3D printing for gas turbine components
Industrialisation of 3D printing
(additive manufacturing)
for gas turbine components
repair and manufacturing
Vladimir Navrotsky, Andreas Graichen and Håkan Brodin
Kurzfassung
Industrialisierung von 3D Drucken
(generative Fertigung) für Gasturbinen-
komponenten-Reparatur und -Herstellung
In den letzten Jahren hat eine neuartige revo-
lutionäre Art der Fertigung namens Additive
Manufacturing (AM) in der Industrie Einzug
gehalten. Diese wird tiefgreifende Veränderun-
gen mit sich bringen. Im Gegensatz zur traditio-
nellen Fertigung, bei der Material durch Fräsen,
Bohren, Erodieren usw. abgetragen wird, wird
bei diesem Verfahren Material durch den Ein-
satz von Laser- oder Elektronenstrahlenergie
aufgetragen. Es gibt verschiedene AM-Techno-
logien, von denen gegenwärtig das Selektive La-
serschmelzen (Selective Laser Melting – SLM)
das interessanteste Verfahren zu sein scheint.
Das AM eröffnet eine neue Dimension der in-
tegrierten Konstruktion und Fertigung. AM
ermöglicht eine schnellere Fertigung und Repa-
ratur von Gasturbinenbauteilen bei gleichzeitig
größerer Funktionalität und Leistungsfähigkeit
der Bauteile. Siemens Power Generation setzt
diese Technologie zur Herstellung von Prototy-
pen (Prototyping) sowie in begrenztem Umfang
für Reparaturarbeiten und die Fertigung von
Gasturbinenbauteilen ein [1 bis 3].
Kürzlich setzte Siemens die SLM-Technologie
zur Reparatur von Gasturbinenbrennern der
Industriegasturbinenbaureihe SGT-800 ein.
Die Ergebnisse zeigten, dass das Ersetzen kon-
ventioneller Reparaturverfahren durch die
SLM-Technologie zu einer signifikanten Verkür-
zung der Reparaturzeit führt und die Bauteile
bei der Reparatur darüber hinaus auf den ak-
tuellen Brennertyp umgerüstet werden können.
Ein weiteres aktuelles Beispiel für die Anwen-
dung der SLM-Technologie bei Siemens stellt die
Fertigung von verbesserten Brenner-Swirlern
VGB PowerTech - Autorenexemplar - © 2015
für Industriegasturbinen der Baureihe SGT-750
dar. In diesem Fall war SLM die einzige Techno-
logie, die in der Lage war, diese Art von Swirler
zu fertigen. Die Ergebnisse haben den Erfolg der
Anwendung der SLM-Technologie in der Kons-
truktion, im Prototyping und in der Fertigung
neuer, verbesserter Brenner-Swirler bestätigt. l
Authors
Dr. Vladimir Navrotsky
Andreas Graichen
Dr. Håkan Brodin
Siemens Industrial Turbomachinery AB
Finspong, Sweden
48
VGB PowerTech 12 l 2015
Introduction
The recent advances in computing power
and cheaper laser sources together with IT-
based networking, open the door for a new
design and manufacturing chain. 3D-CAD/
CAM models themselves contain informa-
tion related to their manufacturing pro-
cess, meaning that – ideally – only one file
is needed to produce the component to the
intended geometry, quality and material
specification. Tooling and fixtures become
obsolete in a blue sky scenario (F i g u r e 1).
Formerly a complicated network of differ-
ent competencies was needed in an ad-
vanced workshop, now it can be performed
by one single “3D-printer”. In the coming
years, we will see AM (additive manufac-
turing) as we are seing colour printing on
paper, something that simply works, with-
out much need for human intervention.
There are many advantages for the design-
er and the supply chain:
–– AM in the form of SLM (selective laser
melting) gives an unprecedented free-
dom of design because geometries are
possible that could not be accessed with
traditional machining methods,
–– many times, complexity of geometry
comes for free, or costs the same as tra-
ditional simple geometries,
–– this means that, for example, for gas tur-
bine components cooling systems, vibra-
tion dampening and lightweight designs
can be improved without extra cost,
–– assemblies can be simplified and inte-
grated,
–– many manufacturing operations that
earlier needed many logistical steps can
be carried out on one single machine,
3D CAD Data
Fig. 1. To manufacture a component by AM technology, the following is needed:
1 = 3D model of the component
2 = appropriate powder and
3 = laser sintering equipment.
