Reheat Burner Front Panel Produced by Additive Manufacturing Challenges: Strategies and Engine Validation

2016 ◽  
Author(s):  
Michael Maurer ◽  
Patricia Sierra ◽  
Patrik Meng
Keyword(s):  
Additive Manufacturing ◽  
Selection Process ◽  
Point Of View ◽  
Metal Sheet ◽  
Front Panel ◽  
General Idea ◽  
Heavy Duty ◽  
Acoustic Damping ◽  
Precision Casting ◽  
Hot Gas

Additive manufacturing radically changes the design process giving unprecedented freedom of design and enabling a step change in part performance. The general idea of selecting appropriate candidates within the Alstom hot gas parts portfolio is described in this paper. The strategy as used in the selection process is to identify parts with either a high (internal) complexity or to choose parts with a high number of sub-parts and the necessary high number of assembly steps, which are needed with the current manufacturing methods (e.g. precision casting or weld assemblies). The current reheat burner front panel of the heavy duty gas turbine is today produced from three metal layers. The layer facing the hot gas contains the complex near-wall cooling channel system. The metal sheet facing the cold side features the acoustic damping volumes. An intermediate metal sheet separated the two systems. Brazing is used to assemble the sup parts into the final front panel. With the identified strategy to use additive manufacturing, the design is adapted to allow the production of a single component that includes all the functionality and avoids heavy machining and assembly steps. The paper focuses on the design changes and challenges that were required and observed during the adaption of the GT26 (Rating 2011 onwards) reheat burner front panel. Also the necessary adaptions of the qualification process and the lifetime assessments are described in detail. Finally, the additive manufacturing version of the reheat burner front panel was subjected to a heavy duty test program. Engine tests were completed. The disassembled SLM component was found in excellent condition. Subsequent material investigations have confirmed the good part condition from a metallurgical point of view.

Additive Manufacturing of Hot Gas Path Parts and Engine Validation in a Heavy Duty GT

2016 ◽  
Author(s):  
Julius Schurb ◽  
Matthias Hoebel ◽  
Hartmut Haehnle ◽  
Harald Kissel ◽  
Laura Bogdanic ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
High Performance ◽  
Turbine Blades ◽  
Combustion Process ◽  
Heavy Duty ◽  
Hot Gas ◽  
Process Chains ◽  
Manufacturing Technologies ◽  
Cooling Air

Additive manufacturing and in particular Selective Laser Melting (SLM) are manufacturing technologies that can become a game changer for the production of future high performance hot gas path parts. SLM radically changes the design process giving unprecedented freedom of design and enabling a step change in part performance. Benefits are manifold, such as reduced cooling air consumption through more efficient cooling schemes, reduced emissions through better mixing in the combustion process and reduced cost through integrated part design. GE is already making use of SLM for its gas turbine components based on sound experience for new part production and reconditioning. The paper focuses on: a) Generic advantages of rapid manufacturing and design considerations for hot gas path parts b) Qualification of processes and additive manufacturing of engine ready parts c) SLM material considerations and properties validation d) Installation and validation in a heavy duty GT Additive Manufacturing (AM) of hot gas path components differs significantly from known process chains. All elements of this novel manufacturing route had to be established and validated. This starts with the selection of the powder alloy used for the SLM production and the determination of essential static and cyclic material properties. SLM specific design features and built-in functionality allow to simplify part assembly and to shortcut manufacturing steps. In addition, the post-SLM machining steps for engine ready parts will be described. As SLM is a novel manufacturing route, complementary quality tools are required to ensure part integrity. Powerful nondestructive methods, like 3D scanning and X-ray computer tomography have been used for that purpose. GE’s engine validation of SLM made parts in a heavy duty GT was done with selected hot gas path components in a rainbow arrangement including turbine blades with SLM tip caps. Although SLM has major differences to conventional manufacturing the various challenges from design to engine ready parts have been successfully mastered. This has been confirmed after the completion of the test campaign in 2015. All disassembled SLM components were found in excellent condition. Subsequent assessments of the SLM parts including metallurgical investigations have confirmed the good part condition.

