håkan brodin siemens industrial turbomachinery ab

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SIEMENS processes for advancedcomponents and prototypes

Håkan Brodin Siemens Industrial Turbomachinery AB, Materials Technology

2014-12-03

Restricted © Siemens Industrial Turbomachinery AB 2014 All rights reserved.

H Brodin / PG DG CE CORE MAT MGT

Possible areas of SLM introduction inindustrial gas turbines

Solid componentsLimited thermal loadHigh mechanical load

Complicated geometriesHigh thermal loadHigh mechanical load (blades)

Weldings, large assembliesModerate to high thermal loadModerate mechanical load

2014-12-03



Challenges with application of AM-components in gas turbine applications

• Very high loads on the rotating components • Combustion gas temperature close to

melting point of steels• At least two years between major

maintenance (chance to take a closer look)• Very high costs can be involved if gas

turbines are forced to outage• Validation of components is time-consuming

2014-12-03



Why did Siemens embrace 3D-printing?

• First SLM equipment on site more than four years ago, today two units (further expansion ongoing)

• Initially, large skepticism within the organization• ”Literature knowledge” on the SLS process assumed (we today denote SLM

as lasersintring – totally incorrect since SLM is a melting/welding process, however on a small scale)

• Inferior microstructure• High porosity• Poor strength• Bad fatigue performance• and the list could be continued…

• KEY: Find an application that is advanced, but easy to monitor/inspect/replace• As seen on TV: Burner tip manufacturing / repair

• Geometry suitable for AM• Required materials available• Inspection possible without to large efforts

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SLM process - Challenges

With our high demands on materials, AM requires a lot from an internal / external service provider and us as a customer• Material properties

• Databases / mat.data not available• Machine – to – machine

variations• Powder sourcing• Powder quality• NDT• Process monitoring

• Modelling• Anisotropic material• Coarse surfaces• Corresponding material

models• New features, lattices

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SLM process - Challenges

With our high demands on materials, AM requires a lot from an internal / external service provider and us as a customer• Quality assurance

• Workshop manufacturing is not ”just” measures, surfaces and tolerances• QA equipment / new operations in routing / post processing• Personnel / skills• Standards• Process window

• Design for AM is not easily implemented• Design guidelines (equipment and material dependence)• Iteration between manufacturing and design

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SLM process - Strengths

Three cornerstones in Siemens Finspång additive manufacturing philosophy:

• Rapid Prototyping• Enables designers to significantly shorten

lead time and cost for design iterations• Rapid Repair

• Upgrades can easily be introduced• Significantly shortened lead time (10x)

• Rapid Manufacturing• SLM the only viable manufacturing method

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Rapid Prototyping: SLM enables fast time to market

Integrated iterative development• Design• 3D-printing• Processing• Testing• Evaluation

Conventionally: Test as a validationNew approach: Testing as an integral part of the process

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• 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

Layer by layer metal powder is melted into a structure (RaBuTir: Rapid Burner Tip Repair)

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So, what makes AM / SLM so special???

Top view

Side view

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So, what makes AM / SLM so special???

Microstructure of a casting

…hot-rolled bar/plate

…and SLM material…

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Conclusions

• AM processes are necessary because they enable us to build the impossible, i.e. anything can be built in our AM-equipment

• AM processes are problematic because anyone can build that ”anything”, (Quality Assurance!!!). Process monitoring and NDT need focus.

• AM will never substitute the traditional manufacturing chain, but rather be a very important part in the chain.

• Three main areas of use within Siemens Finspång. Prototyping, repair and manufacturing the impossible (it is also OK if we can cut costs)

• Material properties are still (to the majority of users) unknown and the initial investment is large in the evaluation and characterization of the AM process / material. Post processing / heat treatment not necessarily as per standard!

• Designers need better tools for assistance in the selection of an AM process for a given application and the design of this component

• Development of modelling tools for mechanical integrity, heat transfer, … also need urgent attention.

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