Turbine from the 3D printer

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

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.

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.

Marie Jurisch

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

Media Contact

Fraunhofer IFAM Dresden Kommunikation Fraunhofer-Gesellschaft

Alle Nachrichten aus der Kategorie: Materials Sciences

Materials management deals with the research, development, manufacturing and processing of raw and industrial materials. Key aspects here are biological and medical issues, which play an increasingly important role in this field.

innovations-report offers in-depth articles related to the development and application of materials and the structure and properties of new materials.

Zurück zur Startseite

Kommentare (0)

Schreib Kommentar

Neueste Beiträge

2020 Arctic sea ice minimum at second lowest on record

NASA and the National Snow and Ice Data Center (NSIDC) at the University of Colorado Boulder shows that the 2020 minimum extent, which was likely reached on Sept. 15, measured…

Dresden physicists develop printable organic transistors

Scientists at the Institute of Applied Physics at TU Dresden have come a step closer to the vision of a broad application of flexible, printable electronics. The team around Dr…

Researchers discover a mechanism that causes cell nuclei to grow

By far the most important process in cell development is how cells divide and then enlarge in order to multiply. A research team headed by Freiburg medical scientist Prof. Dr….

By continuing to use the site, you agree to the use of cookies. more information

The cookie settings on this website are set to "allow cookies" to give you the best browsing experience possible. If you continue to use this website without changing your cookie settings or you click "Accept" below then you are consenting to this.

Close