Session: 03-02 Metals: Design for AM - Industrial Applications

Paper Number: 92004

92004 - Industrialization Advancements for the Production of Hot Gas Parts by Additive Manufacturing 

Industrialization Advancements for L-PBF for Gas-turbine parts

The evolution from 1^st validation of individual hot gas parts produced by Additive Manufacturing (AM) and the subsequent engine validation has been successfully demonstrated over the past years. Meanwhile entire engine sets are being produced and installed in customer engines.

In parallel the industrialization of AM has progressed towards a holistic End-to-End process chain from a dedicated AM suited design towards an engine ready component. Leaving the zone of validation parts with acknowledged ramp-up manufacturing costs and increased lead time.

The challenge of industrialization comes with multiple aspects, like high efforts for post processing, machine qualification and stability, quality assurance and lead time. SIEMENS ENERGY has teamed up with partners from industry and science within a public funded project called “IDEA” to push the industrialization of Additive Manufacturing (AM). Target was to optimize the entire value chain from design until finished product. Advancements were made in design and simulation of the AM parts and processes; tools have been benchmarked against measured vales on printed components and parts. Furthermore, simulation tools have been used to mitigate process induced variation in terms of geometrical tolerances. Quality assurance of components build by AM is associated with in-situ process monitoring yielding into vast amounts of unstructured data, during the project methodologies have been validated and correlations established to assess the part quality based on machine data. The stability of AM systems has been evaluated including in-depth shield gas flow measurements inside the process chamber. Alongside with monolithically produced AM Parts also conventional parts were repaired with a streamlined hybrid AM repair process. In summary throughout the project multiple advancements have been developed and successfully validated which will allow an industrialization by the technical and organizational enablement.

Presenting Author: Julius Schurb Siemens Energy

Presenting Author Biography: Team Lead AM Industrialization <br/>Siemens Energy, Berlin<br/>September 2021 – present<br/>• Drive and execute on SIEMENS ENERGY&#180;s AM Industrialization Roadmap <br/><br/><br/>Industrialization and Technology Expert<br/>Siemens PG, Berlin<br/>December 2017 – September 2021<br/>• Hardware and technology co-lead and public funded R&amp;D project<br/><br/>Additive R&amp;D global lead <br/>GE Power Switzerland<br/>November 2015 - November 2017<br/>• Project lead, High temperature Additve and lead of global R&amp;D activities<br/><br/>Teamleader SLM processing<br/>GE Power Switzerland<br/>November 2015 - September 2016<br/><br/>Teamleader SLM Processing<br/>Alstom Power<br/>November 2013 - October 2015<br/>• Project Lead of SLM Processing within R&amp;D Program Production of hot gas paths Transfer of SLM from lab to fab incl. heat treatments, inspection and testing, validation <br/><br/>Development Engineer<br/>Alstom Power<br/>November 2009 - November 2013<br/>• Process development additive manufacturing Introduction &amp; development of functional prototypes for IGT components by Additive Manufacturing/SLM

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