Sustainable Power Needs Sustainable Parts.
The transition to a net-zero grid isn't just about building new capacity; it's about keeping existing assets running longer and more efficiently. Whether it is an offshore wind turbine battling salt spray or a Concentrated Solar Power (CSP) plant managing molten salt at 600°C, renewable infrastructure faces brutal operating conditions.
LAYRR Materials supplies the advanced powders that extend the life of green infrastructure. We specialise in materials for repair (DED), thermal management, and corrosion resistance, helping operators minimise downtime and maximise output.
1. Wind Energy (Offshore & Onshore)
The Battle Against Friction and Salt.
Wind turbines are massive, remote mechanical systems. When a gearbox fails offshore, the cost is astronomical. Additive Manufacturing—specifically Directed Energy Deposition (DED)—is revolutionising how we maintain these giants.
The Challenge: Gearbox tooth failure and leading-edge erosion on blades.
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The LAYRR Solution:
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Repair, Don't Replace: Using mobile DED robots and LAYRR Stellite® 6 (CoCrW) or Inconel® 625 powder to re-clad worn gear teeth and shafts in situ, without unshipping the component.
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Obsolete Spares: Printing replacement hydraulic manifolds and brackets for 20-year-old turbines where the original supply chain no longer exists.
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2. Solar & CSP (Concentrated Solar Power)
Harvesting Heat.
In CSP plants, mirrors focus sunlight to heat transfer fluids (molten salts). Efficiency is dictated by how hot you can run the system without melting the pipes.
The Challenge: Extreme thermal cycling and heat exchange efficiency.
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The LAYRR Solution:
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Copper (Pure Cu / CuCrZr): Printing complex, topology-optimised heat exchangers that are 40% smaller but transfer 2x the heat compared to shell-and-tube designs.
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High-Temp Alloys: Inconel® 718 and Hastelloy® X for receiver tubes and valves handling molten salt at >550°C.
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3. Hydro & Geothermal
Flow and Fluid Dynamics.
Water and steam are destructive forces. Hydro turbines suffer from cavitation (pitting caused by collapsing bubbles), while geothermal fluids are highly corrosive brines.
The Challenge: Cavitation erosion on runner blades and sulfide stress cracking in geothermal piping.
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The LAYRR Solution:
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Cavitation Resistance: Cobalt-Chrome (CoCrMo) powders for printing or cladding turbine runners. CoCr offers significantly higher cavitation resistance than standard stainless steel.
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Corrosion Armour: Duplex Stainless Steel and Titanium Grade 23 for geothermal pump housings and impellers exposed to acidic brine.
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Critical Materials for Renewables
| Sector | Component | Recommended Material | Why? |
| Wind | Gearbox Gears & Shafts | Maraging M300 / 4340 | High strength repair feedstock for DED applications. |
| Solar | Heat Sinks / Exchangers | Pure Copper / AlSi10Mg | Maximize thermal conductivity for inverters and receivers. |
| Hydro | Pelton / Francis Runners | Stainless Steel 17-4 PH | Balance of corrosion resistance, strength, and printability. |
| Hydrogen | Electrolyser Plates | Titanium / 316L | Corrosion resistance in acidic electrolysis environments. |
| Grid | High Voltage Breakers | Copper / Tungsten-Copper | Arc resistance and electrical conductivity. |
The LAYRR Standard: Large Format Support
Renewable energy parts are rarely small.
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DED Calibration: We supply coarse-cut powders (45-150µm) specifically tuned for high-deposition-rate DED and Cold Spray systems used in heavy industry repair.
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Bulk Logistics: For large-scale repairs, 5kg bottles aren't enough. We offer bulk packaging (20kg – 200kg drums) to keep continuous DED cells running without interruption.