Advanced Welding Technology.

Made for hydropower – engineered by experts. 

In today’s energy landscape, hydropower is more vital than ever. As the world transitions toward sustainable energy systems, hydroelectric plants provide stable, renewable baseload power. But as these facilities age, so do their components. The need for high-quality, efficient replacement runners is growing - and with it, the demand for advanced, reliable manufacturing technologies. We have redefined how runners are made. By combining welding automation, deep hydropower know-how, and forward-thinking R&D. Global Hydro delivers runners that meet today’s performance expectations - and tomorrow’s sustainability goals. 

Welding technology at Global Hydro is not just an upgrade – it’s a complete transformation of how runners are built. Our robotic welding system was developed in-house, tailored for turbine components especially runners, and guided by decades of experience in hydropower. This robotic system handles even the largest runner sizes – greater than 10 tons in weight and 3 m in diameter. Every part of the production process takes place at our headquarters: hydraulic profile development, engineering, milling, welding, polishing, balancing, testing, and the FAT. That means full control over quality, from start to finish. This is especially important for replacement runners, where precision and delivery time matter most — particularly in unplanned situations like turbine failure, where every day of downtime counts. Thanks to our fully automated process, we reduce production time and guarantee consistent results – helping operators keep their plants running with minimal downtime. 

What sets us apart? 

Welding design beyond industry standards.

At Global Hydro, innovation doesn’t stop with automation. What truly sets us apart is our unique welding design, developed specifically to meet the demands of modern hydropower. While many manufacturers still rely on conventional methods — placing weld seams directly in high-stress areas — we take a fundamentally smarter approach. 

Through expertly engineered runner geometry and intelligent planning, our welds are strategically positioned away from the most heavily loaded zones. This avoids peak stress, prevents weak points, avoids premature wear, and ensures maximum strength exactly where it’s needed. 

This design philosophy is a direct result of our decades of hydropower expertise and deep understanding of the forces and stress levels inside components of turbines. Every weld, every joint, every surface follows a clear goal: longer component life, flawless performance, and less downtime for the operator. 

In short: while others simply weld – we design for durability. 

Cold Metal Transfer: Better welds, longer lifespan.

Cold Metal Transfer (CMT) – a modern arc welding process that offers better control and much less heat than traditional welding. The welding wire moves back and forth up to 170 times per second to precisely control each droplet of molten metal. This leads to stronger, cleaner welds, with fewer distortions and better fatigue resistance. Components last longer, because lower heat input results in less internal stress. 

Better for performance, materials and people. 
 

• Homogeneous weld seams – Continuous welds without flaws increase fatigue strength 

• Minimal heat input – Reduces the heat-affected zone (HAZ), avoiding material distortion and ensuring better structural integrity

• Error-free results – Eliminates human mistakes and guarantees consistent, repeatable quality

• High corrosion resistance – Controlled temperature prevents chromium depletion in stainless steel

• Better working conditions – Welders are no longer exposed to 100 °C preheated components

• Reduced material waste – Optimized filler usage and minimized rework

Cladding for extreme conditions.

In hydropower, components like runner blades, buckets, and other hydraulically active surfaces are exposed to continuous mechanical stress, abrasive particles, and high-velocity water flows. These forces can wear down even the strongest materials over time.​ To counteract this, we offer advanced cladding solutions tailored to specific operational demands. Using our in-house robotic welding systems, we can apply stainless steel overlays to critical areas, providing robust protection against wear and corrosion. This automated process ensures consistent quality and precision, even on complex geometries.​ For applications subjected to extreme wear, we provide cladding with Stellite - a cobalt-chromium alloy renowned for its exceptional resistance to erosion, corrosion, and high temperatures. This material is particularly effective for reinforcing the leading and trailing edges of Pelton turbine buckets, where it helps maintain optimal efficiency by preserving the critical hydraulic profiles over time.​ By integrating these cladding techniques, operators can significantly extend the service life of their components, reduce maintenance intervals, and ensure sustained performance under challenging conditions.​

The result: components that last longer, perform more reliably, and reduce unplanned downtime and replacement cycles. Cladding at Global Hydro is not just a finishing step – it’s long-term protection engineered from the start. 

Always one step ahead with research-driven innovation.

We don’t settle for what’s already possible. We constantly question the status quo and push ourselves to go beyond. Together with leading research partners like TU Wien (Vienna University of Technology), we are shaping the future of hydropower manufacturing through bold ideas and technical creativity. 

One of our key initiatives is the A4M project (Additive for Manufacturing) – an ambitious concept that combines 3D sand printing, robotic wire arc additive manufacturing (WAAM), and advanced digitalization into one integrated process. The goal? A smarter, faster, and more flexible production system that sets new standards for quality and efficiency in runner manufacturing. Another exciting project is Green-Turbine, which focuses on restoring worn Pelton runners instead of producing new ones. Using innovative cladding and additive techniques, we can repair and strengthen existing components, saving valuable raw materials and reducing energy consumption. This approach not only saves costs and shortens delivery times, but also supports a more sustainable hydropower future. 

With every project, we prove: innovation isn’t just something we do – it’s how we think.