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    Using plasma spray coating to improve the performance of gears for wind turbine
    (Altınbaş Üniversitesi / Lisansüstü Eğitim Enstitüsü, 2022) Jasim, Jasim Ahmed Jasim; Alaiwi, Yaser
    In a wind turbine, a gearbox is often used to raise the rotating speed from the main shaft's low speed to the shaft that connects to the electrical generator. A wind turbine's gearbox is exposed to significant cyclic stress because of the stochastic, fluctuating wind loads. As a result, the gearbox system is said to have a greater failure rate than the other parts of wind turbines. The wind energy industry is aware that one of the most important factors in lowering wind turbine downtime and raising the competitiveness of wind energy over fossil fuels is enhancing the dependability of gearbox systems. On the other hand, a wind turbine is a sophisticated multi-physics system that incorporates rotor blade aerodynamics, gear dynamics, an electrical generator, and control systems. A difficult problem is getting a precise prognosis of the gearbox lifespan. Moreover, spraying plasma is widely utilized as wear-resistance coatings in critical components in great-tech sectors such as aerospace and nuclear energy and traditional industries such as textiles, chemicals, plastics, and paper. The current thesis aims to improve gears' performance by applying titanium alloy in four different thicknesses (0.1, 0.2, 0.5, and 1 μm) using plasma spray coating, simulated by the ANSYS software program. The results of the ANSYS show that applying Ti-6Al4V in different thicknesses has approximately no effect on the temperature of the gearbox comparison with gears without coating. In contrast, it has a significant effect on the total heat flux. Furthermore, thermal and structural analysis using Ti-6Al-4V as a plasma spray coating on the gearbox significantly affects equivalent (von-misses) stress, maximum principal stress, total deformation, shear stress, and shear strain of them reduced after applying coating on original gears.