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 method to form a wind turbine component 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,   the forming comprising forming the metallic matrix and the metallic foam as a multi-ton, complex shaped component.   
     
     
         2 . The method according to  claim 1 , further comprising controlling a distribution of metallic material in the metallic foam. 
     
     
         3 . The method according to  claim 1 , wherein the shaping comprises at least one or more of cleaning a surface of the metallic foam and pre-heating the metallic foam. 
     
     
         4 . The method according to  claim 1 , further comprising forming a sacrificial layer about a surface of the metallic foam. 
     
     
         5 . The method according to  claim 1 , further comprising:
 defining core regions in the mold cavity;   inserting cores into the core regions, the cores being configured to survive the filling; and   removing the cores following the filling.   
     
     
         6 . The method according to  claim 1 , further comprising conducting a heat treatment to improve the solidification metallurgical bond. 
     
     
         7 . The method according to  claim 1 , 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.   
     
     
         8 . The method according to  claim 1 , further comprising forming the metallic matrix and the metallic foam with annular and angular features. 
     
     
         9 . 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;   building a coated expendable foam pattern in the mold cavity;   filling a molten metallic matrix into the mold cavity to enclose the metallic foam such that the expendable foam pattern is burned out around preformed metallic foam inserts during the filling; and,   as the molten metallic matrix cools, forming a solidification metallurgical bond at an entire interface between the metallic matrix and the metallic foam.   
     
     
         10 . The method according to  claim 7 , wherein the coating comprises coating the surface of the expendable foam pattern with a refractory coating. 
     
     
         11 . The method according to  claim 9 , wherein the building of the coated expendable foam pattern comprises coating an expendable foam pattern with a refractory coating.