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The world’s aboriginal 3-D printed burner for an automated gas agent has been in operation for one year with no appear issues.

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Siemens, which installed the burner for the 32.8-MW SGT-7000 gas agent at E.ON’s accumulated aeon ability bulb in Philippsthal in the German accompaniment of Hessen said on September 19 that it has been operating for added than 8,000 hours, and that “the after-effects are impressive.”

Three-dimensional printing—also alleged “additive manufacturing”—for ability bulb apparatus is a action that builds genitalia layer-by-layer from broken computer-aided architecture models to anatomy solid objects. Siemens, which has researched accretion accomplishment processes back 1989, says the technology could accommodate the development and assembly of components.

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“For example, it can be difficult for accepted accomplishment technologies to aftermath added able or low-emission turbines with college temperature tolerances,” it said. “3-D press now makes it accessible to aftermath about any anatomy imaginable. The action allows agent apparatus like gas agent blades and vanes to be cooled through circuitous centralized ducts, which improves their efficiency.”

(For more, see “3-D Printing: The Future of Accomplishment and Maintenance” in POWER’s May 2017 issue.)

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Siemens began advance in metal 3-D press in 2008 and developed a technology accurately for ability generation. In 2012, the aggregation installed the aboriginal EOS M280 SLM printer and acclimatized it for burner repairs. In 2013, the aboriginal 3-D-printed burner tips and swirlers were installed in bartering gas turbines, and in 2016, Siemens acquired Materials Solutions in the UK, a arch aggregation in the acreage of accretion manufacturing.

In 2017, the aggregation produced the aboriginal burners application careful laser melting technology beneath its able burner accomplishment (IBUMA) affairs in Finspång, Sweden. “Each burner arch is bogus in one allotment compared to acceptable methods that appropriate 13 alone genitalia and 18 welds,” Siemens noted. “Design improvements, such as the pilot-gas augment actuality allotment of the burner arch instead of the alfresco ammunition pipe, acquiesce the operating temperature to be kept lower, appropriately accidental to a best operational lifespan of the apparatus and, ultimately, the gas turbines,” it said.

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Last year, Siemens’ 3-D-Experts additionally advised and printed the world’s aboriginal gas agent blades and accurate them beneath full-load agent conditions, at 13,000 revolutions per minute and temperatures above 1,250C.

“As an activity account provider, attention and bendability are an complete claim for us,” said Niklas Lange, activity administrator at E.ON Activity Projects. “Additive accomplishment not alone delivers this, but in our acquaintance it can alike advance achievement compared with earlier models.”

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For Siemens, the achievement’s acceptation cannot be underscored enough. “These aboriginal after-effects from the IBUMA burner with E.ON validate our acceptance that this technology is a game-changer. We acknowledge E.ON’s alive accord and charge to active addition and attending advanced to our connected aing collaboration,” said Vladimir Navrotsky, arch technology administrator for Siemens Ability Bearing Services, Distributed Generation.

Pictured is Siemens’ 3-D printed gas burner for the SGT-700 gas agent operating at E.ON’s accumulated aeon ability bulb in Philippsthal, Germany. Courtesy: Siemens

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To accumulate its installed abject competitive, GE Ability is additionally advance in accretion manufacturing. In July, the aggregation apparent the aboriginal advancement with accretion bogus apparatus for GT13E2 gas turbines. The new MXL2 with accretion bogus achievement (AMP) advancement “could not be bogus with accepted methods and marks the first-of-its-kind band-aid with the bang of apparatus bogus by accretion technologies,” said Scott Strazik, admiral and CEO of GE’s Ability Services business. GE said the new technology can advice gas bulb ability producers save up to $2 actor in ammunition annually, and accessible up added revenues of up to $3 actor annually in new ability capacity.

The MXL2 with AMP includes two apparatus produced by GE’s Accretion Accomplishment Works teams in Birr, Switzerland, and Greenville, South Carolina: the first-stage agent vanes and calefaction shields. The technology promises to drag the achievement and ability of absolute GT13E2 gas turbines by abbreviation basic cooling requirements by up to 25% and accretion achievement up to 21 MW in accumulated aeon agreement (which comes out to an ability advance of up to 1.6% in accumulated aeon configuration), GE said.

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GE’s advancement will be approved by Vattenfall Europe Wärme AG at its Heizkraftwerk Berlin-Mitte ability bulb in Berlin, Germany. Vattenfall installed four altered 3-D printed apparatus at the bulb in 2015.

—Sonal Patel is a POWER accessory editor (@sonalcpatel, @POWERmagazine)

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