Wind Energy Science
Wind Energy Science
WES
Articles | Volume 11, issue 1
Articles | Volume 11, issue 1
https://doi.org/10.5194/wes-11-89-2026
© Author(s) 2026. This work is distributed under
the Creative Commons Attribution 4.0 License.
https://doi.org/10.5194/wes-11-89-2026
© Author(s) 2026. This work is distributed under
the Creative Commons Attribution 4.0 License.
Articles | Volume 11, issue 1
Research article
 | 
14 Jan 2026
Research article |  | 14 Jan 2026

Hollow-forged AHD steel rotor shafts for wind turbines – a case study on power density, costs and GWP

Christian Hollas, Georg Jacobs, Vitali Züch, Julian Röder, Moritz Gouverneur, Niklas Reinisch, David Bailly, and Alexander Gramlich

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Short summary
Hollow forging and air-hardening ductile steel enable higher power densities for wind turbine main bearing units. For a 2.3 MW base-load-optimised wind turbine, a 37 % increase in rotor shaft power density was achieved compared to a casted shaft. By using green, air-hardening steel, hollow forging achieves a comparable global warming potential to casting. The economic viability of hollow forging is not given for the current surcharges found in small-series production.
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