GEFERTEC | Case study : load collar druck

LOAD COLLAR

INFORMATION ON THE COMPONENT PART

• Part of a Siemens Energy SGT5-2000E heavy-duty gas turbine
• The component is located in the critical downstream area of the turbine
• The robust design ensures an optimum stress curve for LCF and HCF
• Characteristic of the field of application :
  ▪ Low cycle load
  ▪ Corrosive environment
  ▪ High temperature
• Original manufacturing technology :
  ▪ High temperature corrosion resistant steel
  ▪ Machined out of 83 kg billet to 7 kg finished part
• Challenges :
  ▪ Manufacturing according to Siemens Energy internal standards
  ▪ Low Cycle Fatigue testing required
  ▪ Qualification processes according to existing fusion welding standards e.g. DIN EN ISO 15614

MANUFACTURING WITH 3DMP® WAAM

• Existing conditions for Siemens Energy‘s internal and welding qualification process standards:
  ▪ Printing using qualified and documented process (WPQR/WPS)
  ▪ Full documentation of all print process parameters for validation of print quality
• Efficient production process :
  ▪ Batch production approach to reduce cooling times
  ▪ Build-up rate: 3,5 kg/h
• Reduction of material usage by 80 %
  ▪ Blank 16kg instead of 83 kg

TECHNICAL DATA

• Machine : arc405
• Dimensions :
  L x W x H = 100 x 350 x 300 mm
  L x W x H = 3.9 x 13.8 x 11.8 inch
• Wire : ER19-10 H
• Printing mass : 16 kg | 35.3 lb
• Printing time : 4.5 h

BENEFITS OF 3DMP®

• Material savings
• Cost savings