Determination of a Rubber-Like Material Model as an Inverse Problem

2011 ◽  
Vol 70 ◽  
pp. 225-230 ◽  
Author(s):  
Agnieszka Derewonko ◽  
Andrzej Kiczko
Keyword(s):  
Selection Process ◽  
Axial Stress ◽  
Constitutive Models ◽  
Material Model ◽  
Polyester Fabric ◽  
Point Of View ◽  
Air Cushion ◽  
Ill Conditioning ◽  
Stress States

The purpose of this paper is to describe the selection process of a rubber-like material model useful for simulation behaviour of an inflatable air cushion under multi-axial stress states. The air cushion is a part of a single segment of a pontoon bridge. The air cushion is constructed of a polyester fabric reinforced membrane such as Hypalon®. From a numerical point of view such a composite type poses a challenge since numerical ill-conditioning can occur due to stiffness differences between rubber and fabric. Due to the analysis of the large deformation dynamic response of the structure, the LS-Dyna code is used. Since LS-Dyna contains more than two-hundred constitutive models the inverse method is used to determine parameters characterizing the material on the base of results of the experimental test.

Build Time Analysis of Additive Manufacturing for Next Generation SLS Systems

2020 ◽  
Author(s):  
Michael Machado ◽  
Raul Fangueiro ◽  
Daniel Barros ◽  
Luís Nobre ◽  
João Bessa ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Selective Laser Sintering ◽  
Material Point ◽  
Point Of View ◽  
Efficient Production ◽  
Robust Solution ◽  
Functional Product ◽  
Build Time ◽  
Consistent Solution ◽  
Production Solutions

Abstract With the recent advances in the additive manufacturing (AM) production technologies, AM is becoming more common in today’s industry, nowadays is a normal practice to use this solution either to test a new prototype or to manufacture a functional product. The increase application is mainly due to significant developments in the production solutions of the AM. These recent developments are resulting in an increase search for new and more efficient production solutions. This search is always focused in producing more efficiently, with a greater variety of materials and produce part with better quality and proprieties. From an industrial point of view, one of the types of additive manufacturing that is increasing the percentage of use is the selective laser sintering (SLS) technologies. Although this process was first used in the mid-80’s, it has shown great developments in the recent years. This evolution of the process allowed it to become a solid solution even if it is highly time consuming, especially when compared with other types of addictive manufacturing. From the several aspects that make the SLS a robust solution is the fact that it offers a consistent solution to produce high complex part with good mechanical properties, and also the ability to use many core materials, from polymers, metal alloy, ceramics or even composites materials. Due to the fact that the production of part using SLS technologies takes a long time, shows the relevance to study the entire process in order to quantify the time spent in each stage a very important step. This study can be conducted with two major goals, in one hand to be able to predict the build time needed to complete a predetermined task, and in other hand, to improve the overall efficiency of the process based on the knowledge acquired in the previous analysis. These two aspects are important because they allow the machine operator to choose the production plan more carefully and also to know all the parameters of the process to make it more efficient. In this paper will be presented a survey of the major stages of a SLS process in order to quantify the time consumed in each one of the stages, and if possible, determine solution to reduce the time spent. To better understand the topic the paper will be divided according to the proprieties and time consumed in each of the elements of the process. In other words, it will be divided accordingly to a machine, laser and material point of view. Furthermore, this paper will be focused in the SLS process and the productions based in a polymeric powder, therefore also containing aspects related to the power source used.

scholarly journals Use And Comparison of Topis And Electre Methods In Personnel Selection

2018 ◽  
Vol 22 ◽  
pp. 01021 ◽  
Author(s):  
Bilgin Şenel ◽  
Mine Şenel ◽  
Gizem Aydemir
Keyword(s):  
Personnel Selection ◽  
Selection Process ◽  
Minimum Cost ◽  
Point Of View ◽  
Blue Collar Worker ◽  
Automotive Company ◽  
Worker Selection ◽  
Electre Method ◽  
The Right ◽  
Short Time

One of the most important function of human resources is personnel selection process. This process should be done professionally, in a short time and with minimum cost. After personnel selection process, performance of the hired person is very important for the permanence and success of the company. From this point of view, the aim of this study is to select a personnel among the candidates efficiently, with minimum cost and within a short time in one of the leading companies of Turkey in automotive sector. In order to select the right personnel all criterias which has great impact on blue collar worker selection was decided and these criterias are weighted. From the candidate pool of automotive company, appropriate candidates were selected by using TOPSIS AND ELECTRE method which are multi-criteria decision making methods

scholarly journals Belt and Road Initiative: Interim Results and Challenges During Pandemic

2021 ◽  
Vol 65 (3) ◽  
pp. 42-51
Author(s):  
N. Pyzhikov ◽  
E. Gushchin
Keyword(s):  
Selection Process ◽  
Foreign Debt ◽  
Cost Effective ◽  
Point Of View ◽  
Current Status ◽  
Belt And Road Initiative ◽  
Middle Income ◽  
Chinese Investment ◽  
The World ◽  
Belt And Road

