Additive Manufacturing for Turbomachinery & Turbines

3D Printing Application Examples
3D Printing of Turbomachinery Parts
Additive Manufacturing for the Energy Sector

Turbines, Compactors, Compressors & More

Turbomachinery is indispensable for energy generation. Its high-performance parts feature complex, high-tech designs that need to be more and more robust and powerful as the demand for energy increases. In addition, turbomachinery parts need to be resistant and reliable – even at temperatures beyond the melting point.

Additive manufacturing can solve many of these challenges and is suitable for numerous applications:

blades and vanes, fuel injectors, impellers, swirlers, burners and combustion chambers, cladding, seals, housings, and much more. The 3D metal printing process (DMLS) offers the right technological foundations for implementing an optimized cooling strategy, among other things. Parts can be designed and made to transport and apply energy with increasingly precise focus. Innovative repair processes, for example, are revolutionizing the efficiency of turbomachinery parts by building at worn areas directly on the original part.

Our systems can enable new potential for your turbomachinery parts, including improved energy efficiency, reduced development cycles, and a higher return on investment.

Improved performance and efficiency

Drastically reduced lead time

In-sourcing of IP and manufacturing capacity: less dependency

Turbomachinery Impeller

Stator Blade

Euro-K Burner

Linde HYDROPOX Flame Ttreatment Burner

Linde HYDROPOX burner as all-in-one design (AiO) with a complex sandwich structure

Extrude Hone Swirler

Improve Parts & Performance

Accelerate Research & Development

Optimize Repairs & Maintenance

Improve Spare Parts Logistics

Additive manufacturing allows you to manufacture complex parts with integrated functionality. Lower part costs and shorter lead times can also be achieved by reducing the rejection rate.

Directly from CAD data: faster design optimizations and shorter development cycles become possible by building prototypes with 3D printing

Reduced costs thanks to the ability to repair parts with complex cooling channels, less downtime.

Spare parts on request: even small batch sizes can be manufactured cost-efficiency, reducing storage costs.

The collaboration between Siemens, Material Solutions and EOS demonstrates that 3D metal printing is a reliable and proven technology viable even for “moving” applications, without any compromise. In focus: developing a new turbine blade. The part was developed together with Siemens NX, built on EOS systems and produced by Material Solutions.

Performance:
Performance increased to 13,000 rpm

Time savings:
75 % shorter development time
50 % quicker lead time

Heat stability:
Can be used with ambient temperatures of up to 1,250°C

If you can 3D print a turbine blade, you can print pretty much everything.

Dr. Markus Seibold | VP Additive Manufacturing | Siemens Power and Gas

Jens Karnapp

Sales Manager (Key Account/Solution)

EOS GmbH

jens.karnapp@eos.info

Siemens relies on an EOS system to manufacture burner fronts featuring functional integration – redesigned with Siemens NX and manufactured in series on an EOS M 400-4 from EOS NickelAlloy HX.

Robustness

The part is manufactured as a single piece and no longer has 13 different components

Reduced weight

Since less material is used, the part is considerably lighter

Time savings

The lead time is reduced from 26 weeks to 3 weeks

Life cycle optimization

Reduced heating of the metal extends the service life of the part

Innovation Story

Euro-K GmbH | 3D Printed Micro-Burners

Develop and build a multi-fuel burner capable of using gaseous and liquid fuels with additive manufacturing on the EOS M 290.

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Innovation Story

Linde AG | 3D printing of the HYDROPOX® Burner

Redesign and manufacture of a Linde HYDROPOX® Burner. A new type of burner was produced using additive manufacturing: Functionally integrated with an All-in-One Design (AiO).

watch video

Downtime caused by repairs and maintenance work is a huge cost factor in large-scale energy generation plants. Especially for parts with high complexity and integrated channels, the hybrid repair process based on direct metal laser sintering (DMLS) opens up unique opportunities to save time and costs. How does it work? Areas that experience wear are reconstructed directly on the original part.

This has far-reaching advantages:

No additional welding steps are required
Improved quality of the connection between the reconstructed area and the original part
The alignment of internal structures is preserved

Thanks to a customized EOS system, Siemens found success with a precise and fast maintenance process for burner tips subject to high thermal stress in gas turbines. The repairs are performed by building directly onto the worn material, saving time and cost.

Time savings

Repair times were reduced by 90 %

Process optimization

The repair process became significantly more streamlined

Functional integration

Technical improvements can be incorporated during repairs

We offer robust systems with repeatable part quality and a wide portfolio of materials, capable of handling diverse applications, including those involving high temperatures. To complement this, we also offer tools and software for comprehensive quality monitoring and a consulting department to take care of your needs.

EOS M 290

Mid-Size 3D Printer with a Wide Range of Materials

Highly productive, modular and well-established mid-size 3D printing system with a very broad portfolio of materials for the additive manufacturing of high-quality metal components – in series or as prototypes.

more about EOS M 290

EOS M 400

3D Printers for Large Metal Parts Within a Production Environment

Thanks to the build volume of 400 x 400 x 400 mm and 1000-watt laser power, the EOS M 400 makes it possible to produce high-quality materials at industrial scales – directly from the CAD data and without tools.

more about EOS M 400

EOS M 400-4

3D Printing of Metal Parts on Industrial Scales

The ultra-fast four-laser system for the additive manufacturing of high-quality components, achieving up to four times higher productivity. This 3D printing system was made for efficiency and scalability in industrial applications.

more about EOS M 400-4

3D Printing Materials

Nickel Alloys

Alloys for high temperature applications in airplane and gas turbines as well as in the shipping industry.

3D Printing Materials

Stainless Steel

Alloys for printing parts in aerospace, medical, energy, jewelry, shipping and food industries.

3D Printing Materials

Titanium

Ideal for a wide range of high-performance applications in aerospace, automobile and medical as well as in lifestyle industries.

3D Printing of Turbomachinery Parts
Additive Manufacturing for the Energy Sector

Turbines, Compactors, Compressors & More

Additive Part Manufacturing for Turbomachinery 3D Printing for Gas Turbines & More