VGB PowerTech 12 l 2015
3D printing for gas turbine components
Industrialisation of 3D printing
(additive manufacturing)
for gas turbine components
repair and manufacturing
VGB PowerTech - Autorenexemplar - © 2015
Vladimir Navrotsky, Andreas Graichen and Håkan Brodin
Kurzfassung
Introduction
Industrialisierung von 3D Drucken
(generative Fertigung) für Gasturbinenkomponenten-Reparatur und -Herstellung
The recent advances in computing power
and cheaper laser sources together with ITbased networking, open the door for a new
design and manufacturing chain. 3D-CAD/
CAM models themselves contain information related to their manufacturing process, meaning that – ideally – only one file
is needed to produce the component to the
intended geometry, quality and material
specification. Tooling and fixtures become
obsolete in a blue sky scenario (F i g u r e 1).
Formerly a complicated network of different competencies was needed in an advanced workshop, now it can be performed
by one single “3D-printer”. In the coming
years, we will see AM (additive manufacturing) as we are seing colour printing on
paper, something that simply works, without much need for human intervention.
There are many advantages for the designer and the supply chain:
–– AM in the form of SLM (selective laser
melting) gives an unprecedented freedom of design because geometries are
possible that could not be accessed with
traditional machining methods,
–– many times, complexity of geometry
comes for free, or costs the same as traditional simple geometries,
–– this means that, for example, for gas turbine components cooling systems, vibration dampening and lightweight designs
can be improved without extra cost,
–– assemblies can be simplified and integrated,
–– many manufacturing operations that
earlier needed many logistical steps can
be carried out on one single machine,
In den letzten Jahren hat eine neuartige revolutionäre Art der Fertigung namens Additive
Manufacturing (AM) in der Industrie Einzug
gehalten. Diese wird tiefgreifende Veränderungen mit sich bringen. Im Gegensatz zur traditionellen Fertigung, bei der Material durch Fräsen,
Bohren, Erodieren usw. abgetragen wird, wird
bei diesem Verfahren Material durch den Einsatz von Laser- oder Elektronenstrahlenergie
aufgetragen. Es gibt verschiedene AM-Technologien, von denen gegenwärtig das Selektive Laserschmelzen (Selective Laser Melting – SLM)
das interessanteste Verfahren zu sein scheint.
Das AM eröffnet eine neue Dimension der integrierten Konstruktion und Fertigung. AM
ermöglicht eine schnellere Fertigung und Reparatur von Gasturbinenbauteilen bei gleichzeitig
größerer Funktionalität und Leistungsfähigkeit
der Bauteile. Siemens Power Generation setzt
diese Technologie zur Herstellung von Prototypen (Prototyping) sowie in begrenztem Umfang
für Reparaturarbeiten und die Fertigung von
Gasturbinenbauteilen ein [1 bis 3].
Kürzlich setzte Siemens die SLM-Technologie
zur Reparatur von Gasturbinenbrennern der
Industriegasturbinenbaureihe SGT-800 ein.
Die Ergebnisse zeigten, dass das Ersetzen konventioneller Reparaturverfahren durch die
SLM-Technologie zu einer signifikanten Verkürzung der Reparaturzeit führt und die Bauteile
bei der Reparatur darüber hinaus auf den aktuellen Brennertyp umgerüstet werden können.
Ein weiteres aktuelles Beispiel für die Anwendung der SLM-Technologie bei Siemens stellt die
Fertigung von verbesserten Brenner-Swirlern
für Industriegasturbinen der Baureihe SGT-750
dar. In diesem Fall war SLM die einzige Technologie, die in der Lage war, diese Art von Swirler
zu fertigen. Die Ergebnisse haben den Erfolg der
Anwendung der SLM-Technologie in der Konstruktion, im Prototyping und in der Fertigung
neuer, verbesserter Brenner-Swirler bestätigt. l
Authors
Dr. Vladimir Navrotsky
Andreas Graichen
Dr. Håkan Brodin
Siemens Industrial Turbomachinery AB
Finspong, Sweden
48
–– the transmission of CAD/CAM-files is
not restricted by geography. 3D-printing
can take place virtually anywhere as
long as an internet connection exists
(F i g u r e 2).
