Session: 18-11 Sustainable Production of Advanced Turbomachinery Components in a Digitized Environment

Paper Number: 84213

84213 - Sustainable Production of Advanced Turbomachinery Components in a Digital Environment 

Turbomachinery components are among the most challenging parts for the initial manufacturing and also for repair in many regards: They feature difficult to machine materials, highly complex geometries, and are subject to extraordinary quality demands in order to guarantee a safe operation in service. Thus, manufacturing processes for safety-critical gas turbine components in aviation and stationary application are very conservative and based on decades of experience. Significantly increased efficiency demands for contemporary and future gas turbines, however, have lead to more advanced component designs on the one hand, and new, more lightweight and/ or high-temperature resistant materials being introduced on the other. As a consequence, the conventional manufacturing and repair sequences are no longer sufficient to fulfill all component requirements and therefore make novel and specialized technologies inevitable. The tutorial session will provide an overview of the common conventional-, non-conventional manufacturing processes and process chains using additively manufactured components including required post-processing technologies. The session will address state of the art manufacturing sequences for typical turbomachinery components, but also give an outlook on some developments concerning component design, new materials and the consequences of these changes with respect to future machining technologies and manufacturing sequences for new designs. Finally, the sustainability of the manufacturing sequence itself and ways to optimize resource and energy efficiency for different manufacturing processes will be included in the discussion as well.

Presenting Author: Sascha Gierlings Fraunhofer Institute for Production Technology

Presenting Author Biography: Dr.-Ing. Sascha Gierlings, born in 1981, studied mechanical engineering with a focus in production technology at RWTH Aachen University. From 2008 to 2015 he was research associate at the Laboratory for Machine Tools and Production Engineering (WZL) in the department for process and product monitoring. His research focus was in the field of process monitoring for safety-critical aero engine components. Since 2015 he is working with the Fraunhofer-Institute for Production Technology (IPT) where he established the department for prototype manufacture and was responsible for the business development in turbomachinery. Since 2019, he is heading the department for technology-transfer in turbomachinery manufacturing and he is responsible for the entire business unit turbomachinery manufacturing at the WZL and Fraunhofer IPT.

Authors:

Sascha Gierlings Fraunhofer Institute for Production Technology
Robin Day Fraunhofer Institute for Production Technology
Philipp Ganser Fraunhofer Institute for Production Technology
Tim Herrig WZL, RWTH Aachen University