The article analyses the current status of the Belt and Road Initiative (BRI), its key achievements and challenges, including those related to the COVID 19 pandemic. In the 2010s China has become one of world’s largest investors and BRI is one of the most important tools of Chinese investment policy. Due to its flexible structure, BRI has been able to adjust and develop in the context of the U.S. – China trade war and the growing anti-Chinese sentiment in the world that included the concerns over so called China’s debt diplomacy. But this lack of rigidity is also a challenge to those who study BRI because there is no official list of projects (estimations vary between 118 and 374) and countries participating in BRI (up to 138). China’s key BRI partner is Pakistan. The total value of projects implemented by China in Pakistan as part of the China-Pakistan Economic Corridor was initially estimated at $46 billion but now exceeds $70 billion (new projects were signed even during the pandemic). BRI is increasing the number of its participants. In March 2019 Italy became the first G7 country to sign a BRI MoU with China. While implementing BRI China has faced such challenges as rising concerns of “China’s debt trap”, as well as ecological and political issues. In 2020 BRI is facing a new challenge with the COVID-19 pandemic. Some BRI projects were postponed because of the pandemic, but in some cases they were unaffected. There are 64 out of 138 countries participating in BRI that come from low and lower-middle income groups according to the World Bank classification. Their average ratio of foreign debt to GDP was 54% in 2018–2019. It is most likely that these countries will be hit hard by the coronacrisis. Thus the pandemic will encourage China to tighten the selection process for BRI projects with a focus on the most strategically important and cost effective ones. From the point of view of China’s BRI partners, the effect can be two-fold: the most unstable economies will increase their dependence on China, while with the economically strong countries China will be more willing to make concessions and offer more favorable conditions for cooperation.

Favoring Complexity: A Mixed Methods Exploration of Factors That Influence Concept Selection When Designing for Additive Manufacturing

2021 ◽  
Vol 143 (10) ◽  
Author(s):  
Rohan Prabhu ◽  
Rainmar L. Leguarda ◽  
Scarlett R. Miller ◽  
Timothy W. Simpson ◽  
Nicholas A. Meisel
Keyword(s):  
Additive Manufacturing ◽  
Selection Process ◽  
Solution Space ◽  
Idea Generation ◽  
Concept Selection ◽  
Stage Design ◽  
Four Dimensions ◽  
Build Time ◽  
Traditional Manufacturing ◽  
Selection Stage

Abstract The capabilities of additive manufacturing (AM) open up designers’ solution space and enable them to build designs previously impossible through traditional manufacturing (TM). To leverage this design freedom, designers must emphasize opportunistic design for AM (DfAM), i.e., design techniques that leverage AM capabilities. Additionally, designers must also emphasize restrictive DfAM, i.e., design considerations that account for AM limitations, to ensure that their designs can be successfully built. Therefore, designers must adopt a “dual” design mindset—emphasizing both, opportunistic and restrictive DfAM—when designing for AM. However, to leverage AM capabilities, designers must not only generate creative ideas for AM but also select these creative ideas during the concept selection stage. Design educators must specifically emphasize selecting creative ideas in DfAM, as ideas perceived as infeasible through the traditional design for manufacturing lens may now be feasible with AM. This emphasis could prevent creative but feasible ideas from being discarded due to their perceived infeasibility. While several studies have discussed the role of DfAM in encouraging creative idea generation, there is a need to investigate concept selection in DfAM. In this paper, we investigated the effects of four variations in DfAM education: (1) restrictive, (2) opportunistic, (3) restrictive followed by opportunistic (R-O), and (4) opportunistic followed by restrictive (O-R), on students’ concept selection process. We compared the creativity of the concepts generated by students to the creativity of the concepts they selected. The creativity of designs was measured on four dimensions: (1) uniqueness, (2) usefulness, (3) technical goodness, and (4) overall creativity. We also performed qualitative analyses to gain insight into the rationale provided by students when making their design decisions. From the results, we see that only teams from the restrictive and dual O-R groups selected ideas of higher uniqueness and overall creativity. In contrast, teams from the dual R-O DfAM group selected ideas of lower uniqueness compared with the mean uniqueness of ideas generated. Finally, we see that students trained in opportunistic DfAM emphasized minimizing build material the most, whereas those trained only in restrictive DfAM emphasized minimizing build time. These results highlight the need for DfAM education to encourage AM designers to not just generate creative ideas but also have the courage to select them for the next stage of design.

