Additive Manufacturing Onsite Repair brings the world’s most advanced manufacturing technology for repair to your plantOperational disruptions and downtimes are associated with high costs and difficulties for plant operators. Fast, reliable, and straightforward service is crucial for getting plants back into operation as quickly as possible. But spare parts availability might be critical and transporting a valuable component to a workshop can be expensive and a time-consuming logistical operation. Our Additive Manufacturing Onsite Repair solution is designed to restore your critical components – or even improve their performance – onsite using the advanced additive manufacturing technology.
At a glance
Our Additive Manufacturing Onsite Repair solution is designed to enable challenging and value-adding repairs to be carried out onsite.
It saves customers long delivery times and investment costs by using advanced additive manufacturing processes onsite.
Additive Manufacturing Onsite Repair – a unique process intended to restore the original condition of components of any dimension onsite – offers new repair possibilities for power plants and many other industries.
Our solution uses mobile robotics systems that enable both small and large components to be repaired onsite. The system comprises a robot, an additive device/welding head and a control system. It can be combined with a variety of equipment, such as a turntable or a rotation drive, to meet specific needs. The entire system can be deployed to the site and assembled along with a mobile protection system. It designed to be ready to start work within several hours.
Additive Manufacturing (AM) is an emerging and innovative manufacturing process that differs fundamentally from conventional approaches.
Components are built or restored layer by layer which can result in enormous flexibility. Different onsite processes are available, like laser cladding or Wire Arc Additive Manufacturing technologies.
Different powders can be premixed before injection, or several different powders can be used to create a custom alloy. By combining different metals and alloys, sandwich structures can be produced. Material combinations that are difficult to achieve with traditional methods can be generated with laser metal deposition.
The base materials for laser cladding will be qualified and used by Siemens Energy depending on the application.
On-Site Machining plays a key role for helping promote high availability, long service intervals and the shortest possible repair times and costs.
It is intended to save valuable time for transport, and plant operators are ideally equipped to deal with any possible findings or planned downtimes in their plants.
Key intended benefits
- More cost effective via shorter repair times
- Reduced transport times
- Repairs within the critical path of plant downtime
- Worldwide service with advanced technology
For us, reliability begins with precision. And with the sense of responsibility that comes with offering you the best possible service wherever you may need us. And we believe reliability also means working with verified, clearly structured processes and checking our improvements at regular milestones – all with the objective of getting your plant up and running again faster than ever.
Additive Manufacturing Onsite Repair is suitable for various applications.
The process is particularly suitable for power plant components but also for many other industries. When spare parts are not available or it is crucial to restore the original condition of a component, the onsite repair solution is beneficial.
Additive Manufacturing Onsite Repair – The minds behind the solutionTo best meet our customers‘ service requirements, we bring together our top specialists from different disciplines.
With Additive Manufacturing Onsite Repair, we’ve created a new service offering that is designed to provide an optimal solution for fast and efficient component refurbishment. We’ve achieved this by combining our Engineering, Non-destructive Testing, On-Site Machining and Welding specialization.
„Our technological edge starts where we leave standard solutions behind. This was the impetus for us to develop our innovative Additive Manufacturing Onsite Repair solution. And this is how we continue to meet ever higher requirements for precision and quality.“
Felix Vogt, Head of Technology Implementation
Creativity meets experience
To develop the Additive Manufacturing Onsite Repair solution, we combined the creativity of our engineers with our extensive onsite service expertise and in-depth knowledge of Additive Manufacturing.
The Non-destructive Testing Engineer
„Just like our customers, we make the highest demands on our work. For us, Non-destructive Testing is fundamental to the safe and reliable operation of a plant. This way, we ensure that all requirements are fully met.“
Jörg Friedrich, Non-destructive Testing Engineer
Reliable with safety
Non-destructive Testing plays a crucial role in helping to confirm plant integrity. It is based on a wealth of data and knowledge that we have accumulated over many years and ensures that we can accurately determine the condition of components.
The On-Site Machining Engineer
„Our onsite repair capabilities are based on a century of experience in manufacturing reliable plant components and the necessary repair tools. Today, this experience enables us to perform an advanced repair process that combines in-depth expertise with cutting-edge technology.“
Alexander Braun, On-Site Machining Engineer
In any environmental conditions
Performing demanding repairs onsite is a special challenge. Based on our extensive experience, we can perform an Additive Manufacturing Onsite Repair in a wide range of environmental conditions.
The Welding Engineer
„What particularly fascinates me about Additive Manufacturing Onsite Repair is that we have virtually reinvented an age-old repair method. Thanks to the use of advanced industrial robots and laser technology, we achieve fascinating precision without the disadvantages of heat-induced distortion or damage.“
Luk Mühlstein, Welding Engineer – Welding Technologies
Precisely to the point
Since laser metal deposition is designed to allow the amount of energy to be precisely metered and applied to precisely defined areas of the substrate, only a small amount of heat is generated. This is designed to allow components to be refurbished without altering them.
Onsite Journal Repair helps enable the rectification of scoring marks or damages without a journal exchange. The repair is intended to restore the original journal diameters to promote optimal operation. For a successful repair, it’s crucial to precisely meet the tolerances for diameters, all other geometric dimensions and all welding requirements for surface and material quality. Structural properties, such as hardness, are retained. The Additive Manufacturing Onsite Repair technology is tailored to meet these demands and can help save the customer both time and money.
The individual components of rotating equipment are crucial for their reliable and efficient operation. Onsite Component Repair is an excellent solution to refurbish critical components, like gas turbine parts, that are designed to ensure the correct flow of air streams. Wear on these components can affect the safety and efficiency of operation since misdirected cooling air can cause inadequate cooling of the rotating blades and a loss of power. Onsite Component Repair is intended to save the exchange of the component and a significant amount of crucial uptime. Our team of service specialists addresses the entire process, from disassemble to assemble and recommissioning.
Faster and more cost effective:
- Use of mobile additive manufacturing systems is intended to enable the optimization of mechanical properties of weld material in relation to base material, and is expected to offer better resistance against wear (depending on the processes and additives used)
- Total duration of entire process expected to be within the outage schedule
- Total repair costs are estimated to be beneficial compared to a replacement
Onsite Rotor Refurbishment is considered the ideal solution when a rectification is to be carried out without exchanging the entire rotor. For gas turbine, steam turbine, or generator rotors, the original diameters can potentially be restored. The exact tolerances for diameter and all other geometric dimensions are met and all welding requirements for surface and material quality may be fulfilled. In addition, structural properties, such as hardness, are retained. Customers thus intended to save valuable time and money. Our team of service specialists addresses the entire process, from disassemble to assemble and recommissioning.
A broad service portfolio for all requirementsThe service needs of our customers are just as varied as the plants themselves. Additive Manufacturing Onsite Repair complements our existing service portfolios, with which we offer closely interlinked service solutions for all requirements.
Our goal is to provide the best possible, most efficient and uncomplicated service to our cutomers worldwide in order to constantly reduce limitations such as downtime or other inconveniences to an absolute minimum.
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