Another milestone for 3D printing: pre-mixer for SGT-A05

“This is another excellent example of how additive manufacturing is revolutionising 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, CTO, Siemens Power Generation Services, Distributed Generation.

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 requires over 20 parts when produced using traditional manufacturing methods. But employing qualified nickel super alloys as the 3D printing (aka additive manufacturing (AM)) material, the component requires only two parts and lead time is reduced by about 70%. Overall, 3D-printing greatly simplifies production, reduces external supply chain, and improves component geometry, resulting in better fuel–air mixing.

The pre-mixer was 3D printed at Siemens’ additive manufacturing centre of competence in Finspang, Sweden. Engine testing showed no start issues, all fuel transitions were accomplished successfully without any control modifications, there were no combustion dynamics or noise, measurable CO emissions reductions were realised and full power was achieved, says Siemens, reaffirming its “commitment to continuing to advance toward serial production of highly complex components... using AM.”

Last year, Siemens finished its first full- load engine tests on gas turbine blades completely designed and produced using AM technology. Earlier this year, the company 3D-printed and installed into customer’s equipment its first replacement part for an industrial steam turbine. In early 2017, Siemens achieved what is thought to be the first successful commercial installation of a 3D-printed part in a nuclear power plant – an impeller for a fire protection pump. Siemens says it has accumulated more than 30 000 hours of successful operation with SGT- 800 burners repaired with AM technology and with SGT-750 additively manufactured burner swirls.