Industrialization of additive manufacturing at Siemens Industrial Turbomachinery AB Dr. H Brodin, Specialist – Materials Technology

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Answers for energy.

Siemens Industrial Turbomachinery AB (Finspång) • One of the world’s largest manufacturer of land-based gas turbines • Land-based • Power generation • Turbine drives a generator • On-shore / off-shore • Peaker and base-load operation • Mechanical drive • Pumps • Process equipment • On-shore / off-shore • Siemens Finspång has a product range from 20-60MW shaft output • Enough to support a village with electrical power • Turbines are designed, manufactured and customers are supported for maintenance and overhaul from one site • All knowledge on components and material and process is available ”onsite”

Siemens Industrial Gas Turbine: SGT-800 Designed and manufactured in Sweden

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H Brodin / Siemens Industrial Turbomachinery AB

AM at Siemens Industrial Turbomachinery AB (SIT) • Laser powder bed additive manufacturing, a journey that started in 2009 • At that time: One manufacturing unit from EOS (M270DM) • First years, understanding of the manufacturing equipment and the resulting structure • One material (superalloy) • Today an established technology with a handful of components released for use in the hot gas path • Three SIT qualified materials (Superalloys/Stainless) • Eight ”printable” alloys • Center of Competence for manufacturing of AM • Today a dedicated workshop • Four generations EOS Laser Powder Bed units commissioned • One important factor for successful implementation is access to all disciplines from design to production Finspång AM-workshop EOS M290 Siemens Industrial Turbomachinery AB 2016 All rights reserved. Page 3

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H Brodin / Siemens Industrial Turbomachinery AB

Drivers for implementation of additive manufacturing Technology • Part accuracy • In a welded structure, distortions with large variability may take place • Part complexity • Avoid welds in highly loaded areas • Part functionality • Design parts that are difficult / near to impossible to manufacture by other means • Part development • Design iterations (castings) requires lead times of at least 6-12 months

Logistical • Material consumption • Example burners: Replacement of structure turned from hot-rolled bar where 85% of the material volume is removed • Reduction of process steps • Reduction of sub-assemblies • Material lead time • 20-30 weeks not abnormal for high-performing alloys (depending on shape and condition)

Cost out, business case , economical benefit… This is not considered as essential, since the part designed for production by traditional means will most likely NOT be economically viable when produced by AM – Added value is important! Siemens Industrial Turbomachinery AB 2016 All rights reserved. Page 4

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Component manufacturing (typical router) Casting Forging Cold forming Bar / Sheet / …

Heat treat/Ageing Welding Brazing

Coating

Heat treatment

Grit blast Machining Finishing

Coating finishing

Milling Turning EDM Grinding

NDT

NDT Sign-off

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Component manufacturing (SLM introduction – extreme scenario)

? SLM

Coating

Coating finishing

NDT Sign-off

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Additive manufacturing, an industrial revolution (?) The talk on the town… The Economist: …3rd industrial revolution after mechanization of textile industry and introduction of the assembly line. Close-down of mass-production industry… Financial times: …3D printing as a threat to traditional manufacturing… Terry Wohlers: …additive manufacturing will not usurp the current techniques. “You’ve got to look at 3D printing as another tool in your toolbox”… Graphics: www.economist.com

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The repair business is important to Siemens Previous knowledge in two areas…

Two weld repair process types are dominating the turbine repair business: Conventional repair by TIG welding or Laser Cladding

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Background, First component • • • • • • • •

Component that is of high importance Component with easy access (inspection) Component with complex geometry Component with sourcing issues Large number of components (roll-out in ”suitable” engines) Generic interest for many Siemens entities Suitable material available Suitable size for existing AM equipment

=> SGT 800 burner tip repair and manufacture

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

• This technology is complex and requires broad knowledge in many different areas, including materials science, quality management, 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 an AM center of competence within Siemens Siemens Industrial Turbomachinery AB 2016 All rights reserved. Page 10

