February 18, 2025
Metal Steam Turbine Blade Unveils Potential for Large 3D-Printed Parts

Metal Steam Turbine Blade Unveils Potential for Large 3D-Printed Parts

Researchers at the Oak Ridge National Laboratory have achieved a significant breakthrough in 3D printing technology by successfully printing large rotating steam turbine blades for power plants. The project, led by Siemens Technology, demonstrates the feasibility of wire arc additive manufacturing for the production of critical components weighing over 25 pounds. Previously, these parts were primarily made using casting and forging facilities overseas, leaving domestic supply chains vulnerable to disruptions.

Wire arc additive manufacturing utilizes an electric arc to melt metal wire, which is then built up layer by layer using a robotic arm. The resulting printed part is machined to meet the final design requirements. The wire-arc technology used in manufacturing the turbine blade was developed in collaboration with Lincoln Electric under a co-operative research and development agreement.

The versatility of wire arc manufacturing extends beyond the production of new parts. It can also be used to repair existing components, offering companies like Siemens Energy the ability to maintain and upgrade equipment more efficiently under service contracts with electric utilities. Originally focused on component repair, the Siemens wire arc research expanded during the COVID-19 pandemic due to extended wait times for new cast steam turbine blades. As a result, the project expanded to include the printing of entire replacement parts for use in various power plants, including gas, coal, and nuclear facilities.

Researchers at the Oak Ridge National Laboratory conducted material experiments and developed improved methods for evaluating the mechanical performance of printed parts. The large steam turbine blade, made from a steel alloy, represents the culmination of these efforts. Initially, the plan was to print only 25% of the top section of the blade. However, the team realized the potential of the wire arc setup, allowing them to print the entire blade in one build. The real-time scanning capability enabled the team to provide accurate information to the machining staff, significantly reducing production time.

While the wait time for large castings and forgings has reduced to around seven or eight months, the printing and machining process of a blade can be completed in just two weeks. This is a significant improvement compared to the traditional manufacturing methods. Wire arc technology had not been utilized for the production of rotating components of this size. Turbine blades, with their curved and tapered design, present a challenge due to the absence of parallel or perpendicular surfaces. Additionally, larger parts cool more slowly, requiring careful consideration of the layer deposition order and speed.

Following the machining process, Siemens is collaborating with the Electric Power Research Institute for non-destructive evaluation and testing. The goal is to compare the properties of the 3D-printed part with those of traditionally manufactured components. However, for repair purposes, an exact match is not necessary. The current priority is to keep the engines running and minimize downtime.

This breakthrough in 3D printing technology opens up possibilities for on-demand manufacturing and reduces reliance on specific manufacturing tools that may become obsolete. With the ability to replicate any design, 3D printing offers a reliable alternative for producing large-scale components, ensuring the continuity of power generation in various industries.

Note:

  1. Source: Coherent Market Insights, Public sources, Desk research
  2. We have leveraged AI tools to mine information and compile it

Money Singh

Money Singh is a seasoned content writer with over four years of experience in the market research sector. Her expertise spans various industries, including food and beverages, biotechnology, chemical and materials, defense and aerospace, consumer goods, etc.

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