3D printing at Siemens Power Service

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1 Vladimir Navrotsky, Ph.D., CTO, PS DGC 3D printing at Siemens Power Service siemens.com

2 Additive Manufacturing / 3 D Printing / SLM * enabling a revolution in spare parts repair & manufacturing Additive Manufacturing: Technology & Generated Value Technology Development Value generated: Business & Customer Value Prototyping - shorten design & technology validation Reduce manufacturing & repair time Technology market entry Revolutionary approach Integral Design & Manufacturing process - new dimension Design of New materials Evolutionary approach Time Reduce manufacturing & repair cost Regionalization support New approach in Spare Parts (logistics, stock, ) Page 2 *AM - Additive Manufacturing SLM - Selective Laser Melting

3 Power Generation one of the most challenging applications for SLM Technological challenges of gas turbines High temperatures Rapid temperature changes High centrifugal forces + + The thermal loading of the blades is almost as high as the melting point of iron The centrifugal forces acting on the blades is 10,000 times the force exerted by the dead weight of the blades The blade tips reach sonic speed SLM manufactured SGT blade 1 prototype From room temperature to above 1000 o C in seconds Page 3

4 Gas turbine focal areas for Selective Laser Melting (SLM) Combustion System Burner Swirler/Nozzle/Filter/Mixer Turbine Blades & Vanes High Tech Components with complex design and high potential to improve customer value (efficiency, durability) Page 4

5 Why do we use SLM? Lead time reduction & life cycle improvement for complex parts Lead time reduction Faster technology validation & product development Shorter time to market Efficiency increase through practically unlimited options for internal and external cooling duct design Better heat transfer and lattice structures Thinner walls & larger surface areas Reduced number of process steps Simplified manufacturing & repair Faster manufacturing & repair Saving of material Reduced number of parts in a component Integrated functionality Eliminated tools No time consuming casting process Improved mixing of fuel and air Advanced nozzle designs Increased coating adhesion Micro-scale engineered surfaces New powder alloys possible Improved lifetime of the components On-demand, instant, de-centralized production (for e.g. service) Page 5

6 Three pillars for SLM applications 1 Rapid Prototyping 2 Rapid Repair 3 Rapid Manufacturing Blade 1 Burner Burner Product: SGT Component: e.g. Turbine Blade 1 Benefit: Status: Significant reduction of time to market Part of standard process Product: SGT Component: Burner tip Benefit: Status: 10 times faster, easy upgrades In commercial application Product: SGT Component: Burner swirler Benefit: Status: Swirler can only be made via SLM In commercial application Page 6

7 Rapid Prototyping: SLM enables fast time to market and life cycle improvement for new products Integrated development iteration in a few months instead of years 3D Design SLM 3D-Print Processing Instrument. Test 3D integrated CAE/CAD/CAM SLM Machine Conventional procedure "Test as validation at the end of the process" Sequential development process Conservative development approach Moderate development targets/results Long development cycles New approach "Testing as an integral part of the process" Parallel and integrated development processes Radical development approaches Ambitious development targets/results Fast development cycles Page 7

8 Rapid Repair Siemens: Gas Turbine Burner Repair with SLM Efficiency Improvement Advantages Faster repair process Easy upgrade to the latest design Vision: Spare Parts on Demand close to the customer location Page 8

9 Layer by layer metal powder is melted into a structure (RaBuTir: Rapid Burner Tip Repair) This technology is complex and requires broad knowledge in many different areas, including materials science, automation, manufacturing. There are few companies in the world who cover all of these. Siemens is one of them and moving fast in this field. SIT AB established SLM center of competence within Siemens Page 9

10 SLM Examples of Combustor and Turbine Demonstrator Parts Manufacturing: Lattice structure integration into blade design Status: Development and design phase Manufacturing: Fuels strainers Status: Under preparation for production Prototyping: Burner swirler Status: Prototyping in 2012 Otherwise impossible lattice structure and very thin wall 2400 holes 0,3 mm diameter Already part of SLM process Not drilled Functionality & Performance: weight reduction, cooling improvement, life extension Significant simplification of the manufacturing process Lead time reduction: Six months Page 10

11 Thank you for your attention! Vladimir Navrotsky, Ph.D., CTO, PS DGC Page 11

12 Disclaimer This document contains forward-looking statements and information that is, statements related to future, not past, events. These statements may be identified either orally or in writing by words as expects, anticipates, intends, plans, believes, seeks, estimates, will or words of similar meaning. Such statements are based on our current expectations and certain assumptions, and are, therefore, subject to certain risks and uncertainties. A variety of factors, many of which are beyond Siemens control, affect its operations, performance, business strategy and results and could cause the actual results, performance or achievements of Siemens worldwide to be materially different from any future results, performance or achievements that may be expressed or implied by such forward-looking statements. For us, particular uncertainties arise, among others, from changes in general economic and business conditions, changes in currency exchange rates and interest rates, introduction of competing products or technologies by other companies, lack of acceptance of new products or services by customers targeted by Siemens worldwide, changes in business strategy and various other factors. More detailed information about certain of these factors is contained in Siemens filings with the SEC, which are available on the Siemens website, and on the SEC s website, Should one or more of these risks or uncertainties materialize, or should underlying assumptions prove incorrect, actual results may vary materially from those described in the relevant forward-looking statement as anticipated, believed, estimated, expected, intended, planned or projected. Siemens does not intend or assume any obligation to update or revise these forward-looking statements in light of developments which differ from those anticipated. The information, recommendations and descriptions in this document are based on Siemens experience and judgment with respect to the operation and maintenance of the equipment described in this document and should not be considered as all-inclusive or covering all contingencies. NOTHING IN THIS DOCUMENT SHALL CONSTITUTE A WARRANTY OR REPRESENTATION OF ANY KIND, WHETHER STATUTORY, EXPRESSED OR IMPLIED, OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, OR OTHERWISE. Trademarks mentioned in this document are the property of Siemens AG, its affiliates or their respective owners. Page 12

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