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Unrestricted © Siemens AG 2016

May, 2017 CG

From R&D projects to Serial AM Manufacturing

Dr Vladimir Navrotsky - CTO, Senior Principle Key Expert, SiemensOlov Andersson – Senior Key Expert, Siemens

Unrestricted © Siemens AG Österreich 2016. All rights reserved.

May 09, 2017 Dr. Vladimir Navrotsky / PS DG TI

History of AM Industrialization at Siemens

Additive Manufacturing = AM = 3D printing = Selective Laser Melting = SLM



Additive Manufacturing history

1990

Installation of the 1st EOS M270 DMLS system at workshop

2012Installation of the 1st EOS M280 DMLS system at workshop for Rapid Burner Tip Repair

2014

2015

2016

Foundation of the organization unit Manufacturing Development & Industrialization for large gas turbines

Inauguration of the industrial AM workshop in FinspångAcquisition Material Solutions, Ltd in UK

Start of serial production for Rapid Burner Tip Repair.First firing of a fully 3D printed burner front

2013First sets of industrial gas turbine swirlers in commercial operation at customer engines

2013First sets of Rapid Burner Tip Repair components in commercial operation at customer engines

2008

2009

EBV

AM value chain analysis, SLM Process & materials development, first demonstrators

Siemens is investing in Additive Manufacturing since its early days and pushes its industrialization



AM value chain & our focus areas




AM enabling a revolution in spare parts repair & manufacturing

Lead time reduction & life cycle improvement Efficiency increase

• Thinner walls & larger surface areas

• Improved mixing of fuel and air Advanced nozzle designs

• Micro-scale engineered surfaces

• Improved lifetime of the components

Lead time reduction

Reduced number of process steps

Saving of material

Eliminated tools

On-demand

through practically unlimited options for internal and external cooling duct design

for complex parts

• Faster technology validation • Faster product development • Shorter time to market

• Simplified manufacturing & repair • Faster manufacturing & repair

• Reduced number of parts in a component• Integrated functionality

• No time consuming casting process

• Instant, de-centralized production (for e.g. service)

Better heat transfer & lattice structures

Improved mixing of fuel and air

Increased coating adhesion

New powder alloys possible

Two main driver for Siemens to leverage the power of Additive Manufacturing



Siemens software tools and hardware componentsenable quick industrialization of Additive Manufacturing

• Thermal and structural analysis• Level based heat and strength

analysis• Laser power regulation• Topology optimization

• Design rules and conditions • Design of lightweight structures

(lattice/honeycomb)• Support structures • Multi-material support

• Multi-axis additive solution• Multi-laser solution • Model slicing • Deposition patterns• Part orientation and nesting

Data Management and Shop Floor Connectivity

Siemens Production Software and MES Systems

Analysis (CAE)Design (CAD) Manufacturing (CAM)



AM applications at Power generation




Gas turbine focal areas for Additive Manufacturing today

Combustion SystemBurner / Swirler / Nozzle / Mixer

TurbineBlades & Vanes

Complexity

€

High tech components

with complex design and

high potential to improve

customer value:

efficiency, durability,

life cycle improvement



Rapid Prototyping

Three main pillars when applying Additive Manufacturing at Siemens

Rapid Manufacturing

Rapid Repair

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

Product: SGT

Component: Burner swirler

Benefit: Swirler can only be made via SLM

Status: In commercial application



• Excellent tool for optimization of blade cooling designs• Substantial lead time reduction for engine upgrades - 1st blade manufactured already 2 weeks

after receipt of 3D model• Minimized risk by verification of blade temperature prior to casting

Benefits

• Use SLM for rapid prototyping of blades • Rainbow test in gas turbine for selection of

best design• Calibration of calculation tools and design

methods• Full scale engine test performed

Approach

WE achieved a major BREAKTHROUGH …… first turbine blade is printed an tested in the engine



Burner manufacturing by means of SLM for flexibility, shorter lead time and improved life time

• Reduced lead time by 23 w• Enabling customization for fuel flexibility• Removal of TBC

Benefits

• Manufacturing of SGT-700/SGT-800 burners by means of SLM

• Redesign of existing burners for SGT700/800 to utilize the design freedom offered by SLM

• Full scale engine test performed • Commercial operation in 2018

Approach Conventional SLM burner

• 13 parts / 18 welds• TBC on front• 26w lead time

• 1 integrated part• No TBC due• 3w lead time



Current field experience of AM manufactured

components




Current field experience of AM manufactured / repaired components

Rapid Repair Spare parts on demand

Product: SGT-700/800 Component: Burner tip Benefit: 90% lead time reduction

Status: In commercial application since 2013 > 25 000 EOH

Product: SGT-1000F Component: Burner head Benefit: Reduced lead time by up

to 6 months Status: In commercial

application since 2016

Successful in commercial operation

Rapid Manufacturing

Product: SGT-750 Component: Burner swirler Benefit: Swirler can only be made

via SLM Status: In commercial

application since 2013 > 25 000 EOH


May, 2017 Author / Department

AM technology for Burner repair

The repaired part• The burner is 720 mm long. The fired power at full load

is about 4 MW per burner

• Most of the burner is protected by the combustor and only the tip is exposed to the heat from combustion.

• The worn area is in principal only the tip and it is replaced after 20-30 kEOH depending on operation profile and burner type.



AM technology for Burner repairAM versus Conventional

Area for repair

As done earlier:

The front part was cut off and a new pre manufactured part was welded instead

New method:

Only the tip is cut off and a new is printed up



Developing AM technology for Burner repairVerification, operating experience

Feed back from field

• We have now a number of gas turbines with AM repaired burners in operation and we have accumulated more than 25.000 EOH experience on fleet leader

• There has been several inspections done during the verification period and they have not shown any remarks or damages

• The AM repair is now a standard for our burner repair shop

Thank you for the attention!



Contact page

Dr. Vladimir NavrotskyChief Technology Officer, Senior Principle Key Expert,Siemens Power Generation Service,Slottsvaegen 1612 83 Finspong, SwedenPhone: +46 122 82610Mobile: +46 70 202 43 09E-mail: [email protected]

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