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–– the transmission of CAD/CAM-files is
not restricted by geography. 3D-printing
can take place virtually anywhere as
long as an internet connection exists
(F i g u r e 2).
As a result, the development and manu-
facturing time of some components and
products will be significantly reduced. New
products will enter the market, functionali-
ty and product upgrades could be improved
and made more frequently. Further tech-
nology and AM equipment development
will allow for reduced manufacturing cost
for some components in the next 5 years.
National programmes and public funds can
speed up industrialisation of this technol-
ogy and implementation of innovation into
our daily lives.
However, alongside the obvious benefits
and opportunities there are threats and
challenges:
–– powder (e.g. specification, chemistry,
cost, suppliers),
–– AM equipment (e.g. process speed,
equipment cost, components size),
–– AM process parameters,
–– very limited material data,
–– qualification and validation of the
process,
–– design tools and design criteria,
–– industrial standards and regulation
for AM.
Additive manufacturing
technologies
Powder-bed additive layer manufacturing
Additive layer manufacturing (ALM) com-
prises a group of rapid manufacturing pro-
 VGB PowerTech 12 l 2015 3D printing for gas turbine components

in a pre-defined pattern, is expected in terms of improved speed, re-

in order to create a mini- liability, ease of use and operator friendli-
mum of internal stresses ness, 3D-printing quality, standardisation
[14] and the best surface of processes and components inside the
possible [15]. Each pass 3D-printers, etc.
of the laser beam creates A tremendous improvement of AM pro-
Lead time reduction & Faster technology a solidified band of mate-
life cycle improvement for validation & product cess capability can be noted. In 2009, laser
complex parts development rial, producing a micro- sources of 200 W were considered to be
structure similar to how the market standard. In 2011, the mar-
the material would look ket standard became 400 W. In the same
Fig. 2. Additive manufacturing (AM) enables quick realisation if being built up by a num- year, single providers of SLM equipment
of exciting new product features and highly customised ber of weld passes. How- launched prototype 1 kW sources in their
solutions. ever, due to differences in products.
input energy and actual
But maybe the most important effect on
cesses that today can be used as alterna- melt pool size, the microstructure is not a
building speed must be expected by the
tives to normal manufacturing routes for typical weld structure.
introduction of multiple laser sources that
metallic, ceramic and polymer components Building of a component is performed on
work in parallel, independently from each
in many applications, for instance tooling a substrate plate, normally manufactured
other. Market introduction of a double beam
mould inserts, automotive components from steel. The plate is attached onto a
SLM machine was announced in 2011. In
and also details for the aerospace industry processing table that can translate in the z-
this case, a 1 kW source for the melting of
[4 to 6]. Major drivers for the increased direction in a chamber with a controlled at-
large cross sections was coupled together
interest in ALM are: availability of differ- mosphere, typically nitrogen (often used for
with a smaller 400 W source for achieving
ent alloy powders [7] (aluminium, steel, steels) or argon (inert gas, for instance used
precise skin features. In 2015, 4-beams SLM
cobalt base and also nickel base powders), for super alloys). A thin layer of powder (in
machine are expected on the market.
increased production rate [8] (available the range of 20 to 60 µm) is distributed by a
laser power and better understanding of so-called recoater onto the substrate plate. Equipment
the manufacturing process) and high qual- After this, the laser beam travels over the
When comparing available brands of
ity of the manufactured components [9] first powder layer that will form the com-
equipment for additive manufacturing, a
(low amount of porosity, pure material, ponent. The process table is lowered, new
number of European producers are avail-
homogeneous material). Also the number powder distributed and a new laser scan is
able. European equipment manufacturers
of industrially available equipments has performed. Layer by layer, the process is re-
of selective laser melting systems are:
increased over the past years [10].