A Study of the State of the Art in Synthetic Emotional Intelligence in Affective Computing

2020 ◽  
pp. 1199-1212
Author(s):  
Syeda Erfana Zohora ◽  
A. M. Khan ◽  
Arvind K. Srivastava ◽  
Nhu Gia Nguyen ◽  
Nilanjan Dey
Keyword(s):  
Emotional Intelligence ◽  
Affective Computing ◽  
Ethical Issues ◽  
State Of The Art ◽  
Real Life ◽  
Life Time ◽  
The State ◽  
Point Of View ◽  
General Idea ◽  
Tremendous Amount

In the last few decades there has been a tremendous amount of research on synthetic emotional intelligence related to affective computing that has significantly advanced from the technological point of view that refers to academic studies, systematic learning and developing knowledge and affective technology to a extensive area of real life time systems coupled with their applications. The objective of this paper is to present a general idea on the area of emotional intelligence in affective computing. The overview of the state of the art in emotional intelligence comprises of basic definitions and terminology, a study of current technological scenario. The paper also proposes research activities with a detailed study of ethical issues, challenges with importance on affective computing. Lastly, we present a broad area of applications such as interactive learning emotional systems, modeling emotional agents with an intention of employing these agents in human computer interactions as well as in education.

Performance of Public Film Cooling Geometries Produced Through Additive Manufacturing

2020 ◽  
Vol 142 (5) ◽  
Author(s):  
Jacob C. Snyder ◽  
Karen A. Thole
Keyword(s):  
Additive Manufacturing ◽  
Film Cooling ◽  
Gas Turbines ◽  
Nickel Alloys ◽  
Cooling Effectiveness ◽  
Powder Bed ◽  
The Public ◽  
Hot Gas ◽  
Cooling Hole ◽  
Cooling Technology

Abstract Film cooling is an essential cooling technology to allow modern gas turbines to operate at high temperatures. For years, researchers in this community have worked to improve the effectiveness of film cooling configurations by maximizing the coolant coverage and minimizing the heat flux from the hot gas into the part. Working toward this goal has generated many promising film cooling concepts with unique shapes and configurations. However, until recently, many of these designs were challenging to manufacture in actual turbine hardware due to limitations with legacy manufacturing methods. Now, with the advances in additive manufacturing, it is possible to create turbine parts using high-temperature nickel alloys that feature detailed and unique geometry features. Armed with this new manufacturing power, this study aims to build and test the promising designs from the public literature that were previously difficult or impossible to implement. In this study, different cooling hole designs were manufactured in test coupons using a laser powder bed fusion process. Each nickel alloy coupon featured a single row of engine scale cooling holes, fed by a microchannel. To evaluate performance, the overall cooling effectiveness of each coupon was measured using a matched Biot test at engine relevant conditions. The results showed that certain hole shapes are better suited for additive manufacturing than others and that the manufacturing process can cause significant deviations from the performance reported in the literature.

Favoring Complexity: A Mixed Methods Exploration of Factors That Influence Concept Selection in Design for Additive Manufacturing

2020 ◽  
Author(s):  
Rohan Prabhu ◽  
Rainmar L. Leguarda ◽  
Scarlett R. Miller ◽  
Timothy W. Simpson ◽  
Nicholas A. Meisel
Keyword(s):  
Additive Manufacturing ◽  
Selection Process ◽  
Solution Space ◽  
Idea Generation ◽  
Concept Selection ◽  
Educational Groups ◽  
Early Design Stages ◽  
Traditional Manufacturing ◽  
Design For Am

Abstract The capabilities of additive manufacturing (AM) open up designers’ solution space and enable them to build designs previously impossible through traditional manufacturing. To leverage AM, designers must not only generate creative ideas, but also propagate these ideas without discarding them in the early design stages. This emphasis on selecting creative ideas is particularly important in design for AM (DfAM), as ideas perceived as infeasible through the traditional design for manufacturing lens could now be feasible with AM. Several studies have discussed the role of DfAM in encouraging creative idea generation; however, there is a need to understand concept selection in DfAM. In this paper, we investigated the effect of two variations in DfAM education: 1) restrictive DfAM and 2) dual DfAM (opportunistic and restrictive) on students’ concept selection process. Specifically, we compared the creativity of the concepts generated by the students to the creativity of the concepts selected by them. Further, we performed qualitative analyses to explore the rationale provided by the students in making these design decisions. From the results, we see that teams from both educational groups select ideas of greater usefulness; however, only teams from the restrictive DfAM group select ideas of higher uniqueness and overall creativity. Further, we see that introducing students to opportunistic DfAM increases their emphasis on the complexity of designs when evaluating and selecting them. These results highlight the need for DfAM education to encourage AM designers to not just generate but also select creative ideas.

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