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Fast, efficient, flexible: AM makes the difference
Be it rapid prototyping or manufacturing parts for aero-derivative, gas and steam turbines or compressors, they can be designed faster, with increased flexibility, better materials, and optimized efficiency. This way, 3D printing enables cutting edge technologies with reduced time-to-market and quick upgrading of existing assets. Being both a pioneer and a leader in the industrialization of AM, Siemens Energy is in an excellent position to give its customers the products and tools they need for the next generation of power products.
BMBF project "IDEA" - Two production lines with exemplary character for industrial 3D printing
In the BMBF joint project "IDEA", partners from industry and research developed and built two production lines for the automated, additive manufacturing of gas turbines and metal components. Siemens Energy and AT Toolcraft AG produced components using 3D-printing to demonste how not only large corporations, but also SMEs can economically utilize additive manufacturing for individualized components in medium batch sizes. Fraunhofer ILT's Laser Power Bed Fusion process and digital engineering along the entire product development chain play an important role in optimizing the components.
Investment in new digital platform for on-demand additive manufacturing services
Additive manufacturing (AM) has taken on a major role in the development and production of components and spare parts for Siemens Energy in recent years. In addition to setting up its own AM production lines and acquiring AM service provider Materials Solutions in 2016, the company is now expanding its commitment in this area with its investment in the start-up MakerVerse.
Parts can be rapidly printed and checked for certain properties before serial production beings, massively speeding up innovation cycles.
Rapid Repair
With AM, parts for industrial gas turbines and compressors can be repaired up to 60% faster and even upgraded to the latest part design.
Spare Parts on Demand
Traditional stockpiling of parts becomes a thing of the past. Since an AM-printer can precisely reproduce many parts from 3D-datasets, there is no need to have them physically on hand.
Rapid Manufacturing
AM enables the use of new materials and the creation of innovative parts with higher performance and new product features, while at the same reducing time lead times.
AM in Sound and Vision
Sachsen Energy Reference: AM Turbine Vane
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AM projects at the Werner-von-Siemens Centre
Two AM research projects, High Temperature Applications (HTA) 2.0 and Maintenance, Repair and Overhaul (MRO) 2.0, have been kicked-off in summer 2020 and, besides all odds of the pandemic crisis, are successfully reporting the first milestones already.
‘Printing out of the box’ to reduce downtime for gas turbines
Siemens Energy recently began its Onsite Specialty Services that includes welding and coating technologies and CNC and robotic on-site machining. The company’s additive manufacturing capabilities comprise mechanized cladding, micro laser welding, cold spray silver coating and laser metal deposition.
IDEA – Additive Manufacturing for Series Production
The inauguration of the prototype of a serial production line at the gas turbine factory in Berlin marks an important milestone for the IDEA project. It is part of the initiative “Line integration of additive manufacturing processes”, funded by German Ministry of Education and Research.
Siemens Energy is driving the industrialization and commercialization of AM processes. Here are some examples of 3D printed parts working in the real world.
DREWAG AM Reference Story
DREWAG AM Reference Story
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3D-printed vanes proved successful
DREWAG AG operates a 25-year-old CCPP with three Siemens V64.3 gas turbines. As part of a lifetime extension and modernization upgrade, Siemens Energy replaced conventional turbine vanes with 3D-printed ones.
Phase 1 focused on the reproduction of the vanes, while in phase 2 improved, re-designed vanes will be installed. The initial phase already brought remarkable results: The vanes are characterized by high accuracy and show an excellent operational behavior after nearly 8,000 EOHs.
The new generation of vanes, that will be installed in June 2021, have an advanced air cooling design, that can contribute to increased efficiency and decreased emissions.
Industrialized swirler production
Production of more than 1,000 gas turbine swirlers per year with qualified industrial production process.
Lead time for critical component reduced by 20%, with reduced post-processing by 80%.
Optimized design for AM enables part consolidation from 10 pieces to one single piece.
3D-printed gas turbine burners have been “on duty” for more than 8,000 operating hours in E.ON’s plant, which provides electrical energy and steam for a potash mine.
The burners were manufactured in Finspång, Sweden. Each burner is manufactured in one piece, whereas they used to require 13 individual parts and 18 welds.
"As an energy service provider, precision and durability of our turbines are absolute necessities for us," says Niklas Lange, project manager at E.ON Energy Projects. "In our experience, additive manufacturing delivers this and even improves performance compared to older models.”
Materials Solutions in Worcester, UK, produced 3D-printed burner components for a Siemens heavy-duty SGT-1000F gas turbine in a power plant in Brno in the southeast of the Czech Republic. The plant supplies district heating as well as electricity.
The turbine’s operations are now supported by spare parts that no other large Siemens gas turbine before it has used in commercial operation.
It has operated since 2016 without causing any forced outages.
The Technologies
Selective Laser Melting
In use at Siemens Finspang and Materials Solutions in Worcester and Orlando
Selective laser melting (SLM), also known as direct metal laser melting (DMLM) or laser powder bed fusion (LPBF), is a rapid prototyping, 3D printing, or additive manufacturing (AM) technique designed to use a high power-density laser to melt and fuse metallic powders together. SLM is often considered a subcategory of selective laser sintering (SLS). The SLM process has the ability to fully melt the metal material into a solid three-dimensional part unlike SLS.
Laser Cladding
In use at Siemens Gas and Power in Nuremberg
Laser cladding is a form of surface coating that incorporates the use of lasers and a feeding mechanism to coat the substrate with a layer of desired metal or ceramic material. The laser melts the metal and coats the moving substrate with a fine layer. The feed metal is fully melted while the laser also transfers some of its energy to the substrate. This allows for the creation of a strong metallurgical bond between the substrate and the coating.
WireArc
In use at Siemens Gas and Power in Goerlitz
Wire Arc Additive Manufacturing (WAAM) is a large-scale metal AM technology that uses an arc welding process to produce metal parts additively.
Virtual Events
Inside AM
Sebastian Piegert, Technology Field Lead Additive Manufacturing, shared linsights on the Siemens Energy AM approach and strategy.
AM - new opportunities for power plant operation
Additive Manufacturing technology is enabling the transformation of energy systems.
