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Tuesday, March 19, 2019

Two applied technical tutorials will be presented on day one of the program:

Designing for Metal Additive Manufacturing

Prof. Timothy W. Simpson, Penn State University

Additive manufacturing (AM) frees us from many of our manufacturing constraints and provides designers with the capability to engineer lightweight structures, consolidate assemblies, and fabricate complex geometries never before possible. The opportunities that AM is enabling in fields ranging from aerospace and energy to medical and oil and gas is unprecedented, but there are real challenges that must be understood in order to use AM effectively. The potential for part warping and distortion necessitate a careful understanding of the underlying physics occurring during additive manufacturing of metallic parts, and support design and build orientation require careful planning for a successful build. Moreover, when fabricating metal parts, AM is as much about making a material as it is about producing a part, and understanding the process-structure-property relationships with metallic materials is critical to ensure AM parts meet their design specifications. Challenges with part inspection, qualification, process sensing and control, and post-processing also need attention when designing for additive manufacturing. The workshop will provide an overview of these challenges and discuss how the design workflow changes with AM. Examples to illustrate AM’s benefits and drawbacks will also be discussed.

Additive Manufacturing and Advanced Repair for Gas Turbine Components

Dr. Bernd Burbaum, Andreas Graichen, Dr. Reiner Anton, Siemens

Additive Manufacturing (AM) is revolutionizing industrial processes. The integrated software and automation solutions are key technological drivers for cost-efficient industrial use of AM in gas turbine service engineering, some of these solutions will be briefly demonstrated. Industrial examples for the application of AM along the entire product life cycle and particularly for repair and upgrade solutions in the field of gas turbines will be discussed from the point of view of the user.

The extended tutorial on Additive Manufacturing and Advanced Repair in Service Technology will initially provide a broad overview of various technologies and then focus on the application process of Additive Manufacturing across power and gas products specifically for gas turbines. It will cover the general use of technologies such as Laser Metal Deposition and Laser Powder Bed Fusion. Moreover, specific challenges on process development for the non-weldable superalloys will be covered as well as the appropriate lifing assessment for high value components. Finally, line integration for highly productive AM Service solutions will be outlined based on relevant service applications.