As a result, the development and manufacturing time of some components and
products will be significantly reduced. New
products will enter the market, functionality and product upgrades could be improved
and made more frequently. Further technology and AM equipment development
will allow for reduced manufacturing cost
for some components in the next 5 years.
National programmes and public funds can
speed up industrialisation of this technology and implementation of innovation into
our daily lives.
However, alongside the obvious benefits
and opportunities there are threats and
challenges:
–– powder (e.g. specification, chemistry,
cost, suppliers),
–– AM equipment (e.g. process speed,
equipment cost, components size),
–– AM process parameters,
–– very limited material data,
–– qualification and validation of the
process,
–– design tools and design criteria,
–– industrial standards and regulation
for AM.
Additive manufacturing
technologies
Powder-bed additive layer manufacturing
Additive layer manufacturing (ALM) comprises a group of rapid manufacturing pro-
3D CAD Data
Fig. 1. To manufacture a component by AM technology, the following is needed:
1 = 3D model of the component
2 = appropriate powder and
3 = laser sintering equipment.
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VGB PowerTech 12 l 2015
3D printing for gas turbine components
in a pre-defined pattern,
in order to create a minimum of internal stresses
[14] and the best surface
possible [15]. Each pass
of the laser beam creates
Faster technology
Lead time reduction &
a solidified band of matevalidation & product
life cycle improvement for
rial, producing a microdevelopment
complex parts
structure similar to how
the material would look
Fig. 2. Additive manufacturing (AM) enables quick realisation
if being built up by a numof exciting new product features and highly customised
ber of weld passes. Howsolutions.
ever, due to differences in
input energy and actual
cesses that today can be used as alterna- melt pool size, the microstructure is not a
tives to normal manufacturing routes for typical weld structure.
metallic, ceramic and polymer components Building of a component is performed on
in many applications, for instance tooling a substrate plate, normally manufactured
mould inserts, automotive components from steel. The plate is attached onto a
and also details for the aerospace industry processing table that can translate in the z[4 to 6]. Major drivers for the increased direction in a chamber with a controlled atinterest in ALM are: availability of differ- mosphere, typically nitrogen (often used for
ent alloy powders [7] (aluminium, steel, steels) or argon (inert gas, for instance used
cobalt base and also nickel base powders), for super alloys). A thin layer of powder (in
increased production rate [8] (available the range of 20 to 60 µm) is distributed by a
laser power and better understanding of so-called recoater onto the substrate plate.
the manufacturing process) and high qual- After this, the laser beam travels over the
ity of the manufactured components [9] first powder layer that will form the com(low amount of porosity, pure material, ponent. The process table is lowered, new
homogeneous material). Also the number powder distributed and a new laser scan is
of industrially available equipments has performed. Layer by layer, the process is reincreased over the past years [10].
peated and the component is built up.
Most AM technologies for metals share the
Different approaches are used for laser
following procedures [11]:
sources and laser beam positioning. For the
–– produce the raw powder in fine particle SLM process, the laser source is normally
fractions,
an Nd-YAG fiber laser. During building , the
–– spread powder in thin layers of 20 to 100 laser is moved by positioning of a reflectµm thickness,
ing mirror or by moving the laser head. The
–– join the powder particles – to form one laser beam is focused via a series of lenses.
solid layer – using thermal energy such
The current publication focusses on manuas laser or an electron beam that sinter,
facturing of material with the SLM process.
partially or fully melt and weld the particles or adhesive chemicals that are in- Electron-beam melting
jected to glue the particles,
With the electron-beam process, fully
–– repeat the process to build stacked and dense metal components can be manufaccoherent layers,
tured in the same way as described above
–– post-process to increase strength, sur- regarding the SLM process. The main difface or other specific properties.
