cross dimensional manufacturing

Additive manufacturing conquers German energy sector

Additive manufactured gas turbine guide vanes released to serial production

Additive manufacturing is gradually conquering various industrial sectors. The advantages of the method compared to conventional production are significant: complex geometries, internal cavities as well as weight reduction through FEM calculations and topology optimisation. MAN Energy Solutions has successfully qualified the process of manufacturing gas turbines and cleared it for production. Additively manufactured guide vane segments have proven to be particularly suitable. For this purpose, the company carried out intensive research and development on its own as well as in collaboration as well as cooperation with highly specialised suppliers. Thus, the series production of 3D printed vane segments could start. These segments will be incorporated into stationary MAN gas turbines of the MGT series. In a benchmark, toolcraft has proven and established itself as a supplier of 3D printed vane segments with on-time delivery of high-quality components. toolcraft offers the entire additive value chain in-house and can thus ensure the upcoming series production. Since 2011, precision components have been manufactured in Georgensgmünd by using additive manufacturing. Over the years, the team has built its expertise with projects from various industries. The company steadily works on improving the process and expanding capacity. Thus, the machine park has been expanded from initially one to ten systems now. In addition, the quality of the components is proven by optical and tactile measurements as well as by a non-destructive surface testing according to Nadcap. The process of additive manufacturing has recently been certified by Nadcap as well. In addition, analyses of the powder used and fatigue tests of constructed material samples regularly take place in an in-house laboratory.

Watch the video to see the 3D printing of MAN guide vanes.