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Additive Manufacturing: un enorme potenziale per migliorare i costi di manutenzione

Ottimizzando la gestione delle parti di ricambio delle macchine rotanti

(in lingua inglese)
Additive Manufacturing: speed, performance, productivity.
Additive Manufacturing Technologies
DMLM in BHGE TPS: from R&D to qualification and production

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Atti di convegni o presentazioni contenenti case history
MCM ottobre 2018 Le Tecnologie Abilitanti 4.0 -Soluzioni ed applicazioni per una manutenzione competitiva

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da Benedetta Rampini
MCM 2018Segui aziendaSegui




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Estratto del testo
Veronafiere 17-18 ottobre 2018 Vi aspettiamo a mcT Petrolchimico Milano, 29 novembre 2018 Cogenerazione Termotecnica Industriale Pompe di Calore 27 ottobre Cogenerazione Termotecnica Industriale Pompe di Calore Alimentare Alimentare Petrolchimico Alimentare 28 ottobre Alimentare Petrolchimico Alimentare Alimentare Petrolchimico Visione e Tracciabilit 28 ottobre Luce Energia Domotica LED Luce Energia Domotica LED Petrolchimico Alimentare Petrolchimico Petr Confidential. Not to be copied, distributed, or reproduced without prior approval. 2017 Baker Hughes, a GE company, LLC - Al rights reserved. Additive Manufacturing: a huge potential to improve maintenance costs optimizing rotating equipment spare parts management Matteo Delfino
Additive Manufacturing Product Manager
Baker Hughes, a GE company Confidential. Not to be copied, distributed, or reproduced without prior approval. http://www.cyclenews.com/2018/04/article/can-now-3d-print-bmw-spare-parts-bike/ http://www.cyclenews.com/2018/04/article/can-now-3d-print-bmw-spare-parts-bike http://www.cyclenews.com/2018/04/article/can-now-3d-print-bmw-spare-parts-bik https://www.press.bmwgroup.com/global/article/detail/T0279598EN/bmw-motorrad-iparts-revolutionises-spare-parts-
management'language=en https://www.press.bmwgroup.com/global/article/detail/T0279598EN/bmw-motorrad-iparts-revolutionises-spare-parts
management'language=en https://www.press.bmwgroup.com/global/article/detail/T0279598EN/bmw-motorrad-iparts-revolutionises-spare-part
management'language=en http://blog.motorcycle.com/2018/04/02/manufacturers/bmw/bmw-
motorrad-iparts-revolutionizes-spare-parts-management/ http://blog.motorcycle.com/2018/04/02/manufacturers/bmw/bmw
motorrad-iparts-revolutionizes-spare-parts-management/ http://blog.motorcycle.com/2018/04/02/manufacturers/bmw/bm
motorrad-iparts-revolutionizes-spare-parts-management/ http://www.zougla.gr/automoto/moto/article/ta-bmw-iparts-fernoun-tin-epanastasi-sti-diaxirisi-antalaktikon http://www.zougla.gr/automoto/moto/article/ta-bmw-iparts-fernoun-tin-epanastasi-sti-diaxirisi-antalaktiko http://www.zougla.gr/automoto/moto/article/ta-bmw-iparts-fernoun-tin-epanastasi-sti-diaxirisi-antalaktik http://www.today.it/motori/tecnologia/bmw-motorrad-iparts-rivoluzione-pezzi-ricambio-stampanti-3D.html http://www.today.it/motori/tecnologia/bmw-motorrad-iparts-rivoluzione-pezzi-ricambio-stampanti-3D.htm http://mixmotor.eu/26332/bmw-
motorrad-iparts-prinasaju-
revoluciu-medzi-nahradne-diely http://bike-mania.cz/bmw-motorrad-iparts-predstavuje-revoluci-v-dodavkach-
nahradnich-dilu/ http://bike-mania.cz/bmw-motorrad-iparts-predstavuje-revoluci-v-dodavkach
nahradnich-dilu/ Confidential. Not to be copied, distributed, or reproduced without prior approval. SPEED PERFORMANCE PRODUCTIVITY Additive Manufacturing Confidential. Not to be copied, distributed, or reproduced without prior approval. 3 2018 Baker Hughes, a GE company, LLC - Al rights reserved Confidential. Not to be copied, distributed, or reproduced without prior approval. 4 Additive manufacturing is defined as the process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies. 3D CAD model Slicing Layer-wise building Complete part What is Additive Manufacturing' Confidential. Not to be copied, distributed, or reproduced without prior approval. Deposition Laser Powder Forming Cold Spray Large and Thin Low/Medium deposition rate Consolidation Hot Isostatic Pressing Binder Jet Large and Bulk High volume/deposition rate Powder bed Direct Metal Laser Melting Electron Beam Melting Small and Complex Low deposition rate Additive Manufacturing Technologies 5 Confidential. Not to be copied, distributed, or reproduced without prior approval. ' Nickel base alloys ' Cobalt base alloys
' Stainless Steels ' Light alloys
' Techno-polymers Many more materials in development and