peated and the component is built up. –– Electro Optical Systems, EOS (Germany)
Most AM technologies for metals share the –– ConceptLaser (Germany)
Different approaches are used for laser
following procedures [11]:
sources and laser beam positioning. For the –– SLM Solutions (Germany)
–– produce the raw powder in fine particle SLM process, the laser source is normally
–– Renishaw (UK)
fractions, an Nd-YAG fiber laser. During building , the –– Phenix (France)
–– spread powder in thin layers of 20 to 100 laser is moved by positioning of a reflect-
µm thickness, –– Realizer (Germany)
ing mirror or by moving the laser head. The –– Sisma (Italy)
–– join the powder particles – to form one laser beam is focused via a series of lenses.
solid layer – using thermal energy such For electron beam melting, the major
The current publication focusses on manu- equipment supplier today is Arcam (Swe-
as laser or an electron beam that sinter,
facturing of material with the SLM process. den).
partially or fully melt and weld the par-
ticles or adhesive chemicals that are in- Electron-beam melting Equipment manufacturers have so far fo-
jected to glue the particles, With the electron-beam process, fully cussed on development of equipment with
–– repeat the process to build stacked and dense metal components can be manufac- successively larger laser capacities-up to 1
coherent layers, tured in the same way as described above kW. With larger lasers and multiple lasers,
–– post-process to increase strength, sur- regarding the SLM process. The main dif- the productivity will increase through fast-
face or other specific properties. ferences are: er scanning with constant heat input or ap-
–– the material is being melted by an elec- plication of thicker layers in each laser scan.
Selective laser sintering/melting
tron beam, Besides this, the equipment manufacturers
Within the group of additive layer manu-
–– chamber temperature is elevated up to face a number of challenges:
facturing processes one of the processes
around 1,000 °C (material dependent), –– increase of AM equipment productivity
is based on melting powder with a laser
– – powder sieving fractions are coarser and size of the components that can be
source. Two methods of laser sintering need
VGB PowerTech - Autorenexemplar - © 2015

than the powder used for SLM. manufactured,

to be mentioned here: selective laser sinter-
ing (SLS) [12] and selective laser melting
(SLM) [13]. SLS is a method where a pow-
der is partially melted and SLM is a method
where the powder is completely remelted
during the manufacturing process. Both
the SLS and SLM processes are so-called
powder-in-bed methods where a compo-
nent is built up layer-by-layer. A directed
laser beam is used to melt a thin layer of
pre-placed powder into a slice that will rep-
resent a cross-section of the component to
be built. Through addition of successive lay-
ers, the component is manufactured slice
by slice. For each slice the laser will travel
An EBM machine utilises a high power elec-
tron beam that generates the energy need-
ed for high melting capacity and high pro-
ductivity. The electron beam is managed
and controlled by electromagnetic coils in-
stead of mirrors in the laser-based system.
If the SLM processes are using inert gas, the
EBM process takes place in vacuum.
Current status and expected
trends of AM technology
It has been stated that AM today is as ad-
vanced as computers were in the mid-80s.
This is to say that a huge wave of progress
–– AM system users require much more in-
formation available to be read into and
out of an AM system in order to allow for
better quality assurance and productivity
optimisation,
–– process data evaluation tools are needed
in order to better understand process
limits and allow for identification of pro-
cess control limits,
–– equipment of the same make and type
must be able to produce material to iden-
tical quality levels,
–– customers will need better transferabil-
ity of process parameters and material

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49
 3D printing for gas turbine components
Fig. 3. Customised EOS SLM machine for burner repairs.
properties from one generation of SLM
systems to the next,
–– on-line monitoring systems must be de-
veloped and implemented in commercial
products (F i g u r e 3).
In order to address all these challenges in
time and in proper order, cooperation be-
tween AM equipment suppliers and cus-
tomers can be very beneficial for quick
industrialisation of AM technology. As an
example of such cooperation customisa-
tion of EOS equipment for Siemens’ needs
can be mentioned. Based on Siemens’ re-
quest and specification, the company EOS
individually adapted and modified one of
its machines EOSINT M 280 for Siemens
gas turbine burner repair. The scale of the
machine’s interior was enlarged to accom-
modate the 800  millimeter burner. The
manufacturer also amended further hard-
ware components such as a camera system
and an optical measuring system and made
corresponding adjustments to the software.
AM value chain
Powder materials
Understanding powder composition and
morphology are key factors to control
when setting up and managing an AM pro-
cess. Powder cleanliness, chemistry control
and powder homogeneity are some of the
parameters that must be well understood.
