What is PAUT?
Phased Array Ultrasonic Testing (PAUT) is an advanced non-destructive examination technique that utilizes a set of ultrasonic testing (UT) probes made up of numerous small elements, each of which is pulsed individually with computer-calculated timing (“phasing”).
The WeldCast Project
The WeldCast project launched in 2021 with Energy Cluster Denmark, Vestas, Siemens Gamesa, DTU, Force Technology and Baettr, including meetings with wind industry OEMs and suppliers of casting. Additionally, the project has been supported by Innovation Fund Denmark.
The project aim was to develop a welding and inspection method on cast iron to meet the stringent requirements of the wind energy castings. Originally, the project was designed to cover both to weld pieces together on-site and/or do weld repairs on large castings to avoid scrap, but the project’s focus was narrowed to weld repairs in 2023.
The project has led to several significant outcomes, including:
- A standardized weld procedure
- PAUT test for basic material
- A base procedure for inspecting weld repairs areas using PAUT
- An industry-wide quality standard
- A comprehensive repair catalog.
Standard Divided into Two
With Pia Lund Hudlebusch, Quality Specialist – NDT level 3 at Baettr Sales & Services, as lead, Baettr led on this industry standard for PAUT on basic material with great participation from Force Technology and Siemens Gamesa. All work has then been presented for and reviewed and approved by the WeldCast project.
The development of the PAUT procedure has been a very long journey, where a lot of efforts have been put into. At the end, we managed to get the standard for basic material approved and implemented into APQP4Wind. This has been a great step forward.
Strengthening our Relationships
For Baettr, the WeldCast project has been a great opportunity to interact with our customers and strengthening our relationship by participating in the development of the specifications for our products, both in terms of quality requirements (WP3) and the preparation of standardized methods to repair defects (WP4). Baettr is strongly committed to sustainability targets and with this, we will improve these targets by reducing scrap rates – and associated costs.
“The WeldCast project was born with high ambitions to develop a welding standard for wind castings. The project has made it possible to reach these important steps to improve and harmonize our industry even more.
Together with the partners, we are discussing if we should initiate a WeldCast 2 project to pursue the remaining ambitions.” – Ingo Boysen, Senior VP – Technology, Quality & PMO
