Study on the Impact of Fill Gap and Layer Height on Residual Stresses in Arc Cladding Layers in Remanufactured Wind Turbine Broken Gear Teeth

This study investigates residual stresses in arc cladding layers of wind turbine gear teeth via experiments and simulations.The results show that increasing the filling spacing from 1 mm to 3 mm reduces maximum tensile stress, decreases stress fluctuations, and mitigates heat accumulation.However, expanding the spacing to 4 mm intensifies stress fluctuations due to uneven heat input, establishing 3 mm as optimal spacing.Regarding the layer height, increasing from 2.5 mm to 3.5 mm reduces the top-layer tensile stress while creating a concave stress distribution in intermediate zones.At the 4 mm layer height, although the top-layer stress decreases, the intermediate-zone stress rises and transitions to tensile near the centre.The optimal combination -3 mm spacing and 3.5 mm layer height -provides theoretical guidance for wire-arc additive manufacturing of failed wind turbine gears.