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AM is revolutionizing the turbomachinery manufacturing process by offering unparalleled design flexibility, improved efficiency, and faster production times. As the energy sector continues its transition towards cleaner sources, the adoption of AM will be crucial for meeting the demands of the market while reducing environmental impact. By embracing this technology, gas turbine manufacturers can stay ahead in the fiercely competitive turbomachinery sector and contribute to a more sustainable future.
Despite the global push to reduce greenhouse gas emissions, fossil fuels still account for 64 percent of electricity production. However, the energy sector is undergoing a transformation as cleaner-burning natural gas replaces coal and petroleum-based fuels to meet emission reduction targets. This shift is rapidly reshaping power plants, with energy producers constructing new facilities and renovating existing ones to accommodate the change. At the heart of these new facilities are massive industrial turbines that convert natural gas into electricity. To meet the demands of the market for greater fuel efficiency, power generation, and system reliability with lower maintenance costs, the turbomachinery sector is facing fierce competition. Gas turbine manufacturers stand to benefit significantly from this swift transformation, but current production techniques are struggling to keep pace with advancements. One solution to this challenge is additive manufacturing (AM), also known as 3D printing. By embracing AM, makers of cutting-edge turbomachinery can overcome traditional production obstacles and accelerate innovation. AM offers benefits such as design flexibility, improved supply chain efficiency, increased system performance and reliability, and a faster time to market. AM revolutionizes several processes used in the production of turbomachinery components. For example, combustors, critical to the operation of turbomachinery, can be optimized for power output and fuel efficiency. With AM, engineers have unprecedented design flexibility, enabling the creation of innovative internal features for clean combustion. This flexibility eliminates challenges related to superalloy type or shape and allows for the production of monolithic parts, reducing waste and labor costs. Similarly, turbine stator and compressor vanes, subjected to extreme pressures and temperatures, can benefit from AM. By consolidating multiple pieces into single, complex components, AM enhances reliability and manufacturing yield. Additionally, designers can incorporate intricate internal cooling channels into these crucial components, improving efficiency and thermal performance. AM also unlocks new levels of impeller performance by enabling the creation of complex ducted impellers. Engineers can optimize impeller topology and utilize lattice structures to achieve greater air compression efficiency while reducing weight and energy consumption. AM is revolutionizing the turbomachinery manufacturing process by offering unparalleled design flexibility, improved efficiency, and faster production times. As the energy sector continues its transition towards cleaner sources, the adoption of AM will be crucial for meeting the demands of the market while reducing environmental impact. By embracing this technology, gas turbine manufacturers can stay ahead in the fiercely competitive turbomachinery sector and contribute to a more sustainable future.
