Additive manufacturing is a break-through technology for intricately shaping turbine parts. TerniEnergia and Numanova just signed two EPC contracts worth €6.5 million for the turnkey supply of two plants that actually produce the sought-after metal powders – the very basis of the laser printing process. The two facilities will be built some 100km north of Rome, due for completion in the second quarter of 2017.
Known as EIGA (Electrode-Induction Melting Inert Gas Atomization) and VIGA (Vacuum-Induction Melting Inert Gas Atomization), the two plants have already been authorized by the local authorities. To be built on a turnkey basis, the plants will be set up in an industrial area owned by Numanova of Nera Montoro (TR), some 100km north of Rome.
Under the contract, TerniEnergia and Numanova will be responsible for design work, supply and "turnkey" installation, including electrical connections, electrical instrumentation, commissioning and implementation of safety systems. The Italian turnkey energy provider Terna stated the contract is consistent with its strategy to grow within the technical services sector.
Metal powders production based on ALD tech
The actual technology for manufacturing metal powders is ALD Vacuum Technologies, a German company leading in vacuum systems for casting, coating and heat treatment of metals that is part of the Dutch AMG Advanced Metallurgical Group
Operating in all fields of vacuum metallurgy and vacuum heat treatment, ALD produces metals in vacuum to achieve higher purity and quality. Concealed behind the technical term, „vacuum melting and controlled solidification“ as well as „electron beam physical vapor deposition“ are break-through technologies that allow swift mass production of turbine blades – used both for aircrafts and high-efficiency power plants.
Siemens is one of the leading turbine manufacturers that have been making use of 3D printing for years at its Corporate Technology Division in Berlin. "Selective laser melting, allows us to realize geometries that can hardly be manufactured right now.
“We will see new frontiers for heat transfer and structural integrity,” said Nicolas Vortmeyer, Siemens’ head of new technology. "We're talking smaller and stronger,” he told Gas to Power Journal.
Selective laser melting, similar to 3D printing, allows individualised design and manufacturing of items using powder or granulate, and a so-called 'printer'. One tiny point at a time, the 'printer' melts and compiles the material into a three-dimensional object.