Worn Power Generation Shaft: A Case Study

28th November 2024

At a power generation facility, the end of a critical shaft showed significant wear, requiring resurfacing to restore its original dimensions and ensure optimal functionality. This wear posed a risk to equipment performance and could lead to additional maintenance if left unaddressed. A repair solution was essential to avoid operational disruptions and maintain reliable service.

Resimac’s Worn Power Generation Shaft Solution

Prepare the shaft by turning and scoring the surface.
Rebuild to original dimensions with 102 Metal Repair Fluid.

Application Details

The shaft was first turned on a lathe and scored to a depth of 1.5–2mm to create a solid profile for optimal coating adhesion. A Bristle Blaster was then used over the scored surface to enhance preparation and ensure uniform roughness. 102 Metal Repair Fluid was applied to the rotating shaft using a plastic applicator, building up the coating in multiple wet-on-wet layers to prevent air entrapment. The final application reached a thickness of 2–3mm.

After curing overnight, the shaft was precisely machined down to its original dimensions using specialised tips and cutting settings suitable for machining aluminium. This ensured a smooth, flush finish with a high quality surface capable of withstanding operational demands.

Products Used

102 Metal Repair Fluid

Results and Benefits

The application of 102 Metal Repair Fluid restored the shaft to its original specifications, reinstating structural integrity and delivering a smooth, durable surface. This robust multi-layered coating was engineered to withstand the demands of the power generation environment, providing long term durability and consistent performance. The repair extended the shaft’s lifespan, reducing maintenance frequency and associated costs while avoiding the expense of a full replacement.

By minimising downtime, the facility maintained reliable operations, ensuring continued efficiency in power generation. The success of this repair demonstrates Resimac’s ability to deliver effective, high quality solutions for critical industrial applications, meeting the client’s needs for both performance and cost efficiency.