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Focus areas • Quality measures • Material composition (powder) • Recycling / blending (powder) • Process (process window) • Process (machine-to-machine variations) • Process (post-processing, heat treatment) • Geometry (dimensions) • NDT (complex geometries, coarse surfaces) • Design & Integrity • Material data • Physical limitations, dimensions, rules • Mechanical integrity, rules • Flow and heat transfer, rules Siemens Industrial Turbomachinery AB 2016 All rights reserved. Page 11

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Quality, Powder and process specifications • Powder specifications not commonly available • User limited to using powder from laser process OEM – not satisfactory • Composition suitable for welding, development efforts • CalPhad, solidification modelling, precipitation • Powder fractions for the process • Powder test methods • Metallurgy and mechanical testing on manufactured test geometries • In addition to powder specification, SLM material specification needed, • ”Weld procedure specification” needed • Quality instructions, procedures • MES system • ”Delivery conditions”, purchase documents for AM parts Siemens Industrial Turbomachinery AB 2016 All rights reserved. Page 12

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Quality, Powder degradation and need for blending / homogenization • Powder degradation over time • Refresh rate of powders • Blend • Mix, homogenize • Requalify • Sampling rate & scope • Cost issue • Time issue • Suitable equipment needed • Blending • Chem. Analysis • Fractions • Flowability • Powder density • Impact on certain mechanical properties, ductility Siemens Industrial Turbomachinery AB 2016 All rights reserved. Page 13

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Quality, Machine-to-machine variations

• • • • •

Differences between manufacturers Parameter transferability Flexibility Benchmark needs Powder => porosity and property influence (eliminated) • Machines => Difference in residual stresses • Machines => Variation in porosity • Machines => LCF, tensile, creep

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Design capabilities, Material data • Material data generation from scratch • Anisotropy • Test types • Monotonic • Physical • Fatigue • Creep • Fracture mechanics • Heat treatments • Interfaces • Influence of equipment • Influence of powder batch • Powder degradation

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Design capabilities, Life models • Complex material behaviour must be mirrored in the mechanical integrity material models used • Anisotropy causes large numeric issues in calculations • Especially in cyclic constitutive models including orthotropic creep and plasticity descriptions • Lattice truss structures • Extensive development efforts required • Use of lattices and bionic structures complicates the situation further • Sub-modelling

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Quality, Dimension repeatibility and Design philosophy • Dimensional accuracy • Offset • Need for critical to quality follow-up • Process control limits • Adjustment of CAD geometry • Continuous refinement of dimensional accuracy • White light / blue light scanning beneficial • Geometry -> print -> measurement -> adjust CAD -> print -> measure ->… • CT-scanning

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CT-scanning for dimensional and microstructure comtrol • CT mainly being used as a tool for QA during component qualification • Crack detection • Porosity detection • Wall thickness • Blocked inner passages • Alloy-dependent results • Limited possibility for use of other NDT techniques • Complicated inner structures • Rough surface • Lattices / multi-wall designs

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Conclusions – Focus areas • Education • Designer guidelines • Dimensional and surface accuracy • Material behaviour, chemistry, heat treatment • Mechanical integrity • Tools • CAD-tools for lattice structures, integrated design and production • Process optimization • Build quality optimization • Material / alloy design and optimization • Materials • Powder quality (degradation) • Powder handling (blending, storage) • Standards and routines • Material data • Qualification of components • Heat treatments / property improvement Siemens Industrial Turbomachinery AB 2016 All rights reserved. Page 19

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H Brodin / Siemens Industrial Turbomachinery AB

Contact page Håkan Brodin Specialist, Materials Technology RGM, Mateirals Technology Slottsvägen 2-6 SE - 612 83 Finspång Phone: +46 (0)122 82728 Mobile: +46 (0)70 5572207 E-mail: [email protected]

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