Friction Inserts for wind turbines
Energy
Advanced friction increase material for high-load flange connections
Friction Inserts to increase torque transmission and power Density
As wind turbines become larger and more powerful, bolted flange connections are exposed to extreme torque and shear forces. Engineers in predevelopment face the challenge of increasing performance without compromising reliability or redesigning entire systems.
Increasing friction in flange connections helps to safely transmit higher torque and loads. Whereas traditional solutions often fail to provide a high coefficient of friction without affecting tolerances, Freudenberg Friction Inserts are an advanced friction increase material designed specifically to increase friction in critical wind turbine joints while maintaining design integrity.
With the higher coefficient of friction in critical joints allowed by Freudenberg Friction Inserts, you can test, evaluate, and implement next-generation solutions for rotor hubs, shafts, and gearbox interfaces. There is no risk of corrosion of the Freudenberg Friction Inserts over their lifetime.
Key Features
- Increase Static friction coefficient
- Ultra-thin carrier (~20 µm) with no impact on tolerances
- Hard particles (diamonds) creating micro-interlock between surfaces
- Custom geometries and product configurations for specific flange applications
- Color contrast between Friction Inserts and the part surface enables image-based quality assurance (e.g. camera systems)
- 100% inert materials, ensuring no impact on the corrosion behavior in the joint
- Thanks to the nonwoven carrier there is no risk of corrosion of the insert
Key Benefits
- Reliable transmission of higher torque and shear forces
- Increased power density
- Enable downsizing of flanges and components
- Reduce risk of bolt deformation and slippage
- Improves long-term reliability in dynamic loads
- Same performance with fewer or smaller bolts, higher performance from the same components
- Prevent fretting and micro-movements
- Accelerate innovation validation through fast sampling
- Supports simulation and predevelopment validation
How Friction Increase Works
Friction enhancement increases the static friction coefficient between two surfaces. In bolted joints, this allows higher forces to be transmitted without slippage. This is critical in wind turbines where fluctuating loads act continuously on large flange connections.
Friction Inserts use an ultra-thin nonwoven carrier coated with diamonds. When positioned between the components of a friction joint, these hard particles penetrate both contact surfaces and create a micro-interlock, dramatically increasing friction without introducing a gap.
Detailed application insights for wind energy
In modern wind turbines, rotor diameters and torque loads continue to increase. Traditional friction solutions often reach their limits due to tolerance sensitivity or insufficient friction levels. Friction Inserts act as a design-enabling interface, allowing engineers to:
- Evaluate higher load designs early in development
- Reduce bolt sizes or quantities
- Improve flange reliability without redesigning mating parts
Because the inserts are tolerance-neutral, they integrate seamlessly into prototype builds. Engineers can quickly test samples, gather data, and prepare robust recommendations for decision-makers. Freudenberg supports this process with:
- Fast sample availability
- Deep application know-how
- Static and dynamic friction simulation capabilities
- Engineering support for integration into production
- Flexible customization for prototype and serial applications
Comparison of Friction Increase Solutions
Friction Inserts
- Friction level: high
- Tolerance impact: none
- Retrofit capacity: excellent
- Typical lmitation: none signficant
Shims
- Friction level: high
- Tolerance impact: low but present
- Retrofit capacity: medium
- Typical lmitation: adds stack thickness
Coatings
- Friction level: medium
- Tolerance impact: none
- Retrofit capacity: low
- Typical lmitation: requires requalification
Frequently Asked Questions about Friction Inserts for wind turbines
By increasing the static friction coefficient using friction enhancement materials like Friction Inserts with custom size and shape.
The necessary connection parameters are the materials used, surface pressure, surface roughness, and surface geometry.
No, their ultra-thin structure creates no measurable gap.
Yes, samples are quickly available and fully customizable for evaluation.
Self-adhesive stickers are usually used for applications like wind turbines, but the Friction Inserts can also be delivered without additional adhesives.