Abstract: A crane system for a wind turbine is disclosed. The crane system includes a support structure, a movable structure, a slidable device, a first actuator unit, and a plurality of second actuator units. The slidable device includes a base, a retention component, and first, second, third, and fourth pairs of clamping arms. The base is coupled to the support structure. The retention component is coupled to either side of the base to define a channel between the retention component and the base. The first and second pairs of clamping arms are spaced apart and coupled to each other and to the base. The third and fourth pairs of clamping arms are disposed within the channel, spaced apart, and coupled to each other. The first actuator unit is coupled to the slidable device and each second actuator unit is coupled to the first, second, third, and fourth pairs of clamping arms.

Abstract: An integral ring gear and torque arm for a wind turbine gearbox and method of manufacturing same includes forming the ring gear and the associated gear housing as a single part using the same material, e.g., using a casting process. Further, the ring gear defines an inner circumferential surface having a plurality of gear teeth. Thus, the method also includes applying a coating material to the gear teeth of the ring gear via an additive manufacturing process, such as cold spraying, so as to increase a hardness of gear teeth.

Abstract: An integral ring gear and torque arm for a wind turbine gearbox and method of manufacturing same includes forming the ring gear and the associated gear housing as a single part using the same material, e.g., using a casting process. Further, the ring gear defines an inner circumferential surface having a plurality of gear teeth. Thus, the method also includes applying a coating material to the gear teeth of the ring gear via an additive manufacturing process, such as cold spraying, so as to increase a hardness of gear teeth.

Abstract: A crane system for a wind turbine is disclosed. The crane system includes a support structure, a movable structure, a slidable device, a first actuator unit, and a plurality of second actuator units. The slidable device includes a base, a retention component, and first, second, third, and fourth pairs of clamping arms. The base is coupled to the support structure. The retention component is coupled to either side of the base to define a channel between the retention component and the base. The first and second pairs of clamping arms are spaced apart and coupled to each other and to the base. The third and fourth pairs of clamping arms are disposed within the channel, spaced apart, and coupled to each other. The first actuator unit is coupled to the slidable device and each second actuator unit is coupled to the first, second, third, and fourth pairs of clamping arms.

Abstract: Systems and methods for monitoring wind turbine loading are provided. In one embodiment, a system includes a main shaft, a bedplate, and a gearbox coupled to the main shaft and mounted to the bedplate. The gearbox includes an outer casing and a torque arm extending from the outer casing. The system further includes an isolation mount coupled to the torque arm, and a sensor configured to measure displacement of the torque arm. In another embodiment, a method includes operating the wind turbine, and detecting displacement of a torque arm of a gearbox of the wind turbine. The method further includes calculating a moment for a main shaft of the wind turbine based on the displacement of the torque arm.

Abstract: Components and methods of processing such components from precipitation-strengthened alloys so that the components exhibit desirable grain sizes following a supersolvus heat treatment. The method includes consolidating a powder of the alloy to form a billet having an average grain size. The billet is then forged at a temperature below the solvus temperature to form a forging having an average grain size of not coarser than the grain size of the billet. The billet is then forged at a total strain of at least 5%, after which at least a portion of the forging is heat treated at a temperature below the solvus temperature to pin grains within the portion. The entire forging can then be heat treated at a temperature above the solvus temperature of the alloy without coarsening the grains in the portion.

Abstract: A method for operating a gasifier includes detecting a corrosive compound between a combustion chamber defined within the gasifier and an inner wall of a pressure vessel that at least partially surrounds the combustion chamber via a corrosion sensor and increasing the temperature of the inner wall of the pressure vessel to a temperature that is greater than a dew point of the corrosive compound via a heater that at least partially surrounds the pressure vessel. The method may also include adjusting a flow of at least one of a fuel, an oxidant and a diluent to the gasifier in response to the detection of the corrosive compound so as to modify the dew point of the corrosive compound.

Abstract: Components and methods of processing such components from precipitation-strengthened alloys so that the components exhibit desirable grain sizes following a supersolvus heat treatment. The method includes consolidating a powder of the alloy to form a billet having an average grain size. The billet is then forged at a temperature below the solvus temperature to form a forging having an average grain size of not coarser than the grain size of the billet. The billet is then forged at a total strain of at least 5%, after which at least a portion of the forging is heat treated at a temperature below the solvus temperature to pin grains within the portion. The entire forging can then be heat treated at a temperature above the solvus temperature of the alloy without coarsening the grains in the portion.

Abstract: Improved methods and containers for forming billets using hot isostatic pressing are provided. The methods and containers have features that control the deformations of the container during the high temperatures and pressures experienced in such processing so that the loss or removal of material from the resulting billet can be optimized.

Abstract: A method of separating a powder mixture is disclosed. A first magnetic field is applied to the powder mixture which may contains a non-magnetic metal powder and a contaminant powder. A field strength of the first magnetic field magnetizes the non-magnetic metal powder and leaves the contaminant powder non-magnetized. A second magnetic field is applied to the powder mixture to separate the magnetized metal powder from the non-magnetized contaminant powder.