ferences are:
–– the material is being melted by an elecSelective laser sintering/melting
tron beam,
Within the group of additive layer manu–– chamber temperature is elevated up to
facturing processes one of the processes
around 1,000 °C (material dependent),
is based on melting powder with a laser
–
–
powder sieving fractions are coarser
source. Two methods of laser sintering need
than the powder used for SLM.
to be mentioned here: selective laser sintering (SLS) [12] and selective laser melting
(SLM) [13]. SLS is a method where a powder is partially melted and SLM is a method
where the powder is completely remelted
during the manufacturing process. Both
the SLS and SLM processes are so-called
powder-in-bed methods where a component is built up layer-by-layer. A directed
laser beam is used to melt a thin layer of
pre-placed powder into a slice that will represent a cross-section of the component to
be built. Through addition of successive layers, the component is manufactured slice
by slice. For each slice the laser will travel
An EBM machine utilises a high power electron beam that generates the energy needed for high melting capacity and high productivity. The electron beam is managed
and controlled by electromagnetic coils instead of mirrors in the laser-based system.
If the SLM processes are using inert gas, the
EBM process takes place in vacuum.
Current status and expected
trends of AM technology
It has been stated that AM today is as advanced as computers were in the mid-80s.
This is to say that a huge wave of progress
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is expected in terms of improved speed, reliability, ease of use and operator friendliness, 3D-printing quality, standardisation
of processes and components inside the
3D-printers, etc.
A tremendous improvement of AM process capability can be noted. In 2009, laser
sources of 200 W were considered to be
the market standard. In 2011, the market standard became 400 W. In the same
year, single providers of SLM equipment
launched prototype 1 kW sources in their
products.
But maybe the most important effect on
building speed must be expected by the
introduction of multiple laser sources that
work in parallel, independently from each
other. Market introduction of a double beam
SLM machine was announced in 2011. In
this case, a 1 kW source for the melting of
large cross sections was coupled together
with a smaller 400 W source for achieving
precise skin features. In 2015, 4-beams SLM
machine are expected on the market.
Equipment
When comparing available brands of
equipment for additive manufacturing, a
number of European producers are available. European equipment manufacturers
of selective laser melting systems are:
–– Electro Optical Systems, EOS (Germany)
–– ConceptLaser (Germany)
–– SLM Solutions (Germany)
–– Renishaw (UK)
–– Phenix (France)
–– Realizer (Germany)
–– Sisma (Italy)
For electron beam melting, the major
equipment supplier today is Arcam (Sweden).
Equipment manufacturers have so far focussed on development of equipment with
successively larger laser capacities-up to 1
kW. With larger lasers and multiple lasers,
the productivity will increase through faster scanning with constant heat input or application of thicker layers in each laser scan.
Besides this, the equipment manufacturers
face a number of challenges:
–– increase of AM equipment productivity
and size of the components that can be
manufactured,
–– AM system users require much more information available to be read into and
out of an AM system in order to allow for
better quality assurance and productivity
optimisation,
–– process data evaluation tools are needed
in order to better understand process
limits and allow for identification of process control limits,
–– equipment of the same make and type
must be able to produce material to identical quality levels,
–– customers will need better transferability of process parameters and material
49
VGB PowerTech 12 l 2015
3D printing for gas turbine components
of avoiding costly scrap and rejections.
Traditional processes like casting and hotrolling are well-understood and process
control limits are frequently used, in order
to secure a flow of material with acceptable
quality. In additive manufacturing, today
no philosophy and, accordingly, no commercially available equipment exist, for
on-line process monitoring control. This
causes unnecessarily large efforts in terms
of destructive testing and high cost added
in production, causing AM to lose in terms
of competitiveness.
Currently, Siemens is looking for cooperation with AM OEMs to initiate development
and implementation of process monitoring
into AM equipment.
Fig. 3. Customised EOS SLM machine for burner repairs.
properties from one generation of SLM
systems to the next,
–– on-line monitoring systems must be developed and implemented in commercial
products (F i g u r e 3).
