Customer background and needs
Our client is a power company based in Singapore that operates a large gas-fired power station. These power stations use gas turbines manufactured by internationally renowned brands, but during long-term operation, the turbine segment components have suffered serious wear and performance degradation. The original parts are not only expensive, but also the delivery cycle is as long as several months, which seriously affects the operational efficiency and cost control of the power station. As a result, customers urgently need an alternative that is both economical and efficient to ensure the stable operation of the power station.
Project initiation and analysis
Upon receiving the customer’s request, our technical team acted quickly to conduct a comprehensive reverse engineering analysis of a badly worn turbine section provided by the customer. We obtained detailed geometric data using a high-precision 3D scanner and determined the alloy composition and microstructure through material analysis. This process not only helped us to accurately understand the design characteristics of the original part, but also found the inadequacies in the design and material selection.
Optimized design and custom development
Based on the reverse engineering data, our design team set out to optimize the design of the turbine section. First, we simulated the gas flow using advanced CFD (Computational Fluid dynamics) software and optimized the blade shape to improve aerodynamic efficiency. Secondly, we adjusted the cooling channel layout to increase the cooling effect, thus extending the service life of the components. Finally, we chose a nickel-based super alloy that is more resistant to high temperature and corrosion, further improving the overall performance of the components.
Optimized design and custom development
Based on the reverse engineering data, our design team set out to optimize the design of the turbine section. First, we simulated the gas flow using advanced CFD (Computational Fluid dynamics) software and optimized the blade shape to improve aerodynamic efficiency. Secondly, we adjusted the cooling channel layout to increase the cooling effect, thus extending the service life of the components. Finally, we chose a nickel-based super alloy that is more resistant to high temperature and corrosion, further improving the overall performance of the components.
Directional solidification casting process
In order to achieve the above design goals, we used the Directional Solidification (DS) process. This process can precisely control the liquid flow and solidification process of the metal, forming a columnar crystal structure, significantly improving the mechanical properties and fatigue resistance of the material. To be specific:
1. Mold design: We have designed a special ceramic core and shell mold to ensure the accuracy of the internal structure of the casting.
2. Temperature control: Through the precision temperature control system, we achieve progressive solidification from the bottom to the top, avoiding common shrinkage holes and cracks.
3. Heat treatment: After the casting is completed, we carry out a strict heat treatment to further improve the mechanical properties of the material.
Delivery and verification
After several months of hard work, we successfully produced the first customized turbine segments and delivered them to the customer on time. After installation and commissioning, the new turbine segment performed well, not only meeting the expected performance indicators, but also surpassing the original parts in some aspects. Especially in long-run tests, the new parts demonstrated increased reliability and longer service life, significantly reducing maintenance costs and downtime for customers.
Customer feedback and cooperation prospects
The customer spoke highly of this collaboration, believing that our customized solution not only solved their immediate needs, but also brought long-term cost savings and technical advantages. They particularly appreciate our expertise in design optimization, material selection and manufacturing processes. Based on this successful collaboration, the client has decided to establish a long-term partnership with us and plans to further cooperate on more projects in the future.
Conclusion
Through this real case, we can see that with strong reverse development capabilities and customization experience, we are able to provide customers with high-quality, high-performance gas turbine parts solutions. Whether faced with complex engineering challenges or tight time requirements, we are able to meet the challenges and provide satisfactory answers to our customers. In the future, we will continue to focus on technological innovation and service improvement to help customers around the world achieve more efficient and reliable energy production.
If you are interested in our directional casting turbine parts technology, or want to learn more about how this advanced process can improve the performance and efficiency of your gas turbine, please feel free to contact us. We are committed to providing high quality gas turbine fitting solutions to our customers worldwide and have the experience and expertise to meet your specific needs.
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- E-mail：peter@turbineblade.net