Since powder manufacturing, especially
for AM processes requires tight alloying
VGB PowerTech - Autorenexemplar - © 2015
element control and atomising equipment
specialised to maximise yield and pro-
ductivity for the very specific powder size
ranges used, large efforts are put into set-
ting up a process for additive manufactur-
ing. A good example could be an AM plant
where not only component but also powder
manufacturing is established. Through this
set up, it is possible to maximise the value
added to any given component manufac-
tured. Also the powder can be better uti-
lised, since different AM processes will use
different fractions of the atomised powder.
Powder suitable for AM is typically sieved
into fractions where the yield is gained
50
between 10 to 160 µm. When the powder
is sieved to fit, for instance in SLM, a large
portion of the powder has to be recycled
with increased powder cost. If two comple-
mentary processes are utilising the same
powder, the yield in atomising will dra-
matically increase. This would be the case
comparing SLM and EBM manufacturing.
Several suppliers can provide powders
suitable for additive manufacturing. Gas
atomised powder is required with sieving
fractions in a relatively tight size range.
Depending on equipment and setup (layer
thickness), the sieved fractions will be in
the range of 10 µm to 30 µm up to 10 µm
45 µm for thin layer thicknesses.
Process parameters
Equipment for AM processes is readily
available. However, the knowledge regard-
ing how to set up and maintain an AM pro-
cess cannot easily be acquired. Knowledge
on laser or electron beam performance,
process parameter optimisation and pro-
cess performance and stability it is hard to
be gained from original equipment manu-
facturers (OEM). In many cases, the selec-
tion of available materials and correspond-
ing process parameters does not match the
needs from large companies. Especially
advanced materials for aggressive environ-
ments and high temperatures are not read-
ily available. This means that large efforts
need to be put into the equipment process
parameter development. In order to fully
utilise the AM process, it is highly likely
that several alternative process param-
eter packages could be available for one
material. Depending on the component
requirements, the process will need to be
set up for best economy (speed), accuracy
(tolerances and surfaces) or performance
(strength).
At Siemens Power Generation, authors are
keeping high focus on establishment of the
process parameters for nickel based mate-
rials.
Process monitoring
Process monitoring is, for all traditional
manufacturing processes, a natural way
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VGB PowerTech 12 l 2015
of avoiding costly scrap and rejections.
Traditional processes like casting and hot-
rolling are well-understood and process
control limits are frequently used, in order
to secure a flow of material with acceptable
quality. In additive manufacturing, today
no philosophy and, accordingly, no com-
mercially available equipment exist, for
on-line process monitoring control. This
causes unnecessarily large efforts in terms
of destructive testing and high cost added
in production, causing AM to lose in terms
of competitiveness.
Currently, Siemens is looking for coopera-
tion with AM OEMs to initiate development
and implementation of process monitoring
into AM equipment.
Post-treatment
Materials manufactured with AM tech-
niques are, in many cases, superior to tra-
ditionally manufactured components even
without any post-processing. The materi-
als created are very homogeneous without
internal flaws and defects. However, there
are a number of properties that might
cause problems (surfaces, internal stresses,
behaviour at extreme temperatures) that
require improvements. Material response
to external loading will also typically be
anisotropic. These, and other factors, will
put requirements on post-treatments to
further optimise component performance.
Depending on the type of post-processing,
the cost associated with the treatment can
be low (heat-treatment) or high (surface
improvement). However, the cost associ-
ated with establishment of a cheap post-
processing operation might be substantial
(e.g., as in development of heat treatments
for optimal mechanical material properties
for different applications).
Material data and design criteria
As previously mentioned, material data
generation can be required for a number
of variations of one given material. The
cost associated with material data genera-
tion is very dependent on the application.
Depending on the application, the cost
associated with material data generation
and implementation for one material into
designer-friendly tools can range from
modest numbers up to 1 to 1.5 m €. If gen-
erated, this type of data is today typically
not readily available in open sources.
It is very likely that the full understand-
ing of AM materials can be gained only, if
larger consortia are formed, where syner-
gies will allow for good understanding of
residual stresses, mechanical properties
and physical properties coupled to process
behaviour and part performance described
as dimensional accuracy or bulk and sur-
face quality.
