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Pro FIT HTA Phase II

Exploiting the potential of additive manufacturing to optimize gas turbine components for high-temperature applications.

Details
To
Project

sponsored by the state of Berlin

At one glance

Project start: January 2023
Duration: 2,5 years
Funded with: approx. 8 Mio. €
Number of partners: 11
Location Huttenstraße

Christoph Heinze, Siemens Energy

Project Management

Cynthia Wirth, Siemens Energy

Project Management

Insights into our work

Milestones

Here we document important milestones from the project. Current news, special publications or appearances at trade fairs and congresses are made visible here.

JAN

2024

NEWS

1st milestone meeting

First milestone meeting “check”. We met at BAM on 25.01.24 for our first project review with IBB and the experts from VDI/VDE. It was a successful day, which shows that we are working in a productive team on interesting tasks such as process development, post-processing, simulation, life cycle analysis, recycling, etc.

JAN

2024

NEWS

1st milestone meeting

First milestone meeting “check”. We met at BAM on 25.01.24 for our first project review with IBB and the experts from VDI/VDE. It was a successful day, which shows that we are working in a productive team on interesting tasks such as process development, post-processing, simulation, life cycle analysis, recycling, etc.

2023

NEWS

HTA2 Deep Dives

Within the first months of the project, deep dives were carried out in our workstreams “Materials & Processes”, “Post-Processing” and “Sustainable Product Development” for the entire consortium. The aim was to describe the main fields of work and objectives of the 12 work packages and to encourage an exchange between the workstreams. Around 25 participants at each of the three sessions took advantage of this opportunity for networking and coordination, paving the way for the first milestone meeting in January 2024.

2023

NEWS

HTA2 Deep Dives

Within the first months of the project, deep dives were carried out in our workstreams “Materials & Processes”, “Post-Processing” and “Sustainable Product Development” for the entire consortium. The aim was to describe the main fields of work and objectives of the 12 work packages and to encourage an exchange between the workstreams. Around 25 participants at each of the three sessions took advantage of this opportunity for networking and coordination, paving the way for the first milestone meeting in January 2024.

JUL

2023

NEWS

Kick-Off

On July 11, 2023, the partners, IBB and the review team met to get to know each other and get an overview of the Phase II roadmap. Research topics include design for additive manufacturing, life cycle analysis, process and material development, robotic post-processing, FEM simulations, high-energy synchrotron experiments, powder/support structure recycling, and more.

JUL

2023

NEWS

Kick-Off

On July 11, 2023, the partners, IBB and the review team met to get to know each other and get an overview of the Phase II roadmap. Research topics include design for additive manufacturing, life cycle analysis, process and material development, robotic post-processing, FEM simulations, high-energy synchrotron experiments, powder/support structure recycling, and more.

With us:

Voices from the project

In the project, BAM is developing new methods for in-situ quality assurance and an understanding of microstructure development and creep behavior. In this way, we are contributing to the safe and reliable use of AM components.

Kai Hilgenberg

Project manager HTA at BAM

Additively manufactured components are often not immediately ready for use after printing. Fraunhofer IPK is therefore conducting intensive research into automated post-processing in order to enable production with the highest possible efficiency in batch size 1, even for the most complex geometries.

Tobias Neuwald

Project manager HTA at Fraunhofer IPK

The project in pictures

Gallery

Science, research and education

About the project

Following the successful completion of HTA2.0 at the end of 2022, the 2nd phase will start in January 2023 with a duration until June 2025. Here, we welcome new partners within the HTA network and look forward to working together.

 

What it’s all about
High-temperature applications involve the development and production of components that come into contact with the hot gas jet, which reaches temperatures of well over 1000 degrees Celsius, in high-efficiency gas-fired power plants. To ensure their function and service life, additive manufacturing is used to implement innovative concepts that are not technically feasible using conventional manufacturing processes.

 

Aims of the research project
Development of new additive manufacturing processes and components for high-temperature components in large gas turbines, taking into account sustainable product development.

Motivation

The focus of the 2nd phase is the extension of the Design for Additive Manufacturing method with further processes (wire-based generation of large components DED-Arc, selective laser beam melting with high-temperature preheating and selective electron beam melting PBF-EB/M in powder bed) and the aspect of life cycle analysis (LCA). In this context, process and material development for the DED-Arc and PBF-EB/M processes will be brought to a higher level of maturity.

Furthermore, the topic of post-processing of additively manufactured components is being given greater attention in order to enable automated and small-series processing. In addition, the recycling of metal powders and support structures will be highlighted, with the aim of achieving greater resource efficiency and thus contributing to the economic presentation of AM components.

The consortium

Project Partner

The “Werner-von-Siemens Centre for Industry and Science” ecosystem is a colorful mix of renowned scientific institutions and universities, excellent industry, innovative SMEs and agile, young companies. They all combine their expertise in a future-oriented research cooperation.

 

The project partners are:

  • Siemens Energy
  • Bundesamt für Materialforschung und -prüfung
  • Fraunhofer
    • Fraunhofer-Institut für Produktionsanlagen und Konstruktionstechnik
  • Technische Universität Berlin
    • FG Methoden der Produktentwicklung und Mechatronik
    • FG Werkstofftechnik
    • FG Werkzeugmaschinen und Fertigungstechnik
    • FG Keramische Werkstoffe
    • FG Metallische Werkstoffe
    • FG Numerik der Nichtlinearen Optimierung
    • FG Numerische Mathematik
    • FG Service-centric Networking
    • FG Industrielle Informationstechnik
    • FG Industry Grade Networks and Clouds
  • Siemens
  • Gestalt Robotics
  • YOUSE
  • Datalyze Solutions
  • PROCEED Labs
  • 3YOURMIND
  • XPLORAYTION

The Werner-von-Siemens Centre for Industry and Science e.V. is supported by federal and state funds within the framework of the Joint Task “Improvement of the Regional Economic Structure” (GRW).

 

Our projects are co-financed by the European Regional Development Fund (ERDF).