In order to address all these challenges in
time and in proper order, cooperation between AM equipment suppliers and customers can be very beneficial for quick
industrialisation of AM technology. As an
example of such cooperation customisation of EOS equipment for Siemens’ needs
can be mentioned. Based on Siemens’ request and specification, the company EOS
individually adapted and modified one of
its machines EOSINT M 280 for Siemens
gas turbine burner repair. The scale of the
machine’s interior was enlarged to accommodate the 800 millimeter burner. The
manufacturer also amended further hardware components such as a camera system
and an optical measuring system and made
corresponding adjustments to the software.
AM value chain
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Powder materials
Understanding powder composition and
morphology are key factors to control
when setting up and managing an AM process. Powder cleanliness, chemistry control
and powder homogeneity are some of the
parameters that must be well understood.
Since powder manufacturing, especially
for AM processes requires tight alloying
element control and atomising equipment
specialised to maximise yield and productivity for the very specific powder size
ranges used, large efforts are put into setting up a process for additive manufacturing. A good example could be an AM plant
where not only component but also powder
manufacturing is established. Through this
set up, it is possible to maximise the value
added to any given component manufactured. Also the powder can be better utilised, since different AM processes will use
different fractions of the atomised powder.
Powder suitable for AM is typically sieved
into fractions where the yield is gained
50
between 10 to 160 µm. When the powder
is sieved to fit, for instance in SLM, a large
portion of the powder has to be recycled
with increased powder cost. If two complementary processes are utilising the same
powder, the yield in atomising will dramatically increase. This would be the case
comparing SLM and EBM manufacturing.
Several suppliers can provide powders
suitable for additive manufacturing. Gas
atomised powder is required with sieving
fractions in a relatively tight size range.
Depending on equipment and setup (layer
thickness), the sieved fractions will be in
the range of 10 µm to 30 µm up to 10 µm
45 µm for thin layer thicknesses.
Process parameters
Equipment for AM processes is readily
available. However, the knowledge regarding how to set up and maintain an AM process cannot easily be acquired. Knowledge
on laser or electron beam performance,
process parameter optimisation and process performance and stability it is hard to
be gained from original equipment manufacturers (OEM). In many cases, the selection of available materials and corresponding process parameters does not match the
needs from large companies. Especially
advanced materials for aggressive environments and high temperatures are not readily available. This means that large efforts
need to be put into the equipment process
parameter development. In order to fully
utilise the AM process, it is highly likely
that several alternative process parameter packages could be available for one
material. Depending on the component
requirements, the process will need to be
set up for best economy (speed), accuracy
(tolerances and surfaces) or performance
(strength).
Post-treatment
Materials manufactured with AM techniques are, in many cases, superior to traditionally manufactured components even
without any post-processing. The materials created are very homogeneous without
internal flaws and defects. However, there
are a number of properties that might
cause problems (surfaces, internal stresses,
behaviour at extreme temperatures) that
require improvements. Material response
to external loading will also typically be
anisotropic. These, and other factors, will
put requirements on post-treatments to
further optimise component performance.
Depending on the type of post-processing,
the cost associated with the treatment can
be low (heat-treatment) or high (surface
improvement). However, the cost associated with establishment of a cheap postprocessing operation might be substantial
(e.g., as in development of heat treatments
for optimal mechanical material properties
for different applications).
Material data and design criteria
As previously mentioned, material data
generation can be required for a number
of variations of one given material. The
cost associated with material data generation is very dependent on the application.
Depending on the application, the cost
associated with material data generation
and implementation for one material into
designer-friendly tools can range from
modest numbers up to 1 to 1.5 m €. If generated, this type of data is today typically
not readily available in open sources.
At Siemens Power Generation, authors are
keeping high focus on establishment of the
process parameters for nickel based materials.
It is very likely that the full understanding of AM materials can be gained only, if
larger consortia are formed, where synergies will allow for good understanding of
residual stresses, mechanical properties
and physical properties coupled to process
behaviour and part performance described
as dimensional accuracy or bulk and surface quality.
