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 initially turned on a lathe and scored to a depth of 1.5-2mm, creating a solid profile for coating adhesion. A Bristle blaster was used over the scored surface to enhance the preparation further. 102 Metal Repair Fluid was then applied to the rotating shaft with a plastic applicator, gradually building up the coating in multiple wet-on-wet layers to prevent any air entrapment. The final application thickness reached 2-3mm. After curing overnight, the shaft was turned and machined down to a smooth, flush finish using tips and cutting settings typically used for machining aluminium. This process allowed for precise control and ensured a high quality surface finish.

Products Used

102 Metal Repair Fluid

Results and Benefits

The application of 102 Metal Repair Fluid successfully restored the shaft to its original specifications, reinstating structural integrity and providing a smooth, durable surface. This robust multi-layered coating was designed to withstand the demands of the power generation environment, offering long term durability and performance stability. The repair significantly extended the shaft’s lifespan, reducing the frequency of maintenance and the associated costs. By avoiding a costly replacement, the facility minimised downtime, ensuring continued reliability in power generation operations and contributing to overall efficiency. The client’s satisfaction with the solution highlights Resimac’s effectiveness in delivering high quality repairs suited to critical industrial applications.