Siemens has hit another milestone in its use of additive manufacturing.
“This is another excellent example of how additive manufacturing is revolutionizing our industry, delivering measurable benefits and real value to our customers, particularly as they look to further reduce emissions to meet environmental targets,” said Vladimir Navrotsky, chief technology officer for Siemens Power Generation Services.
“Our achievements using AM are paving the way for greater agility in the design, manufacturing and maintenance of power generation components.”
Navrotsky said that from concept to engine test, the development took only seven months, “which is impressive for a component that requires such tight tolerances and works in high load and temperature”.
The DLE pre-mixer is highly complex. Using traditional manufacturing methods, it has over 20 parts involved in the casting and assembly. However, by utilizing Siemens’ qualified nickel super alloys as the AM printing material, the 3D-printed component required just two parts and the lead time was cut by around 70 per cent.
3D-printing of the DLE pre-mixer allows Siemens to simplify complexity in the production process, reduce external dependencies in the supply chain, and improves the geometry of the component, thus allowing a better fuel-air mix.
First engine testing of the AM-manufactured DLE pre-mixer, which was 3-D printed in Siemens’ base in Finspang, Sweden, was recently completed and the data received is said to be promising. It showed no start issues, all fuel transitions were accomplished successfully without any controls modifications required, there were no combustion dynamics or noise, measurable CO emissions reductions were realized and full power was achieved.
Read more about Siemens’ 3D-printing journey: Siemens spends $36m on 3D printing facility