High-Precision Renewable Energy & Wind Turbine Castings

Thanks to U.S. goals for clean electricity generation, the demand for wind energy will only increase. Bescast is at the forefront of this trend, casting the parts of a wind turbine that the industry needs to continue to grow.

High-Precision Investment Casting for the Win

Bescast uses high-precision investment casting, also called lost-wax casting, to deliver the mission-critical components of a wind turbine. This process is an age-old method of making detailed and intricate metal pieces.

Investment casting is straightforward:

1. We shape the required part out of wax.

2. We cover that wax model with a ceramic coating.
3. We melt the wax away, leaving behind a ceramic mold.
4. Molten metal is poured into this mold.
5. After the metal cools and hardens, we break the ceramic mold to uncover the finished metal part.

The result is a precision component cast to tight tolerances.

Why Use Investment Casting for Casting the Parts of a Wind Turbine?

Investment casting is perfect for making precise wind turbine parts. This method creates top-notch turbine castings due to several key benefits:

Versatility and Complex Geometry

Unlike other casting methods, investment casting can easily handle complex shapes, including undercuts, slots, holes, and intricate details needed for wind turbine parts. This flexibility allows for the creation of unique, customized components necessary for advanced wind turbine technology.

High-Dimensional Accuracy and Detail

Investment casting can achieve very tight tolerances, often within ±0.005 inches, and even finer for smaller parts. This precision is essential for casting the parts of a wind turbine where even a small error in size or shape can impact the turbine's performance.

Wide Material Selection

Casting steel parts is essential for wind turbines. Investment casting works with a wide range of materials, including stainless steel, enabling manufacturers to select the best material for each component's specific performance needs. Some materials are better at resisting corrosion, handling extreme temperatures, or providing particular mechanical properties crucial for wind turbine parts.

Reduced Assembly Operations

Investment casting allows for the creation of single, monolithic components, eliminating the need for multiple pieces that require assembly. This reduces potential failure points and enhances the strength and reliability of the part, which is vital for wind turbine manufacturers.

Quality and Reliability

The investment casting process results in minimal surface defects and internal porosities, meaning the finished parts need less machining and finishing. This saves time and resources and leads to highly reliable components, critical for wind turbines where failure can have significant consequences.

The Capabilities You Want in Your Turbine Castings Supplier

Investment casting is an excellent method for creating precise and reliable turbine castings. Bescast, a top provider of turbine components, excels in this advanced technique to meet the rigorous standards of the renewable energy industry. Our capabilities are second to none.

Bescast certifications include:

ISO 9001:2015
Nadcap
Heat treatment

NDT (non-destructive testing) (radiography & penetrant)
Welding

We use advanced casting simulation software and CAD CAM technologies to quickly create prototypes and validate engineered castings. Our all-in-one manufacturing and logistics capabilities ensure a smooth production process, casting the parts of a wind turbine that you need. You can rely on our:

Design, Prototyping, and Engineering Support

Bescast offers expert engineering services throughout a product's lifecycle. We assist with design and development and produce components to our clients' specifications. Using our advanced engineering tools, we can quickly move from a design blueprint to a 3D prototype. Our CAD CAM services and casting software allow us to accurately simulate and verify all manufacturing steps.

ProCast Software Usage

ProCast, a widely recognized simulation tool in product design and process development, improves casting quality and yield for wind turbine components. It uses Finite Element Analysis (FEA) to rapidly simulate casting processes, aiding in a better understanding of solidification.

Developed with leading research institutes, ProCast is a comprehensive and precise casting software solution meeting the needs of the renewable energy sector. Compared to traditional methods, ProCast is essential for engineered castings, reducing manufacturing costs, shortening mold development time, and enhancing casting quality.

CAD CAM Solutions

We use your electronic data to import your solid model or CAD CAM design into our fully integrated system. This allows us to quickly create rapid prototype models and start tool builds in our internal tooling department. With our CAD CAM solutions, we can produce rapid prototype castings swiftly and provide crucial design feedback, saving clients time and money during production.

CURRENT PRODUCTION

Manufacturing Capacity

• 75,000 ft2 manufacturing facility

• 10,000 ft engineering and customer service

• 200+ full-time employees

Alloys Currently Poured on a Production Basis

Steel

• 15-5PH

• 17-4PH

• 300 Series

• 400 Series

Cobalt

• MM509

• L605

• X40 (S31)

• WI-52

Nickel (vacuum)

• HastX

• IN100

• IN625

• IN713

• IN718

• IN738

• IN792

• MM247

• R77

• R80

• R125

• U500

Quality Certifications

• ISO9001:2015

• AS9100 Rev D

• Nadcap

• Heat Treat

• NDT (Non-Destructive Testing) (Radiography & Penetrant)

• Welding

Approved Supplier To:

• Advanced Atomization Technologies
• Collins Aerospace
• Eaton Corporation
• GE Aviation
• Parker Hannifin

• Pratt Whitney Canada
• Prat Whitney America
• Rolls Royce N.A.
• Siemens Energy
• Solar Turbines

• Woodward

Frequently Asked Questions About Casting Parts for a Wind Turbine

As a trusted supplier in the $2.4 billion wind turbine casting market, Bescast has a wealth of information to share. Here are some questions we commonly get from our clients.

What Are the Benefits of Using Investment Casting for the Parts of a Wind Turbine?

Investment casting offers high precision, allowing for the creation of intricate and detailed parts with tight tolerances. This method is ideal for producing the complex shapes and designs often required in wind turbine components. Additionally, investment casting can handle a wide range of materials, providing flexibility in material selection to meet specific performance requirements.

How Does Investment Casting Contribute to the Efficiency of Wind Turbine Production?

Investment casting streamlines the production process by creating complex parts in a single component, decreasing the need for assembly and additional machining. This saves time and resources and enhances the wind turbine components' overall reliability and efficiency.

What Quality Control Measures Are in Place for Investment Casting of Wind Turbine Parts?

Quality control in investment casting involves several steps, including using advanced simulation software to predict and correct potential issues before production begins. We also employ non-destructive testing (NDT) methods, such as radiography and penetrant testing, to ensure the integrity of the cast parts. These measures help maintain high standards of quality and reliability in the final wind turbine components.

Trust Bescast for Casting the Parts of Wind Turbines

Backed by years of expertise, Bescast is the source you want for your turbine castings. You can rely on us to cast parts of your wind turbines. Our experience and dedication to quality ensure you get the high-precision parts you need. Contact us today for assistance with your next project.

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