Hybrid laser-arc welding of large steel structures in the wind turbine industry

The hybrid laser-arc welding technology has been utilized in shipbuilding since the 1990's, and its capability has been proven for steel plate thicknesses less than 15 mm. However, when applying this technology to larger dimension, the risk of the formation of hot cracks in welds increases, which is one of the main constraints for using hybrid laser-arc welding in fatigue-affected structures, e.g. wind turbine monopiles and offshore jackets.

The objective of this project is to take advantage of recently gained insight into the cause of hot cracks in thick section steel welds, and transfer this technology to the wind power industry. More specifically, the goal is to implement a robotized hybrid laser-arc welding setup that allows quality welds and minimized distortion in large steel structure related to wind power industry.

The purpose of the project is to minimize the production cost of wind energy. This price largely depends on the manufacturing costs for the turbine, where a significant part comes from the welding procedures of the towers.

Less expensive welds made with a combination of lasers and ordinary welding torches has a great potential in the industry, and this project aims to show this.

This project will mature the welding technique and prepare it for use in the wind industry, to weld thick sections of steel. The project will also treat issues regarding work safety, costs and changes in production planning.