-Market department, led a technical study that dives deep into how advanced surface-coating techniques can give main shafts a second life.

The paper — “Performance enhancement in wind turbine main shafts using surface coating techniques” — looks at two promising processes: thermal spray (HVOF/EAWS) and laser cladding. Both show remarkable gains in wear resistance and bending-fatigue performance compared to untreated base materials.

A few key takeaways:

• Main-shaft failures are increasing as turbines grow in size and power output — a challenge the industry can’t ignore.
• Coating technologies make it possible to refurbish worn shafts instead of replacing them, cutting down both costs and lead times.
• Lab tests confirm that, when process parameters are tightly controlled, coated shafts deliver significantly lower wear and better fatigue resistance.

These findings point to a clear direction: smarter, more sustainable ways to keep turbines running longer and stronger. It’s the kind of innovation that defines our aftermarket approach — practical, data-driven, and aimed at real-world impact.

Read the full article on Wind Systems Magazine.