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Advantages of 3D Printing for Energy

The energy industry is characterized by a significant high level of customization in its asset. Therefore, the yearly production volume falls in the range of hundreds or rather thousands parts per year each design. Such volume is on the left-low cost effective capacity range of investment casting and forging while it fits perfectly in the highest cost efficiency point for additive manufacturing. Avoidance of tooling, full design flexibility and immediate production planning redefinitions are key enabler of a smart and lean supply chain.

The traditional business model of energy operators contemplate a huge immobilized capital of spare parts, because of procurement lead time and asset downtime cost. AM is measuring parts production and delivery into days - vs. weeks or months - enabling the most efficient just-in-time production scenario. Moreover, thanks to its flexibility it allows efficient production close to the point of use eliminating transportation, duties delays and increasing local content.

Selective Laser Melting Solutions for Energy Applications

  • Stator Vanes

    AM is a smarter and cost competitive alternative to investment casting of strator vanes. The combination of conformal cooling channels and high temperature resistant superalloys enables increases in operating temperature and therefore efficiency increase and emission reduction of strator vanes.

  • Fuel Nozzles / Burners

    Additive Manufacturing is enabling the combustion next generation of design. Thanks to the possibility to additively manufacture internal channels with SLM® technology the fluids can be mixed more efficiently enabling higher performance and lower emission. That is also a key enabler to increase H2 content in hydrogen-fueled turbines.

  • Rotoric Blades

    Selective Laser Melting provides benefits in the prototyping of rotor blades, allowing quick and economically viable test of different design solutions.

  • Strator Shroud

     The combination of conformal cooling channels and high temperature resistant superalloys enables increases in operating temperature and therefore efficiency increase and emission reduction.

Success Stories

Pump Impeller for Equinor

Printed on: SLM®280
Material: IN625
Layer Thickness: 50µm,
Build Time: 43h (full load, 1 piece) 

This pump impeller for firefighting has been produced in the course of a joint innovation project with Equinor. Additive manufacturing lead to a weight reduction of 70% while lead time has been reduced from 20 to 4 weeks, thereby lowering inventory levels and costs. Additionally, better sea water corrosion resistance could be reached with no signs of corrosion at 90°C (compared to forged material with corrosion occurring at 80°C). 

 

Success Stories

Glass Lined High Pressure Reactors from Thaletec


Printed on: SLM®280
Layer Thickness: 60 µm
Build Time: 3d 3h 1min (full load, 5 pieces)

Weight savings, increased performance and temperature control channel to improve heat transfer, this glass-lined high pressure reactor for the process industry combines multiple benfits of selective laser melting.

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Recommended SLM® Machine For Energy

SLM®280 Production Series

The SLM®280 Production Series targets the serial production processes with fully automatic powder management in inert gas atmosphere and provides a patented, enhanced gas flow that creates a clean process environment and increase build quality. A permanent filter module additionally increases machine uptime and safety.

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SLM®500

The SLM®500 system is optimized for the serial production of high volume projects. Safety and material quality are increased through closed loop powder handling and a part removal station for efficient unpacking additionally increases machine downtime.

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SLM®800

With an extended z-axis, the SLM®800 is suitable for the large-scale production of parts with up to 850mm height. Up to five machines can be connected to one SLM®HUB, SLM Solutions' fully automatic handling station.

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SLM® Material for Energy Applications

SLM Solutions sells appropriate powder and parameter sets for the most common powders in the energy industry:

  • Ni-Based Alloys: IN625, HX, IN718, IN939
  • Fe-Based Alloys: 316L (1.4404)  
  • Cu-Based Alloys: CuSn10

 

More SLM® Materials

Within several developemt projects we also work on new parameter sets for new materials. If you have any questions to your individual material solution, feel free to contact us.