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Restricted © Siemens AG 2014 All rights reserved. siemens.com 3D printing at Siemens Power Service Vladimir Navrotsky, Ph.D., CTO, PS DGC
Restricted © Siemens AG 2014 All rights reserved. siemens.com
3D printing at Siemens Power Service
Vladimir Navrotsky, Ph.D., CTO, PS DGC
Restricted © Siemens AG 2014 All rights reserved.
Page 2 Vladimir Navrotsky, Ph.D. / Power Generation Services
Additive Manufacturing / 3 D Printing / SLM *enabling a revolution in spare parts repair & manufacturing
Time
Evolutionary approach
Technology market entry
Prototyping - shorten design & technology validation
Reduce manufacturing & repair time
Integral Design & Manufacturing
process - new dimension
Design of New materials
Reduce manufacturing & repair cost
Regionalization support
New approach in Spare Parts (logistics, stock,… )
Business & Customer Value
Revolutionary approach
Technology Development Value generated:
*AM - Additive Manufacturing
Additive Manufacturing: Technology & Generated Value
SLM - Selective Laser Melting
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Page 3 Vladimir Navrotsky, Ph.D. / Power Generation ServicesPage 3
Technological challenges of gas turbines
Power Generation – one of the most challenging applications for SLM
The blade tips reach sonic speed
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 SLM manufactured
SGT blade 1 prototype
+
Rapid temperature changesHigh temperatures
+
High centrifugal forces
From room temperature to above 1000oC in seconds
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Page 4 Vladimir Navrotsky, Ph.D. / Power Generation Services
Gas turbine focal areas for Selective Laser Melting (SLM)
Combustion SystemBurner
Swirler/Nozzle/Filter/Mixer
TurbineBlades & Vanes
High Tech Components with complex design and high potential to improve customer value (efficiency, durability)
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Page 5 Vladimir Navrotsky, Ph.D. / Power Generation Services
Why do we use SLM?
Lead time reduction & life cycle improvement for complex parts
Efficiency increasethrough practically unlimited options for internal and external cooling duct design
• Lead time reduction Faster technology validation & product development Shorter time to market
• Better heat transfer and lattice structures Thinner walls & larger surface areas
• Reduced number of process steps Simplified manufacturing & repair
Faster manufacturing & repair
• Improved mixing of fuel and air Advanced nozzle designs
• Saving of material
• Reduced number of parts in a component
Integrated functionality
• Increased coating adhesion Micro-scale engineered surfaces
• Eliminated tools
No time consuming casting process
• New powder alloys possible Improved lifetime of the components
• On-demand, instant, de-centralized production (for e.g. service)
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Page 6 Vladimir Navrotsky, Ph.D. / Power Generation Services
Three pillars for SLM applications
Product: SGT
Component: Burner tip
Benefit: 10 times faster,easy upgrades
Status: In commercial application
Product: SGT
Component: e.g. Turbine Blade 1
Benefit: Significant reduction of time to market
Status: Part of standard process
Rapid Repair Rapid Manufacturing
Product: SGT
Component: Burner swirler
Benefit: Swirler can only be made via SLM
Status: In commercial application
Burner Burner
Rapid Prototyping1 2 3Blade 1
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Page 7 Vladimir Navrotsky, Ph.D. / Power Generation Services
Rapid Prototyping: SLM enables fast time to market and life cycle improvement for new products
Conventional procedure"Test as validation at the end of the process"
• Sequential development process• Conservative development approach• Moderate development targets/results• Long development cycles
• Parallel and integrated development processes• Radical development approaches• Ambitious development targets/results• Fast development cycles
New approach "Testing as an integral part of the process"
SLM Machine
3D integrated CAE/CAD/CAM
3D Design SLM 3D-Print Processing Instrument. Test
Integrated development iteration in a few months instead of years
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Page 8 Vladimir Navrotsky, Ph.D. / Power Generation Services
Rapid Repair
• Efficiency Improvement
• Faster repair process
• Easy upgrade to the latest design
• Vision: ‘Spare Parts on Demand’ close to the customer location
Adv
anta
ges
Siemens: Gas Turbine Burner Repair with SLM
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Page 9 Vladimir Navrotsky, Ph.D. / Power Generation Services
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
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Page 10 Vladimir Navrotsky, Ph.D. / Power Generation Services
SLM Examples of Combustor and Turbine Demonstrator Parts
Lead time reduction: Six months
Functionality & Performance: weight reduction, cooling improvement, life extension
Significant simplification of the manufacturing process
Manufacturing: Lattice structure integration into blade design Status: Development and design phase
Prototyping: Burner swirlerStatus: Prototyping in 2012
Manufacturing: Fuels strainers Status: Under preparation for production
Otherwiseimpossible
lattice structureand very thin wall
2400 holes0,3 mm diameterAlready part ofSLM processNot drilled
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Page 11 Vladimir Navrotsky, Ph.D. / Power Generation Services
Thank youfor your attention!Vladimir Navrotsky, Ph.D., CTO, PS DGC
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Page 12 Vladimir Navrotsky, Ph.D. / Power Generation Services
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