Laser Metal Deposition for Maintenance, Repair and ... · PDF fileLaser Metal Deposition for...
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© Siemens AG 2012.
Laser Metal Deposition for Maintenance, Repair and
Overhaul at Siemens Fossil Power Generation
AKL - International Laser Technology Congress
Dr. D. Thomaidis, Dr. M. Ott, N. Arjakine,
Dr. G. Bostanjoglo
Aachen Mai 9th, 2012
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Content
Introduction
Examples of advanced repair welding technology at Siemens AG
Laser cladding
Laser build-up welding
Summary
Content
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HealthcareEnergyIndustry Infrastructure & Cities
Oil & Gas
Fossil Power Gen.
Wind Power
Solar & Hydro
Energy Service
Power Transmission
Generators (E F PR GN)
Sales (E F PR S)
Products (E F PR)
Steam Turbines (E F PR SU)
System Integration (E F PR SI)
Feeder Plants (E F PR FP)
Sector
Division
Business Unit
Business Segment Gas Turbines (E F PR GT)
Siemens Energy Sector – New set-up for the future requirements of the market
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Siemens Energy Sector – New set-up for the future requirements of the market
Solar & Hydro(E X)
Power Transmission
(E T)
Oil & Gas
(E O)
Fossil PowerGeneration
(E F)
Wind Power(E W)
Energy Service
(E S)
Energy products and solutions – in 6 DivisionsProducts and solutions – in 6 Divisions
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50 Hz 292 MW
168 MW
375 MW
60 Hz
274 MW
208 MW
113 MW
SGT5-8000H
SGT5-4000F
SGT5-2000E
SGT6-2000E
SGT6-5000F
SGT6-8000H
Siemens large-scale gas turbines
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Slide 6
Products Business Unit – Innovation highlight: Siemens SGT-8000H series gas
turbine
Strong fluctuations in grid demand and feed-inrequire higher operational flexibility
The focus on “clean energy” is driving the demand for more efficient power generation solutions
The high-tech class is the fastest growing gas turbine market segment of the future
Market requirements
Siemens SGT-8000H series solution Reduction of emissions per kWh generated Higher efficiency: over 60% in combined cycle
operation Maximum operational flexibility due to highest part-
load efficiency and highest ramp rates
Proven rotor design, free radial thermal expansion andcentral tie bolt
Evolutionary 3D compressorblades
Improved combustionsystem forUltra-low NOx
High load flexibility through improvedblade cooling system
Four-stageturbine
Customer benefits Lower investment costs per kW Lower lifecycle costs High reliability and availability Short start-up times and high operational flexibility
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Development tendency of materials for increased turbine inlet temperature in gas
turbines
1950 1965 1980 1995 2010
800
950
1100
1250
1500
T°C1800
2025
Turb
ine
Inle
t Te
mpe
ratu
re
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Prager’s plot of weldability versus Al and Ti content - Cracking Categories
Types of cracking which may occur during and after welding
include:
• Solidification cracking (SC)
• Liquation cracking (LC)
• Ductility dip cracking (DDC)
• Reheat (strain age) cracking (RHC)
For example: a) - SC and b) - LC
a b
1 2 3 4 5 6
1
2
3
4
5
6
Titanium, %Alu
min
ium
, %
Inconel 718
Udimet 600 Astroloy
IN 100
Udimet 500
Rene 41
Difficult To Weld
Readily Weldable
Source: Journal
of Materials Engineering and
Performance
Volume 6(5)
October 1997
Rene 80
IN738
IN 939
IN 625
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Solutions to minimize cracking caused by the welding process
Lower heat input during
welding
Beam Welding
Micro Plasma Powder Welding
Improvement of welding parameters
Heat treatment
Welding filler materials Use of ductile welding filler materials
Pre weld H/T
(solutioning / overaging)
Post weld H/T
Hotbox – welding
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Solutions to minimize cracking caused by the welding process
Development of a LMD process at room temperature for highly γ’-strengthened nickel-base superalloys with
a γ’-strengthened filler material to create material properties for a structural repair.
Development of process parameters for LMD with reduced heat affected zone in the base material to avoid
negative impact on the substrate microstructure.
Development of a numerical model and resulting process parameters for LMD to adjust the cooling rates
during solidification
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Transitions wear at the MC
Gap of only 3,5-4mm at the transitions
Casing deformation during operation
Hammering and abrasion occurs
Laser hard facing of the transitions
Increasing the wear resistance
Repairable by TIG welding on site
Field testing ongoing
Hard facing technology – Demand and Solution
Hard facing of
the cooling air ring
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• Hard facing by laser welding for production
• Field test shows good results
• Application for Siemens patent
• Replacement of Parts possible
during scheduled Major Outages
Product improvement available
For New Part and Service!
Status: Hard facing Solution
20mmProduction Laser weld
Testing in GT
Hard faced spots
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Blade tip restoration by
Manual TIG-welding Laser powder welding
multiple layers
small amount of overlaying
material
reduced re-contouring effort
low process time
few layers
remarkable amount of overlaying
material
respective re-contouring effort
high process time
m-TIG vs. Laser Powder Welding
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m-TIG vs. Laser Powder Welding
Improved Quality
HAZ:
up to 0.5 mm
visible 3 mm
respective high
heat input
risk of crack
introduction &
propagation
HAZ: up to 0.15 mm
reduced heat input
Laser process is more robust, faster and offers better quality
Laser powder weldingManual TIG-welding
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Further Laser Powder Applications
…rubbing marks at stationary blades…
Repair of…
…and at guide ring
Combination of Laser and
Hot-Box
Possibility of high-strength matching filler
welding
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Summary
The low weldability of advanced GT materials represents a significant challenge.
The combination of advanced welding technologies like LMD with in-depth materials knowledge and their
behavior during welding allow the repair of these material systems.
The ability to perform such repair of GT components reduces life cycle costs and repair lead time, lowers
the scrap rate and makes repair and refurbishment more cost effective for gas turbine owners.
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Thank you for your attention – any questions?
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