Session: 24-01: Emerging Methods in Engine Design and Life Assessment

Paper Number: 152300

Long-Term Lifetime Validation of Hot Turbine Guide Vanes Manufactured by Laser Powder Bed Fusion 

The advent of additive manufacturing, specifically Laser Powder Bed Fusion (LPBF), has revolutionized the production of gas turbine components. This paper presents a comprehensive study on the application of LPBF in serial production of turbine guide vanes, which are critical for the efficient performance of gas turbines. The guide vanes manufactured using LPBF have been subjected to rigorous verification and validation in commercial engine conditions, spanning operational intervals of 27-30 thousand hours, to assess their performance and durability.

The paper focuses on four distinct components: guide vanes from both the first and second stages of the turbine, with operational experience gathered from five different engines. The scope of the components studied ranges from those with traditional as-cast designs to those that incorporate advanced in-wall cooling features, which have been made possible by the capabilities of metal additive manufacturing. This innovative approach to design and manufacturing allows for intricate internal structures that enhance cooling efficiency, thus potentially improving the overall performance and emissions of the turbine what is shown in detail in this paper.

An in-depth analysis of the condition of these parts post-operation is conducted to compare their actual performance against the expected outcomes, particularly in areas known for stress concentration. The paper details the laboratory evaluation process, which includes a thorough examination of the microstructure of the components. This microstructural analysis is critical for understanding the behavior of the material under operational stress and high-temperature conditions.

Furthermore, the paper evaluates the condition of the printed cooling channels after extended use. These channels play a vital role in maintaining the temperature of the guide vanes within safe operating limits, and their functionality over time is essential for the reliability of the component.

Another aspect covered in the paper is the behavior of the printed components under local overheating conditions, which can occur due to various operational anomalies. Understanding how these components react to such extreme conditions is crucial for ensuring their reliability and safety in the field.

The findings presented in this paper highlight the robustness of LPBF-manufactured gas turbine guide vanes, showcasing their capability to withstand both design and off-design operational conditions. The accumulation of operational experience with these components is a significant step towards the widespread adoption of additive manufacturing technologies in the production of gas turbine parts. By demonstrating the successful application of LPBF in high-stress, high-temperature environments, this paper provides valuable insights into the future of manufacturing for gas turbine applications, where efficiency and reliability are paramount.

Presenting Author: Ilya Fedorov Siemens Energy AB

Presenting Author Biography: Graduated from Bauman Moscow State Technical University, Applied Mathematics.
PhD from Bauman Moscow State Technical University, Blade Dynamics.
23 years industry experience in Gas Turbine design and manufacturing.
12 years experience in Design for Additive Manufacturing in Gas Turbines.
Currently R&D Project Manager at Siemens Energy AB.

Authors:

Ilya Fedorov Siemens Energy AB
Martin Lindbaeck Siemens Energy AB
Jan Muenzer Siemens Energy AG
Oleg Naryzhnyy Siemens Energy AB