Vladimir Navrotsky, Ph.D., CTO, PS DGC 3D printing at Siemens Power Service siemens.com
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
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
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
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
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
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
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
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
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
Thank you for your attention! Vladimir Navrotsky, Ph.D., CTO, PS DGC Page 11
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