Process monitoring
Design tools
Process monitoring is, for all traditional
manufacturing processes, a natural way
Design criteria are not only material data
and design data developed from material
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VGB PowerTech 12 l 2015
1
Rapid prototyping
Blade 1
Product:
3D printing for gas turbine components
2
Rapid repair
Burner
SGT
Product:
3
Siemens is using AM (SLM) technology for
three main applications (F i g u r e 4):
–– rapid prototyping,
–– rapid repair and
–– rapid manufacturing.
Rapid manufacturing
Burner
Product:
SGT
SGT
Component: E.g. turbine blade 1
Component: Burner tip
Component: Burner swirler
Benefit:
Significant reduction
of time to market
Benefit:
Benefit:
Status:
Part ot standard
process
Status:
10 times faster,
easy upgrades
In commercial
application
Status:
Swirler can only
be made via SLM
In commercial
application
Fig. 4. Three pillars of SLM application.
performance. Design data also include design features and guidelines on how to and
how not to design an element with additive
manufacturing. This type of information
can, to some extent, be found in open literature and can be used as an input. However,
adoption to the local situation will always be
required. Guidelines when to and when not
to select an AM process also need to be available in order to minimise the needs for parallel development of a component adopted
for different manufacturing processes.
In order to fully utilise AM technologies,
the mind-set of designers and engineers
must be changed.
Standards
Today, standards for additive manufacturing in general and specifically for SLM are
not readily available. The standards for
SLM are limited to a handful documents
within (sections here adopted as per ASTM
grouping):
VGB PowerTech - Autorenexemplar - © 2015
Design
–– ISO/ASTM52915 – 13: Standard Specification for Additive Manufacturing File
Format (AMF) Version 1.1
–– ISO/DIS 17296 – 4: Additive manufacturing – General principles – Part 4:
Overview of data processing
Materials and Processes
–– ASTM F2924 – 12a: Standard Specification for Additive Manufacturing Titanium-6 Aluminum-4 Vanadium with
Powder Bed Fusion
–– ASTM F3001 – 13: Standard Specification for Additive Manufacturing Titanium-6 Aluminum-4 Vanadium ELI (Extra
Low Interstitial) with Powder Bed Fusion
–– ISO/DIS 17296 – 2: Additive manufacturing – General principles – Part 2:
Overview of process categories and feedstock
Terminology
–– ASTM F2792 – 12a: Standard Terminology for Additive Manufacturing Technologies
–– ISO/CD 17296 – 1: Additive manufacturing – General principles – Part 1: Terminology
Test Methods
–– ISO/ASTM52921 – 13: Standard Terminology for Additive Manufacturing-coordinate Systems and Test Methodologies
–– ISO/DIS 17296 – 3: Additive manufacturing – General principles – Part 3:
Main characteristics and corresponding
test methods
It is obvious that the process is yet not fully
standardised but also important to notice
that the basic concepts are settling in the
standards mentioned above.
Applications
As already mentioned, AM is a revolutionary technology enabling simultaneously
enhancement of component performance
and reduction of delivery time. SLM is a
new dimension in integrated design and
manufacturing, converting our dreams
into reality, with practically no limitation
and at extremely short delivery times.
With this technology, complex multi-elements components could be produced as aone integral part with higher performance
and, in majority of cases practically at the
same cost (e.g. GT burners with lower
emissions and higher lifetime, GT vanes
with better cooling efficiency and longer
life time).
Rapid prototyping
Integration of AM into the product development process enables significant speedup of design and validation of new components and system, as well as ensuring
high reliability and performance of newly
designed components prior to final engine
testing and product release.
In the past, due to long delivery time of
new components manufactured by conventional methods (e.g. casting), component
validation testing was done almost at the
end of the development process, during
the final engine test. This is why a conventional development procedure has some
disadvantages and consequences:
–– sequential development process,
–– conservative development approach,
–– moderate development targets/results,
–– long development cycles.
With new approach, when AM is an integral part of the development process (F i g u r e 5) and can be used for rapid components design and manufacturing, the following advantages can be realised:
–– parallel and integrated development
processes,
–– radical development approaches,
–– ambitious development targets/results,
–– fast development cycles.
