3D printing allows China’s gas turbine manufacturing technology to take off

3D printing allows China's gas turbine manufacturing technology to take off

3D printing technology, due to its unique principle of layered forming, allows simple and complex forms to be treated almost equally. Just need to have 3D modeling scheme, suitable raw materials and 3D additive manufacturing instruments, you can immediately print parts; because of dumping the mold, so you can use a cheaper price, manufacturing the traditional mold factory can not be manufactured out of the design; if the design subsequently occurred to modify, just modify the design 3D modeling scheme, and print again; 3D printed parts appear damaged, and can even print directly at the breakage repair. So 3D printing on industrial manufacturing disruptive visible. After more than thirty years of development, 3D printing has long been out of the ivory tower and out of the self-indulgence of geeks. Open a treasure, search for “3D printing”, from keychains to ice cream, there is always one to meet your next Tanabata’s stocking needs.

  But the real pursuit of industrial manufacturing, should be the so-called “big sound, big elephant invisible”. The great man of chivalry, for the country and the people, even if there are a thousand pounds of power, hidden but not issued. Truly worthy of praise a thousand pieces of 3D printing, but also when the resounding metal 3D printing. Under the mainstream laser sintering technology, parts are printed and shaped after thousands of times of sintering, and a thousand hammers are sharpened into a sword.

  3D printing – to meet the precision requirements of modern industry

  Known as the “crown jewel of manufacturing” of the gas turbine to date has been developed for more than half a century, want to continue to progress, requiring near-peak technical ability and imagination. In the process of climbing to the top, 3D printing technology can be said to have emerged to make up for the limitations of traditional manufacturing methods. For example, the leading combustion engine – H-class combustion engine, turbine initial temperature of 1500 degrees Celsius, combined cycle efficiency of 62.22%, extremely high flexibility, ultra-low emissions, the culmination of a century of human industrial civilization, the essence of 3D additive manufacturing.

  One of the core components of the GE 9HA gas turbine – the fuel nozzle and premixer of the combustion chamber – uses 3D additive manufacturing processes, and the microporous premixing technology ensures the effective performance of GE’s low-NOx combustion technology DLN2.6e. Combined with many equally cutting-edge technologies, the 9HA unit at the Bouchon power plant in France finally achieved the Guinness World Record breaking combined cycle efficiency of 62.22%. Guinness World Record combined cycle efficiency – 62.22%.

  This is how the “big sound and the big elephant are invisible”.

  Don’t be anxious to read this, such a good thing, how can my country not have, soon, 9HA gas turbine will be settled in Tianjin military grain city.

  3D printing can actually achieve how much change? Let’s take the fuel nozzle in the GE9HA combustion engine as an example. The dense inlet holes allow the 9HA to achieve micro-hole premixing and full premixing combustion in the low-NOx combustion technology DLN2.6E, which ensures that the fuel and air are mixed in a better ratio to achieve a full premixing combustion mode for the start-stop process, without diffusion flame, to meet the ultra-low NOx emissions (only 25ppm under the lowest load to 30% of the operating conditions NOx emissions), supporting rapid load increase and decrease of the combustion engine.

  3D printing – the world’s most advanced combustion engine

  The H-class combustion engine is huge, GE’s 9HA combustion engine is about 12 meters high (about four floors) and weighs about 400 tons (about two blue whales), and in actual use, the combustion engine itself will have many “auxiliary machines” to help fully recover the waste heat of exhaust gases, etc. In addition to the large size, many parts, and the need for “auxiliary engine” compatibility, the power generation industry also expects the combustion engine to work 24×7, while meeting increasingly stringent environmental regulations. All of this requires the design and manufacture of H-class combustion turbines to be infinitely close to perfection – with precision tolerances of up to a few tens of microns for the core components of the gas turbine.

  One of the reasons why the GE9HA turbine is the most efficient gas turbine in the world (there is no one) is 3D additive manufacturing.

  Specifically, the full application of 3D printing technology on key components was able to help increase the output of the GE9HA gas turbine by 1% compared to traditional manufacturing methods. GE’s 9HA unit at the Bouchon power plant in France can supply the electricity needs of about 680,000 French households, which means that these two components will bring light to an additional 6,800 households, while the original energy consumption remains unchanged.