Forum for Science, Industry and Business

Sponsored by:     3M 
Search our Site:

 

Turbine from the 3D printer

18.09.2019

Together with the H+E-Produktentwicklung GmbH in Moritzburg, Saxony, the Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM in Dresden has developed a true-to-scale gas turbine that impressively demonstrates the current potentials and limitations of powder bed-based additive technologies. The technology demonstrator "Siemens SGT6-8000 H", a scaled model of a gas turbine for power generation on a scale of 1:25, was completely manufactured with additive processes except for the shaft.

The component assembly consists of 68 parts made of aluminium, steel and titanium, which through component optimisation and the possibilities of Electron and Laser Beam Melting technologies replace the almost 3000 individual parts that make up the original component.


Scaled model of a gas turbine for power generation; completely manufactured with additive manufacturing technologies.

Fraunhofer IFAM Dresden

The turbine is fully functional. At the same time the combination of conventional manufacturing technologies - in this case machining - and additive processes with Laser Beam Melting (LBM) and Selective Electron Beam Melting (SEBM) is shown in one component.

Fraunhofer IFAM was involved in the manufacturing of the component as well as the data modification for the technology-adapted production. The housing components with stator stages were manufactured directly on site at the Innovation Center Additive Manufacturing ICAM® in Dresden.

They were produced using Electron Beam Melting (EBM) of Ti-6Al-4V in the Arcam Q20+ plant. The turbine stages and the other housing components were manufactured at H+E using Laser Beam Melting.

The production planning was particularly important and accordingly complex to determine the right technology for each component. The accuracy and roughness of the surfaces, for example, had to be taken into account. Also the necessity and number of support structures as well as the component size had to be considered.

The functionality of the demonstrator was a prerequisite for all considerations. For example, the shaft and turbine stages had to be able to rotate freely between the stator stages and the individual components of the demonstrator had to be connected to each other with minimum effort - by screwing and plugging on.

The components were modified constructively with the experience of the process experts involved in order to be able to manufacture "first time right" for the additive manufacturing technologies used. This goal was achieved. For example, the 316L housing segment could be manufactured by LBM completely without support structures after the adaptations.

The combination of different materials commercially available from the respective plant manufacturers is demonstrated in the component. Not all processed materials correspond to the target materials for turbines. The limitation lies in the fact that these materials cannot yet be processed in such a way that they can be offered commercially.

In the Innovation Center Additive Manufacturing ICAM®, Fraunhofer IFAM Dresden has bundled its technologies in the field of additive manufacturing at one location and can, thus, offer tailor-made solutions for a wide variety of problems from a single source. The customer can choose from Selective Electron Beam Melting, three-dimensional screen printing, Fused Filament Fabrication as well as three-dimensional stencil printing and dispensing at the site.

Wissenschaftliche Ansprechpartner:

Marie Jurisch

Weitere Informationen:

https://www.ifam.fraunhofer.de/en/Research/additive_manufacturing.html

Fraunhofer IFAM Dresden Kommunikation | Fraunhofer-Gesellschaft

Further reports about: 3D printer Beam Electron Electron Beam IFAM Innovation Laser Melting Turbine manufacturing technologies

More articles from Materials Sciences:

nachricht Heat energy leaps through empty space, thanks to quantum weirdness
12.12.2019 | University of California - Berkeley

nachricht How light a foldable and long-lasting battery can be?
12.12.2019 | Pohang University of Science & Technology (POSTECH)

All articles from Materials Sciences >>>

The most recent press releases about innovation >>>

Die letzten 5 Focus-News des innovations-reports im Überblick:

Im Focus: Cheers! Maxwell's electromagnetism extended to smaller scales

More than one hundred and fifty years have passed since the publication of James Clerk Maxwell's "A Dynamical Theory of the Electromagnetic Field" (1865). What would our lives be without this publication?

It is difficult to imagine, as this treatise revolutionized our fundamental understanding of electric fields, magnetic fields, and light. The twenty original...

Im Focus: Highly charged ion paves the way towards new physics

In a joint experimental and theoretical work performed at the Heidelberg Max Planck Institute for Nuclear Physics, an international team of physicists detected for the first time an orbital crossing in the highly charged ion Pr⁹⁺. Optical spectra were recorded employing an electron beam ion trap and analysed with the aid of atomic structure calculations. A proposed nHz-wide transition has been identified and its energy was determined with high precision. Theory predicts a very high sensitivity to new physics and extremely low susceptibility to external perturbations for this “clock line” making it a unique candidate for proposed precision studies.

Laser spectroscopy of neutral atoms and singly charged ions has reached astonishing precision by merit of a chain of technological advances during the past...

Im Focus: Ultrafast stimulated emission microscopy of single nanocrystals in Science

The ability to investigate the dynamics of single particle at the nano-scale and femtosecond level remained an unfathomed dream for years. It was not until the dawn of the 21st century that nanotechnology and femtoscience gradually merged together and the first ultrafast microscopy of individual quantum dots (QDs) and molecules was accomplished.

Ultrafast microscopy studies entirely rely on detecting nanoparticles or single molecules with luminescence techniques, which require efficient emitters to...

Im Focus: How to induce magnetism in graphene

Graphene, a two-dimensional structure made of carbon, is a material with excellent mechanical, electronic and optical properties. However, it did not seem suitable for magnetic applications. Together with international partners, Empa researchers have now succeeded in synthesizing a unique nanographene predicted in the 1970s, which conclusively demonstrates that carbon in very specific forms has magnetic properties that could permit future spintronic applications. The results have just been published in the renowned journal Nature Nanotechnology.

Depending on the shape and orientation of their edges, graphene nanostructures (also known as nanographenes) can have very different properties – for example,...

Im Focus: Electronic map reveals 'rules of the road' in superconductor

Band structure map exposes iron selenide's enigmatic electronic signature

Using a clever technique that causes unruly crystals of iron selenide to snap into alignment, Rice University physicists have drawn a detailed map that reveals...

All Focus news of the innovation-report >>>

Anzeige

Anzeige

VideoLinks
Industry & Economy
Event News

The Future of Work

03.12.2019 | Event News

First International Conference on Agrophotovoltaics in August 2020

15.11.2019 | Event News

Laser Symposium on Electromobility in Aachen: trends for the mobility revolution

15.11.2019 | Event News

 
Latest News

Weizmann physicists image electrons flowing like water

12.12.2019 | Physics and Astronomy

Revealing the physics of the Sun with Parker Solar Probe

12.12.2019 | Physics and Astronomy

New technique to determine protein structures may solve biomedical puzzles

12.12.2019 | Life Sciences

VideoLinks
Science & Research
Overview of more VideoLinks >>>