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Aluminum foam in wind energy

Aluminum foam or aluminum foam sandwiches can also be used in wind turbines. In turbine blades or guide plates, this can save weight and with it drive power. Another advantage is that it saves considerable manufacturing effort on the turbine blades: aluminum foam shaped elements can be given the desired shape as they are produced.

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What are the advantages of aluminum foam in wind turbines?

Aluminum foam or aluminum foam sandwiches replace solid aluminum and so save weight, which means lower drive forces are needed. Dropping the stabilizing sheets also saves space. The material can be shaped and welded; joints can be made with threaded inserts, which makes it easier to mount the components in the turbine.

  • Weight saving by using aluminum foam or aluminum foam sandwiches instead of solid aluminum
  • Lower drive forces needed as a result
  • Space saving / no stabilizing sheets
  • Can be shaped and welded, joints possible with threaded inserts

In which components of a wind turbine is aluminum foam used?

Two areas of use are documented: turbine blades and guide plates. In both, aluminum foam or aluminum foam sandwiches can save weight and with it drive power. On the turbine blades in particular, considerable manufacturing effort is also saved, because the aluminum foam shaped elements are given the desired shape as they are produced, instead of being laboriously machined afterwards.

How does shaping the foam reduce manufacturing effort?

Aluminum foam shaped elements are given the desired shape as they are produced. For wind turbines, that saves considerable manufacturing effort on the turbine blades. Because the material can be shaped and welded and joints can be made with threaded inserts, it can be integrated directly into existing designs, without additional stabilizing sheets, and leaving them out saves space.

A tunnel-shaped element of aluminum foam with a continuous rectangular channel; the outer surfaces are coarsely faceted, the inner surfaces of the channel smoother.
A shaped element with a continuous channel. The contour comes from the tool; the channel was not drilled afterwards.Photo: Yvonne Spielmann

Frequently asked questions

Why does aluminum foam reduce the drive power a wind turbine needs?

In turbine blades or guide plates, aluminum foam used instead of solid aluminum saves weight, and so lower drive forces are needed.

Can aluminum foam components in wind turbines be bolted and welded?

Yes. The material can be shaped and welded; joints can be made with threaded inserts.

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