Developing Additive Manufacturing Technology for Burner Repair

2016 ◽  
Vol 139 (3) ◽  
Author(s):  
Olov Andersson ◽  
Andreas Graichen ◽  
Håkan Brodin ◽  
Vladimir Navrotsky
Keyword(s):  
Additive Manufacturing ◽  
Gas Turbines ◽  
Research Work ◽  
Manufacturing Technology ◽  
Heat Radiation ◽  
Original Design ◽  
Repair Work ◽  
Additive Manufacturing Technology ◽  
Low Emission ◽  
Industrial Gas Turbines

Low emission combustion is one of the most important requirements for industrial gas turbines. Siemens industrial gas turbines SGT-800 and SGT-700 use dry low emission (DLE) technology and are equipped with third generation of DLE burners. These burners demonstrate high-performance and reliable operation for the duration of their design lifetime. The design and shape of the burner tip is of great importance in order to achieve a good fuel/ air mixture and at the same time a resistance to the fatigue created by heat radiation input. This gives a requirement for a tip structure with delicate internal channels combined with thicker structure for load carrying and production reasons. It was found that the extension of the burner lifetime beyond the original design life could be accomplished by means of repair of the burner tip. Initially, the tip repair has been done by conventional methods— i.e., cutting off the tip and replacing it with a premanufactured one. Due to the sophisticated internal structure of the burner, the cuts have to be made fairly high upstream to avoid having the weld in the delicate channel area. Through the use of additive manufacturing (AM) technology, it has been possible to simplify the repair and only replace the damaged part of the tip. Special processes have been developed for AM repair procedure, including the following: machining off of the damaged and oxidized tip, positioning the sintered model on the burner face, sintering a new tip in place, quality assurance and inspection methods, powder handling, material qualification including bonding zone, development of methods for mechanical integrity calculation, and qualification of the whole repair process. This paper describes how we have developed and qualified SGT-800 and SGT-700 DLE burners repair with the help of additive manufacturing technology and our research work performed. In addition, this paper highlights the challenges we faced during design, materials qualification, and repair work shop set up.

Developing Additive Manufacturing Technology for Burner Repair

2016 ◽  
Author(s):  
Olov Andersson ◽  
Andreas Graichen ◽  
Håkan Brodin ◽  
Vladimir Navrotsky
Keyword(s):  
Additive Manufacturing ◽  
Gas Turbines ◽  
Research Work ◽  
Manufacturing Technology ◽  
Heat Radiation ◽  
Original Design ◽  
Repair Work ◽  
Additive Manufacturing Technology ◽  
Low Emission ◽  
Industrial Gas Turbines

Low emission combustion is one of the most important requirements for Industrial gas turbines. Siemens Industrial gas turbines SGT-800 and SGT-700 use DLE (Dry Low Emission) technology and are equipped with 3rd generation of DLE burners. These burners demonstrate high performance and reliable operation for the duration of their design lifetime. The design and shape of the burner tip is of great importance in order to achieve a good fuel/ air mixture and at the same time a resistance to the fatigue created by heat radiation input. This gives a requirement for a tip structure with delicate internal channels combined with thicker structure for load carrying and production reasons. It was found that the extension of the burner lifetime beyond the original design life could be accomplished by means of repair of the burner tip. Initially the tip repair has been done by conventional methods — i.e. cutting off the tip and replacing it with a premanufactured one. Due to the sophisticated internal structure of the burner the cuts have to be made fairly high upstream to avoid having the weld in the delicate channel area. Through the use of AM (Additive Manufacturing) technology it has been possible to simplify the repair and only replace the damaged part of the tip. Special processes have been developed for AM repair procedure, including: a) machining off of the damaged and oxidized tip, b) positioning the sintered model on the burner face, c) sintering a new tip in place, d) quality assurance and inspection methods, e) powder handling, f) material qualification including bonding zone, g) development of methods for mechanical integrity calculation, h) qualification of the whole repair process. This paper describes how we have developed and qualified SGT-800 and SGT-700 DLE burners repair with the help of additive manufacturing technology and our research work performed. In addition, this paper highlights the challenges we faced during design, materials qualification and repair work shop set-up.

scholarly journals Research Progress of Arc Additive Manufacture Technology

Materials ◽  
2021 ◽  
Vol 14 (6) ◽  
pp. 1415
Author(s):  
Dan Liu ◽  
Boyoung Lee ◽  
Aleksandr Babkin ◽  
Yunlong Chang
Keyword(s):  
Additive Manufacturing ◽  
Research Work ◽  
Manufacturing Technology ◽  
Theoretical Research ◽  
Research Progress ◽  
Additive Manufacture ◽  
High Deposition Rate ◽  
Development History ◽  
Additive Manufacturing Technology ◽  
Wire Arc Additive Manufacturing

Additive manufacturing technology is a special processing technology that has developed rapidly in the past 30 years. The materials used are divided into powder and wire. Additive manufacturing technology using wire as the material has the advantages of high deposition rate, uniform composition, and high density. It has received increasingly more attention, especially for the high efficiency and rapid prototyping of large-size and complex-shaped components. Wire arc additive manufacturing has its unique advantages. The concept, connotation, and development history of arc additive manufacturing technology in foreign countries are reviewed, and the current research status of arc-based metal additive manufacturing technology is reviewed from the principles, development history, process, and practical application of arc additive manufacturing technology. It focuses on the forming system, forming material, residual stress and pores, and other defect controls of the technology, as well as the current methods of mechanical properties and process quality improvement, and the development prospects of arc additive manufacturing technology are prospected. The results show that the related research work of wire arc additive manufacturing technology is still mainly focused on the experimental research stage and has yet not gone deep into the exploration of the forming mechanism. The research work in this field should be more in-depth and systematic from the physical process of forming the molten pool system from the perspectives of stability, the organization evolution law, and performance optimization. We strive to carry out wire arc additive forming technology and theoretical research to promote the application of this technology in modern manufacturing.

scholarly journals Evaluation of explosive parameters of fuel oil additive manufacturing technology

2021 ◽  
Vol 723 (5) ◽  
pp. 052017
Author(s):  
V Monashkov ◽  
I Russkova ◽  
Y Logvinova ◽  
N Rumyantseva ◽  
A Uljanov
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Technology ◽  
Fuel Oil ◽  
Additive Manufacturing Technology

scholarly journals The Adoption of Additive Manufacturing Technology in Sweden

Procedia CIRP ◽  
2016 ◽  
Vol 40 ◽  
pp. 7-12 ◽  
Author(s):  
Babak Kianian ◽  
Sam Tavassoli ◽  
Tobias C. Larsson ◽  
Olaf Diegel
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Technology ◽  
Additive Manufacturing Technology
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