company news about The Strategic Advantages of Free Forging in Wind Power Turbine Manufacturing

Enhancing Reliability, Performance, and Cost Efficiency in Renewable Energy Infrastructure

As the global wind energy sector expands—with capacity expected to reach 1,400 GW by 2030 (Global Wind Energy Council, GWEC)—the demand for high-integrity turbine components has never been greater. Free forging, a proven industrial manufacturing process, is increasingly recognized as the optimal solution for critical wind turbine parts such as main shafts, gearbox rings, and flanges.

Key Advantages of Free Forging for Wind Turbines

1. Superior Mechanical Properties

   • Free forging refines the grain structure of metals (e.g., ASTM A668 steel), delivering 30% higher fatigue strength compared to cast or machined alternatives (ASM International, 2022). This is critical for turbine components subjected to cyclic loads exceeding 10 million revolutions annually.

2. Enhanced Reliability in Harsh Conditions

   • Forged components exhibit 50% lower failure rates in offshore wind farms, where saltwater corrosion and extreme weather prevail (DNV GL Energy Transition Outlook).

3. Cost Efficiency at Scale

   • While initial tooling costs are lower than closed-die forging, free forging reduces material waste by up to 20% (U.S. Department of Energy, 2023), aligning with wind energy’s push for sustainable manufacturing.

4. Flexibility for Large-Scale Parts

   • Free forging accommodates massive single-piece designs (e.g., 8-meter-diameter rotor flanges), eliminating weak points from welded joints.

Industry Adoption & Future Outlook

Leading OEMs like Siemens Gamesa and Vestas now prioritize free-forged components for next-gen turbines exceeding 15 MW capacity. According to Wood Mackenzie, the wind turbine forging market will grow at 6.8% CAGR through 2030, driven by offshore wind investments in Europe and Asia.

Why Partner with Changzhou Tiangong Forging Co.Ltd ?

• Certified Expertise: ISO 9001 & EN 15085 compliant forging processes.

• Proven Track Record: 10,000+ turbine components supplied since 2015.

• R&D-Driven Solutions: Custom alloys tested to IEC 61400-6 wind turbine standards.