being prioritized by business impact ' GT 108 GT 262 GT 414 CoCr 17-4 PH 15-5 PH Ti 64 AlSi 10Mg PEEK + 316L Hast X IN 718 HS188 IN 625 Bronze Ti6246 Materials 6 Confidential. Not to be copied, distributed, or reproduced without prior approval. 7 Manufact urability 3D Printing Post processing Ef fo rt Print S u rf ac e f in is h in g Assembly & testing 3DP production process Time required What's beyond Additive Manufacturing' Confidential. Not to be copied, distributed, or reproduced without prior approval. Process development 8 Ef fo rt 3DP production process Time required Material characterization Design for Additive ' and before it Confidential. Not to be copied, distributed, or reproduced without prior approval. October 15, 2018 Machine & process Material Component ' Capability assessment ' Capability adjustment Requirements ' Laser melting parameters ' Powder mechanical specs Functional Test & NDT Destructive Testing # of t es t & c he ck s DMLM in BHGE TPS: from R&D to qualification and production Three pillars defining final product requirements ' Material requirements ' Functional requirements Confidential. Not to be copied, distributed, or reproduced without prior approval. Firenze (Italy) - 2013 DMLM: 1x EOS M290 + 2x EOS M280 + 1M400 DMLM: 1x EOS M280 Bangalore (India) - 2015 Material Lab Vacuum heat treatment Metrology Lab X-Ray Tomography 3D light scanning Metal Working Lab Die sink and wire EDM Material Lab Alloy characterization Post-Process Labs Additive Manufacturing in BHGE TPS ' R&D 10 Confidential. Not to be copied, distributed, or reproduced without prior approval. 11 TPS Production Plant: Talamona (Italy) Additive manufacturing production line for gas turbine fuel burners and hot gas path components Confidential. Not to be copied, distributed, or reproduced without prior approval. 12 Additive Manufacturing ... from technology to service New Units components ' Faster go-to- market ' Rapid prototyping and testing ' Improved performance ' Available Spare Parts ' Lead time reduction ' Extended life ' Improved performance ' Available Service Bureau ' Cycle time reduction ' Obsolete components ' Improved performance ' Available Digital Inventory ' Reduce Inventory ' JIT production ' Local capabilities ' Piloting Print @ site ' Fabrication at point of use ' Print during maintenance ' End-to-end process ' +5 years Confidential. Not to be copied, distributed, or reproduced without prior approval. Experience the technology' Service Bureau 13 Performance enhancement Obsolete component ' Quick time to market ' Viable for small lot production ' No need of tooling ' Design freedom ' Material flexibility ' Lightweight structure 1957 gas turbine
stage 1 nozzle Pump impeller Motor cooling fan Gas turbine
combustor Journal
bearing Labyrinth
seal Pump
impeller Challenged by spare parts obsolescence' Concerned by long lead time' Facing plant bottleneck' A dedicated team of AM experts and a network of design Engineers can re-design and 3D print on demand your spare parts, in weeks. Gas turbine
swirler Valves
components Heat
Exchangers Confidential. Not to be copied, distributed, or reproduced without prior approval. 14 Service Bureau: obsolete pump impellers Pilot project completed:
' Identified pilot component ' Reverse engineered, optimized and produced with DMLM in less than 30 days ' Test bench successfully completed, impeller installed and currently in field operation
since more than 1 year Confidential. Not to be copied, distributed, or reproduced without prior approval. ' 1957 model' out of production ' AM 60% faster than any other solution ' Alloy characterized ' Process ' tested, verified ' Welding ' Low Cycle Fatigue (LCF) characterized ' Structural analysis comparison vs baseline: ' Static Thermal-Mechanical Analysis ' Creep and LCF for life assessment CAD 3D Model Thermal Model FE structural Model 3D model 15 Service Bureau: FR32C - First Stage Nozzle In operation since June 2018... collected more than 1.000 firing hours Confidential. Not to be copied, distributed, or reproduced without prior approval. Matteo Delfino Additive Manufacturing Product Manager Baker Hughes, a GE company Copyright 2018 by <Giulio Canegallo - Baker Hughes, a GE company .> All rights reserved.
This presentation or any portion thereof may not be reproduced or used in any manner whatsoever without the express written
permission of the author or rights holder. +39 342 333 0974
matteo.delfino@bhge.com Additive Manufacturing: a huge potential to improve
maintenance costs optimizing
rotating equipment spare parts
management


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