Session: 24-02 Additive Manufacturing - Session 2

Paper Number: 127568

127568 - Conventional Design to Design for Additive Manufacturing for Frame 5/1 Stage 1 Nozzle 

Baker Hughes has been providing industrial gas turbines globally since the 1950s. Baker Hughes's Frame 5/1 machine is well-known for its long-running performance in the field. This machine requires parts to be replaced after their service life is completed. New technologies like Additive Manufacturing (AM) can reduce lead time and provide design engineers with the freedom to explore designs that were not possible with conventional manufacturing in the past. This paper discusses the journey from conventional design to design for additive manufacturing for the Stage 1 nozzle (S1N) of the Frame 5/1 Machine.

Direct Metal Laser Melting (DMLM), an AM technology, was considered for producing this nozzle. Additionally, the years of knowledge gained by Baker Hughes from many machines operating in the field were integrated to optimize the nozzle design. Using an in-house developed equivalent material in DMLM, the nozzle was redesigned to be compatible with the current machine and its supporting structure without affecting performance. The new S1N AM design underwent analysis following the internal standard methodology of thermo-mechanical Finite Element (FE) analysis.

Based on the results of the FE analysis, further improvements were made through multiple design changes and iterations, resulting in the final design. This final design exhibits lower metal temperatures compared to the conventional nozzle. The analysis results demonstrate a significant improvement in overall stresses, plastic strains, creep strains and crack initiation life when compared to the conventional nozzle. Moreover, the predicted amount of oxidation for the new design is much lower than that for the conventional design.

Presenting Author: Nikunj Avaiya Baker Hughes

Presenting Author Biography: Mechanical Engineer with M.Tech from Indian Institute of Technology Madras and 8 years of experience including Additive Manufacturing like Design, Manufacturing Process, Post processing and detailed knowledge of DMLS(DMLM), Binder Jet and MJF Technologies. At Baker Hughes, working on Gas Turbine parts for structural analysis and looking adapt additive manufacturing for various components. An EEDP graduate from GE Transportation and worked in Locomotive industry. Also, have experience in tire industry, starting from knowledge of standards to design, analysis and manufacturing of tires and various parameters that affect performance of tire.

Authors:

Nikunj Avaiya Baker Hughes
Lorenzo Cocchi Baker Hughes
Abhimanyu Soman Baker Hughes
Girolamo Tripoli Baker Hughes
Simone Colantoni Baker Hughes
Babu Santhana Gopalakrishnan Baker Hughes
Paolo Del Turco Baker Hughes