BAM research at Werner-von-Siemens Centre enters second stage of Additive Manufacturing for gas turbines

March 21, 2024

BAM is researching manufacturing and maintenance Additive Manufacturing processes for gas turbine blades together with partners at the Werner Von Siemens Center (Courtesy BAM)
BAM is researching manufacturing and maintenance Additive Manufacturing processes for gas turbine blades together with partners at the Werner Von Siemens Center (Courtesy BAM)

Germany’s Federal Institute for Materials Research and Testing (Bundesanstalt für Materialforschung und -prüfung, [BAM]) has announced that it is continuing its research projects focused on highly efficient gas turbines at the Werner von Siemens Centre for Industry and Science eV (WvSC) for another two years. The projects — funded by the state of Berlin and the European Union — aim to optimise the maintenance, repair and operations process of gas turbine blades and develop sustainable Additive Manufacturing solutions.

Subscribe to our weekly newsletter
Sign up

MRO 2.0: Human-machine interaction and AI

The MRO 2.0 project focuses on optimising the gas turbine blade repair process by developing automated, digitalised refurbishment process chains that enable efficiency upgrades. During the first phase of this project, demonstrators and systems for assessing the condition of the turbine blades and AM repair processes. The second phase will focus on transferring these findings into use cases and working to get resultant processes and procedures accepted by the workforce.

During Phase Two, BAM will test new methods for determining the remaining wall thickness and assessing damage near the surface of turbine blades. The methods will enable the team to analyse the condition of the used turbine blades in order to appropriately repair the part with Additive Manufacturing processes such as Directed Energy Deposition (DED).

BAM scientists are also developing virtual models (’digital twins’) of the entire process. Using AI algorithms, the team continuously analyses data on the operating conditions and behaviour of the turbine blades in use. This allows for predictions about the remaining life of components, the proactive planning of maintenance measures and the minimisation of downtime.

Ten partners are involved in the project, including Siemens Energy, several Fraunhofer Institutes and the Technical University of Berlin.

HTA 2.0: Sustainable Additive Manufacturing for high-temperature applications

The HTA 2.0 project will work towards sustainable Additive Manufacturing processes and components for high-temperature components in large gas turbines. It will build on the successful results of the first funding period, in which the processing of complex, high-temperature materials produced via Laser Beam Powder Bed Fusion (PBF-LB) was characterised, and effective process monitoring techniques were developed. This allows for errors to be detected during the build process.

Currently, the team is looking into faster, more efficient Additive Manufacturing processes. These processes will then be evaluated in the context of sustainable product development in order to achieve economically and ecologically more efficient production solutions for components which will be in contact with high temperatures.

Another central research focus is on increasing the reusability of the starting material for Additive Manufacturing processes and reducing material waste. To this end, recycling strategies for both used powder and consolidated solid material from waste that comes from faulty construction processes and support structures are being developed and tested in an effort to reduce high material costs and environmental impact. Holistic life cycle analyses evaluate the economic and ecological impacts.

This project includes eleven partners, including scientific institutions, large corporations and several SMEs. BAM is contributing its expertise in comprehensive material characterisation, Additive Manufacturing processes, process observation and component inspection, as well as determining material behaviour at high temperatures.

Download Metal AM magazine

In the latest issue of Metal AM magazine

Download PDF

Extensive AM industry news coverage, as well as the following exclusive deep-dive articles:

  • Metal powders in Additive Manufacturing: An exploration of sustainable production, usage and recycling
  • Inside Wayland Additive: How innovation in electron beam PBF is opening new markets for AM
  • An end-to-end production case study: Leveraging data-driven machine learning and autonomous process control in AM
  • Consolidation, competition, and the cost of certification: Insight from New York’s AM Strategies 2024
  • Scandium’s impact on the Additive Manufacturing of aluminium alloys
  • AM for medical implants: An analysis of the impact of powder reuse in Powder Bed Fusion

The world of metal AM to your inbox

Don't miss any new issue of Metal AM magazine, and get the latest industry news. Sign up to our twice weekly newsletter.

Sign up

Discover our magazine archive…

The free to access Metal Additive Manufacturing magazine archive offers unparalleled insight into the world of metal Additive Manufacturing from a commercial and technological perspective through:

  • Reports on visits to leading metal AM part manufacturers and industry suppliers
  • Articles on technology and application trends
  • Information on materials developments
  • Reviews of key technical presentations from the international conference circuit
  • International industry news

All past issues are available to download as free PDFs or view in your browser.

Browse the archive

Looking for AM machines, metal powders or part manufacturing services?

Discover suppliers of these and more in our comprehensive advertisers’ index and buyer’s guide, available in the back of Metal AM magazine.

  • AM machines
  • Process monitoring & calibration
  • Heat treatment & sintering
  • HIP systems & services
  • Pre- & post-processing technology
  • Powders, powder production and analysis
  • Part manufacturers
  • Consulting, training & market data
View online
Share via
Copy link
Powered by Social Snap