Utilisation of AM technology for compressor turbine blade design enables the evaluation a few blade cooling concepts and
their tests in a real engine environment in
a few months instead of a few years.
Rapid repair
Repair of components has also been identified as an application with big potential.
Damaged areas of material can be removed
and new material built up. Just as for new
manufacturing, the lead time reduction is
expected to be significant, especially for
complex compound structures or raw materials with long lead time from order to
supply.
Recently developed the repair procedures
for SGT-700 & -800 burners tips using SLM
Integrated development -> Iteration in a few months instead of years
3D-design
SLM 3D-print
Processing
Instrument.
Test
3D-integrated
CAE/CAD/CAM
Fig. 5. SLM as a part of product development process.
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51
VGB PowerTech 12 l 2015
3D printing for gas turbine components
Metal powder
Laser
Platform
Burner
It starts on the computer - the
gas turbine burner needs a new tip
A layer of powder
is applied
A laser beam fuses
the powder
–– increased coating adhesion: micro-scale
engineered surfaces,
–– new powder alloys possible: improved
lifetime of the components.
Despite all these benefits and advantages,
there are several aspects that make the AM
process difficult to use today:
–– the process is slow, development of
equipment is needed,
–– quality assurance measures need to be
refined,
–– design tools are not readily available,
–– material data is not generated to the extent required by users,
–– available materials do not match needs
from industry.
The research community and industry together need to resolve all these challenges
to speed up industrialisation of AM to its
full extent.
References
The platform lowers
A new layer of metal
by a few micrometers powder is applied
The process is
repeated, layer
by layer
This process gradually produces a
new burner tip that is melted onto
the rest on the component
Fig. 6. SGT-800 & SGT-700 burner SLM repair procedure.
technology is 10 times quicker than previously used “conventional” repair procedures, as it avoids quite a few manufacturing and inspection processes.
Conventional repair procedure required
prefabrication of a large portion of the
burner tip. This prefabricated burner tip is
used for replacement of the burner tip after the specified operation time (the old tip
was cut off and the prefabricated one welded on). Conventional repair procedure was
time-consuming, with a significant number
of sub-processes and examinations.
AM repair process of SGT-700 & SGT-800
burners is shown in F i g u r e 6.
Replacement of conventional repair processes with SLM provided not only a significant reduction in repair time, but also
an opportunity to modify repaired components to the latest burner design.
VGB PowerTech - Autorenexemplar - © 2015
Rapid manufacturing
AM technology industrialisation is also
enabling new opportunities for spare part
and supply chain enhancement:
–– manufacturing of spare parts on demand,
–– regionalisation of rapid repair and manufacturing of GT components,
–– simplification of logistics and investment
reduction on stocks.
Currently, Siemens Power Generation is
focusing on industrialisation of SLM for
rapid repair and manufacturing of Siemens
gas turbine components.
Today, we already have burner swirls in
commercial operation in one of our industrial gas turbines. We used AM technol52
ogy for this complex burner swirl, because
AM was the only technology that can produce it.
In the next few years we are planning to
extend the scope of AM manufactured gas
turbine components to burners, fuel strainers, heat shields and guide vanes.
Conclusion
Additive manufacturing enables a revolution in spare parts manufacturing and generates the following values and opportunities:
Lead time reduction and life cycle
improvement for complex parts:
–– lead time reduction: faster technology
validation and product development,
shorter time to market,
–– reduced number of process steps: simplified manufacturing and repair, faster
manufacturing and repair,
–– saving of material,
–– reduced number of parts in a component: integrated functionality,
–– eliminated tools: no time consuming
casting process,
–– on-demand, instant, de-centralized production (e.g. for service).
Efficiency increase through practically
unlimited options for internal and
external cooling duct design:
–– better heat transfer and lattice structures: thinner walls and larger surface
areas,
–– improved mixing of fuel and air: advanced nozzle designs,
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International Journal for Electricity and Heat Generation
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