From Powder to Power: Advancing Gas Turbines with 3D Printing

Additive manufacturing (AM) is transforming the landscape of industrial gas turbine (IGT) technology, offering unprecedented opportunities for innovation in performance, durability, and efficiency. This presentation focuses on PSM’s advancements in additive manufacturing, particularly the design, validation, and full-interval inspection of the GTOP7 R1 vane components. These components leverage cutting-edge AM processes to enhance thermal and mechanical performance while reducing manufacturing complexities.

Laser Powder Bed Fusion (LPBF) enables the creation of highly intricate cooling designs, enhancing the performance of R1V turbine components by improving thermal efficiency and supporting higher rotor inlet temperatures. These advancements have demonstrated their ability to increase power output and efficiency. Field validation has confirmed their success, with multiple installations and over 25,000 hours of operation achieved by the fleet-leading unit.

Looking ahead, PSM aims to expand the application of AM technologies across multiple IGT frames, incorporating advanced alloys, larger build volumes, and improved laser processing techniques. These innovations not only enhance the scalability of AM but also enable the development of next-generation combustor designs for improved fuel flexibility and reduced emissions.

This presentation provides a comprehensive overview of PSM's journey from material development to commercial validation, showcasing the transformative potential of additive manufacturing in the energy sector. Attendees will gain insights into how AM is reshaping turbine component design and contributing to cleaner, more efficient energy solutions for the future.