Abstract: Various turbine component preforms are disclosed having near-net shape features. In one embodiment, a turbine casing preform is disclosed. The turbine casing preform includes an as-cast body comprising a partially cylindrical wall section of a turbine casing, the wall section having an inner surface and an outer surface. The turbine casing preform also includes a circumferentially-extending vane slot formed in the wall section on the inner surface. In another embodiment, a turbine nozzle diaphragm preform is disclosed. The turbine nozzle diaphragm preform includes an as-cast body comprising a partially-cylindrical wall section of a turbine nozzle diaphragm having an inner surface and an outer surface. The turbine nozzle diaphragm preform also includes an as-cast, circumferentially-extending seal member projecting from one of the outer surface or inner surface.

Abstract: Systems and methods for monitoring wind turbine loading are provided. In one embodiment, a system includes a main shaft, a bedplate, and a gearbox coupled to the main shaft and mounted to the bedplate. The gearbox includes an outer casing and a torque arm extending from the outer casing. The system further includes an isolation mount coupled to the torque arm, and a sensor configured to measure displacement of the torque arm. In another embodiment, a method includes operating the wind turbine, and detecting displacement of a torque arm of a gearbox of the wind turbine. The method further includes calculating a moment for a main shaft of the wind turbine based on the displacement of the torque arm.

Abstract: A crack-resistant member for preventing crack propagation, a method of preventing crack propagation, and method of assembly a tower are provided. The crack-resistant member includes at least one insert attached to at least one removed portion at a predetermined location along a girth weld and adjacent a heat affected zone of the tower. The at least one insert is positioned perpendicular to a weld direction and intersecting the girth weld. The at least one insert prevents crack propagation in the girth weld of the tower.

Abstract: A method of separating a powder mixture is disclosed. A first magnetic field is applied to the powder mixture which may contains a non-magnetic metal powder and a contaminant powder. A field strength of the first magnetic field magnetizes the non-magnetic metal powder and leaves the contaminant powder non-magnetized. A second magnetic field is applied to the powder mixture to separate the magnetized metal powder from the non-magnetized contaminant powder.

Abstract: A crack-resistant member for preventing crack propagation, a method of preventing crack propagation, and method of assembly a tower are provided. The crack-resistant member includes at least one insert attached to at least one removed portion at a predetermined location along a girth weld and adjacent a heat affected zone of the tower. The at least one insert is positioned perpendicular to a weld direction and intersecting the girth weld. The at least one insert prevents crack propagation in the girth weld of the tower.

Abstract: A method for operating a gasifier includes detecting a corrosive compound between a combustion chamber defined within the gasifier and an inner wall of a pressure vessel that at least partially surrounds the combustion chamber via a corrosion sensor and increasing the temperature of the inner wall of the pressure vessel to a temperature that is greater than a dew point of the corrosive compound via a heater that at least partially surrounds the pressure vessel. The method may also include adjusting a flow of at least one of a fuel, an oxidant and a diluent to the gasifier in response to the detection of the corrosive compound so as to modify the dew point of the corrosive compound.

Abstract: A crack-resistant member for preventing crack propagation, a method of preventing crack propagation, and method of assembly a tower are provided. The crack-resistant member includes at least one insert attached to at least one removed portion at a predetermined location along a girth weld and adjacent a heat affected zone of the tower. The at least one insert is positioned perpendicular to a weld direction and intersecting the girth weld. The at least one insert prevents crack propagation in the girth weld of the tower.

Abstract: A casting process for producing metal alloy castings, facecoats and apparatuses suitable for carrying out the process, and castings produced by the process. The casting process entails the use of a mold having a cavity with a continuous aluminum-containing solid facecoat on its surface. A molten quantity of a metal alloy is introduced into the mold cavity so that the molten alloy contacts the solid facecoat. The mold is then allowed to cool to solidify the molten alloy and form a cast product. During the casting process, aluminum in the solid facecoat diffuses into the cast product to form an aluminum-containing surface region at the casting surface. Following removal of the cast product from the mold, an alumina-containing scale grows on the casting surface as a result of oxidation of the casting surface region.

Abstract: Components and methods of processing such components from precipitation-strengthened alloys so that the components exhibit desirable grain sizes following a supersolvus heat treatment. The method includes consolidating a powder of the alloy to form a billet having an average grain size. The billet is then forged at a temperature below the solvus temperature to form a forging having an average grain size of not coarser than the grain size of the billet. The billet is then forged at a total strain of at least 5%, after which at least a portion of the forging is heat treated at a temperature below the solvus temperature to pin grains within the portion. The entire forging can then be heat treated at a temperature above the solvus temperature of the alloy without coarsening the grains in the portion.

Abstract: A crack-resistant member for preventing crack propagation, a method of preventing crack propagation, and method of assembly a tower are provided. The crack-resistant member includes at least one insert attached to at least one removed portion at a predetermined location along a girth weld and adjacent a heat affected zone of the tower. The at least one insert is positioned perpendicular to a weld direction and intersecting the girth weld. The at least one insert prevents crack propagation in the girth weld of the tower.