Additive solutions for industrial gas turbines

The new generation of gas turbines will be a game changer. Additive technologies are the key to more sustainable turbines - learn how industrial gas turbines will benefit from additive manufacturing.

  • The global energy demand is rising and a reliable power source is needed
  • A large portion of power added in the next decade will be gas power
  • The increasing demand for electricity will create a subsequent demand for efficient gas turbines
  • Potential for further de-carbonization with gas-to-hydrogen turbines
Shanghai by night

New technologies, new solutions

Dreaming of big and heavy additive parts for the next generation of gas turbines? 

The additive manufacturing process maximizes the design flexibility and allows the integration of additional functions - at no additional costs for extra geometry changes as no prior models or tools are needed. Geometries are no longer limited to the possibilities of traditional technologies.

In addition, with printing space as big as 500 x 500 x 500 mm, we offer serial production of large additive manufactured components with extremely complex shapes integrating more details and functions. 

The GF Casting Solutions 3D-printed demonstrator for Industrial Gas Turbines The GF Casting Solutions 3D-printed demonstrator for industrial gas turbines: 498 x 498 x 425 mm

Material

Alloy X

Density

8.2 g/cm³

Weight

29.7 kg

Volume

3626 cm³

Additive manufacturing with GF

We team up with you

We offer full R&D Service, including material, process and design development; excellent project management and we consult and support during the set-up of specifications.

Printing space

We print in a 500 x 500 x 500 mm printing space. Big and heavy parts are possible as well as small parts in big volumes (part quantity in one print job).

All out of one hand

We offer all post-processes in-house. We have more than 50 years experience in casting and combine it with additive manufacturing in high-end parts. We work time efficiently with one touchpoint in communication.

Finding the best solution

We make objective & reliable technical decisions regarding manufacturing technology (additive manufacturing vs. casting) and experience in customer applications, processes and production costs.

Full speed

Benefit from fast turnaround time, a single point of contact and independence from third parties: All processes from development to finishing take place under one roof.

Proven quality

Our additive manufacturing and follow-up processes are certified according to EN 9100 and Nadcap. Our teams are trained and experienced and take care of the highest standards and quality management.

GF colleague working on the 3D printer - GF Casting Solutions Our teams are ready to support your 3D metal printing project

Our offer

Our expert teams and certified manufacturing environment are ready to realize your 3D-printing challenge.

In the following, we describe the key players and technologies behind optimized IGT solutions like the 3D-printed GF demonstrator. 

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Development expertise

Our development team is ready to support you and your project:

  • Support and consulting in the product development process
  • Additive manufacturing oriented and compliant designs
  • Characterization of material properties
  • Static and dynamic validation of components also under thermal boundary conditions
  • Topology optimization and FEM simulation
  • Metallurgical analysis of components 
Three of our GF colleagues working on the product design.

Printing space
Printing job in full swing
  • 500 x 500 x 500 mm
  • Big and heavy parts are possible
  • Small parts in big volumes (part quantity in one print job) 

Great design freedom
  • Better design possibilities even compared to casting
  • Extreme shapes: Hollow structures and very thin walls <1mm
  • Very complex shapes from thick to thin in one part
  • Topological optimization: reducing weight and material 
3D-printed metal part with very coplex structures - engineered and manufactured by GF Casting Solutions

High functional integration
3D-printed metal component for Industrial Gas Turbines - by GF Casting Solutions

Functional integration through product development and process know-how:

  • Integrating up to 40 single parts into one design
  • Reduction of welding for joining and assembly activities
  • Reduction of process steps e.g. tooling and machining processes

Optimized part cooling
The possibilities in 3D printing in combination with the know-how in optimizing of the product design are key to make IGT solutions even better in their functionality.
  • Conformal cooling channels in near net shape design instead of a straight line
  • Complex shapes in additive design instead of additional laser finishing
  • Cost advantage through geometry and performance of the application and the reduction of process steps
CAD screenshot of the part and its cooling details

Surface geometry and design
IGT Demonstrator by GF with complex shapes and surface design
  • Surface enlargement to achieve improved cooling of the component from the outside
  • Flow optimization on the surface with direct impact on air or liquid flow
  • Cost-neutral feature
  • Further application options: assembly surfaces and grip

Bionic design
  • Shaping the product and its structures based on the principles of nature
  • High strength with reduced material and weight
  • Sustainable and cost efficient 

Additive manufacturing process steps

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Print job preparation

With state-of-the-art tools and proven expertise, our additive manufacturing team takes care of the print job preparation to make sure that the process can run properly. 

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Preparing the printer

We provide the printer with the right powder, clean the optic lenses and take care of the machine calibration.

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Print job

The laser is directly melting the component layer by layer. The remaining powder can be reused after a dedicated sieving process.

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Depowdering

Once the print job is completed, powder and component are separated automatically and individually. 

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Post processes

Our post processing capabilities

  • Vacuum & cryogenic heat treatment
  • NDT inspection 
    (including analog & digital RX, LPI lines, 3D measurement, Zeiss equipment, GOM – Atos measurements syst. and electronic gauges)
  • Welding
  • Airflow test
  • Installation for chemical etching
  • Surface superfinishing processes
  • Finishing and polishing (more than 50 years of experience)
  • HIP**
  • Computer tomography**
  • Machining for semi-finished and finished components**

** not in-house

A GF colleague from Novazzano controlling a big machine in post processing.

Finding the right technology

Additive manufacturing or precision casting? 

The choice for the perfect technology depends on the specific project requirements and needs. GF brings long-standing experience with similar component families from the casting process which is now built upon when offering additive solutions: of course at the same high quality level.

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Concept

We keep an eye on cost efficiency, component lifetime, number of parts, geometry and part size.

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Precision casting

Depending on your needs and project requirements, the precision casting process may be the right choice.

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Additive manufacturing

The flexibility and speed for the manufacturing of complex shapes in AM is unbeatable. With an expert team and certification, we support your 3D-printing project.

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Solution

What matters most is the accuracy of your solution and the fit to your needs. GF is your partner for casting and additive manufacturing and helps you decide on the right technology. 

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Quality you can rely on

  • Complete additive manufacturing and follow-up processes certified according to EN 9100
  • Trained and experienced teams to handle critical and complex parts requiring highest standards
  • Proven experience in quality management
  • Nadcap standard & certification for all processes

We offer fully certified additive manufacturing, repair welding, heat treatment and non-destructive testing (X-Ray and FPI).

Get in touch with us!

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Your Contact

as-valentina-zangheri-contact.jpg

Valentina Zangheri

Process Engineer

GF Additive Novazzano SA

Via Gaggiolo 27

6855 Stabio

Switzerland

+41 91 695 77 11 +41 76 281 27 73 website e-mail

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