Design tools
Design criteria are not only material data
and design data developed from material
 VGB PowerTech 12 l 2015
1 Rapid prototyping 2 Rapid repair
Blade 1 Burner
Product: SGT Product:
Component: E.g. turbine blade 1 Component: Burner tip
Benefit: Significant reduction Benefit:
of time to market
Status: Part ot standard Status:
process
Fig. 4. Three pillars of SLM application.
performance. Design data also include de-
sign features and guidelines on how to and
how not to design an element with additive
manufacturing. This type of information
can, to some extent, be found in open litera-
ture and can be used as an input. However,
adoption to the local situation will always be
required. Guidelines when to and when not
to select an AM process also need to be avail-
able in order to minimise the needs for par-
allel development of a component adopted
for different manufacturing processes.
In order to fully utilise AM technologies,
the mind-set of designers and engineers
must be changed.
Standards
Today, standards for additive manufactur-
ing in general and specifically for SLM are
not readily available. The standards for
SLM are limited to a handful documents
within (sections here adopted as per ASTM
grouping):
Design
–– ISO/ASTM52915 – 13: Standard Speci-
fication for Additive Manufacturing File
Format (AMF) Version 1.1
–– ISO/DIS 17296 – 4: Additive manu-
facturing – General principles – Part 4:
Overview of data processing
Materials and Processes
–– ASTM F2924 – 12a: Standard Specifi-
VGB PowerTech - Autorenexemplar - © 2015
cation for Additive Manufacturing Ti-
tanium-6 Aluminum-4 Vanadium with
Powder Bed Fusion
–– ASTM F3001 – 13: Standard Specifica-
tion for Additive Manufacturing Titani-
um-6 Aluminum-4 Vanadium ELI (Extra
Low Interstitial) with Powder Bed Fusion
–– ISO/DIS 17296 – 2: Additive manu-
facturing – General principles – Part 2:
Overview of process categories and feed-
stock
Terminology
–– ASTM F2792 – 12a: Standard Terminol-
ogy for Additive Manufacturing Tech-
nologies
3 Rapid manufacturing
Burner
SGT Product: SGT
Component: Burner swirler
10 times faster, Benefit: Swirler can only
easy upgrades be made via SLM
In commercial Status: In commercial
application application
–– ISO/CD 17296 – 1: Additive manufactur-
ing – General principles – Part 1: Termi-
nology
Test Methods
–– ISO/ASTM52921 – 13: Standard Termi-
nology for Additive Manufacturing-coor-
dinate Systems and Test Methodologies
–– ISO/DIS 17296 – 3: Additive manu-
facturing – General principles – Part 3:
Main characteristics and corresponding
test methods
It is obvious that the process is yet not fully
standardised but also important to notice
that the basic concepts are settling in the
standards mentioned above.
Applications
As already mentioned, AM is a revolution-
ary technology enabling simultaneously
enhancement of component performance
and reduction of delivery time. SLM is a
new dimension in integrated design and
manufacturing, converting our dreams
into reality, with practically no limitation
and at extremely short delivery times.
With this technology, complex multi-ele-
ments components could be produced as a-
one integral part with higher performance
and, in majority of cases practically at the
same cost (e.g. GT burners with lower
emissions and higher lifetime, GT vanes
with better cooling efficiency and longer
life time).
Integrated development -> Iteration in a few months instead of years
3D-design SLM 3D-print
3D-integrated
CAE/CAD/CAM
Fig. 5. SLM as a part of product development process.
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3D printing for gas turbine components
Siemens is using AM (SLM) technology for
three main applications (F i g u r e 4):
–– rapid prototyping,
–– rapid repair and
–– rapid manufacturing.
Rapid prototyping
Integration of AM into the product devel-
opment process enables significant speed-
up of design and validation of new com-
ponents and system, as well as ensuring
high reliability and performance of newly
designed components prior to final engine
testing and product release.
In the past, due to long delivery time of
new components manufactured by conven-
tional methods (e.g. casting), component
validation testing was done almost at the
end of the development process, during
the final engine test. This is why a conven-
tional development procedure has some
disadvantages and consequences:
–– sequential development process,
–– conservative development approach,
–– moderate development targets/results,
–– long development cycles.
