Siemens has successfully produced gas turbine blades using additive manufacturing and tested them under full engine conditions – 13,000 RPM and temperatures beyond 1250°C.
"This is a breakthrough success for the use of Additive Manufacturing (AM) in the power generation field, which is one of the most challenging applications for this technology," said Willi Meixner, CEO of Siemens Power and Gas Division.
The company tested a new blade design with a completely revised and improved internal cooling geometry manufactured using the AM technology. The turbine blades are made out of a powder of high performing polycrystalline nickel superalloy, allowing them to endure high pressure, hot temperatures and the rotational forces of the turbine's high speed operation. They were installed in a Siemens SGT-400 industrial gas turbine with a capacity of 13 MW. At full load each blade is travelling at over 1600 km/h, carrying around 10 t.
Meixner said the successful tests were the result of a dedicated international project team with contributions from Siemens engineers in Finspång, Sweden, Lincoln, England and Berlin, Germany.
"In just 18 months they completed the entire chain from component design and AM material development to new methods for lifing simulations and quality controls," he said.
"With our combined know-how in 3D printing, we will continue to drive the technological development and application in this field."
He said additive manufacturing is changing the way they manufacture by reducing the lead time for prototype development up to 90 per cent.
"Additive Manufacturing is one of our main pillars in our digitalisation strategy," Meixner said.
"We can accelerate the development of new gas turbine designs with an increased efficiency and availability and can bring these advancements faster to our customers. This new flexibility in manufacturing also allows Siemens to develop closer to the customer's requirements and also to provide spare parts on demand."
[3D-printed turbine blades. Photo: Siemens]