Swedish-based company, Siemens Industrial Turbomachinery AB (SIT), manufactures gas turbines for power generation in industrial and oil & gas applications. The performance spectrum of these Siemens industrial turbines ranges between 15 and 60 MW. Besides construction, the Siemens subsidiary also provides long-term service and maintenance for these engineering masterpieces. In an effort to help reduce maintenance costs, Siemens is currently working with the development and implementation of Additive Manufacturing technology, utilising EOS technology and equipment.
Additive Manufacturing opens up new dimensions for us in the use of integrated design and production. This technol ogy enables us to manufacture and repair components for our industrial gas turbines far quicker than before. At the same time the functionality and performance of the part is increased.
Undertaking such an operation requires an innovative partner. Siemens found just that in EOS: in addition to having the right Additive Manufacturing technology, EOS was also able, within a short time frame, to individually adapt one of its in-house machines – an EOSINT M 280 – for metal processing.
The alterations concerned, in particular, the scale of the machine's interior, which had to be enlarged to accommodate the 800 mm burner. The manufacturer also amended further hardware components such as a camera system and an optical measuring system and made corresponding adjustments to the software. EOS carried out the extensive re-working of the EOSINT system in under a year.
From the outset it was clear that the approach was reaping benefits. Rather than replacing a large portion of the burner tip, Siemens began by removing the damaged material only. Moreover during repair, former versions of the burners in the fleet could be re-built to the latest design. This meant that older fleet burner versions could not only be repaired, but also improved – thus bringing new meaning to the term “Additive Manufacturing".