With new approach, when AM is an inte-
gral part of the development process (F i g -
u r e 5) and can be used for rapid compo-
nents design and manufacturing, the fol-
lowing advantages can be realised:
–– parallel and integrated development
processes,
–– radical development approaches,
–– ambitious development targets/results,
–– fast development cycles.
Utilisation of AM technology for compres-
sor turbine blade design enables the evalu-
ation a few blade cooling concepts and
their tests in a real engine environment in
a few months instead of a few years.
Rapid repair
Repair of components has also been iden-
tified as an application with big potential.
Damaged areas of material can be removed
and new material built up. Just as for new
manufacturing, the lead time reduction is
expected to be significant, especially for
complex compound structures or raw ma-
terials with long lead time from order to
supply.
Recently developed the repair procedures
for SGT-700 & -800 burners tips using SLM
Processing Instrument. Test
51
 3D printing for gas turbine components
Platform
It starts on the computer - the A layer of powder
gas turbine burner needs a new tip is applied
The platform lowers A new layer of metal
by a few micrometers powder is applied
Fig. 6. SGT-800 & SGT-700 burner SLM repair procedure.
technology is 10 times quicker than previ-
ously used “conventional” repair proce-
dures, as it avoids quite a few manufactur-
ing and inspection processes.
Conventional repair procedure required
prefabrication of a large portion of the
burner tip. This prefabricated burner tip is
used for replacement of the burner tip af-
ter the specified operation time (the old tip
was cut off and the prefabricated one weld-
ed on). Conventional repair procedure was
time-consuming, with a significant number
of sub-processes and examinations.
AM repair process of SGT-700 & SGT-800
burners is shown in F i g u r e 6.
Replacement of conventional repair pro-
cesses with SLM provided not only a sig-
nificant reduction in repair time, but also
an opportunity to modify repaired compo-
nents to the latest burner design.
Rapid manufacturing
AM technology industrialisation is also
enabling new opportunities for spare part
VGB PowerTech - Autorenexemplar - © 2015
and supply chain enhancement:
–– manufacturing of spare parts on de-
mand,
–– regionalisation of rapid repair and man-
ufacturing of GT components,
–– simplification of logistics and investment
reduction on stocks.
Currently, Siemens Power Generation is
focusing on industrialisation of SLM for
rapid repair and manufacturing of Siemens
gas turbine components.
Today, we already have burner swirls in
commercial operation in one of our indus-
trial gas turbines. We used AM technol-
52
Metal powder Laser
Burner
A laser beam fuses
the powder
The process is This process gradually produces a
repeated, layer new burner tip that is melted onto
by layer the rest on the component
ogy for this complex burner swirl, because
AM was the only technology that can pro-
duce it.
In the next few years we are planning to
extend the scope of AM manufactured gas
turbine components to burners, fuel strain-
ers, heat shields and guide vanes.
Conclusion
Additive manufacturing enables a revolu-
tion in spare parts manufacturing and gen-
erates the following values and opportuni-
ties:
Lead time reduction and life cycle
improvement for complex parts:
–– lead time reduction: faster technology
validation and product development,
shorter time to market,
–– reduced number of process steps: sim-
plified manufacturing and repair, faster
manufacturing and repair,
–– saving of material,
–– reduced number of parts in a compo-
nent: integrated functionality,
–– eliminated tools: no time consuming
casting process,
–– on-demand, instant, de-centralized pro-
duction (e.g. for service).
Efficiency increase through practically
unlimited options for internal and
external cooling duct design:
–– better heat transfer and lattice struc-
tures: thinner walls and larger surface
areas,
–– improved mixing of fuel and air: ad-
vanced nozzle designs,
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VGB PowerTech 12 l 2015
–– increased coating adhesion: micro-scale
engineered surfaces,
–– new powder alloys possible: improved
lifetime of the components.
Despite all these benefits and advantages,
there are several aspects that make the AM
process difficult to use today:
–– the process is slow, development of
equipment is needed,
–– quality assurance measures need to be
refined,
–– design tools are not readily available,
–– material data is not generated to the ex-
tent required by users,
–– available materials do not match needs
from industry.
The research community and industry to-
gether need to resolve all these challenges
to speed up industrialisation of AM to its
full extent.
References
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May 2015, Lübeck/Germany.
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12-2015.
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3D printing at Siemens Power Generation
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