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Metal-based additive manufacturing (AM) technologies such as selective laser melting (SLM) have seen successful applications in the gas turbine industry over the past years. The rapidly growing demand in AM requires in-depth knowledge of the process, materials and design for additive manufacturing (DFAM). However, the material characterization and process development are highly specific to a particular AM system, even for a number of standard alloys such as IN718 that are suitable for gas turbine applications. When the AM system changes or a new material becomes available, the whole development workflow needs to start almost “from scratch,” which consumes considerable time and effort. To address these issues, Siemens Power & Gas has established cross-divisional competence centers for AM to enhance collaborative material and process development. The article describes this framework and its effectiveness in streamlining the AM process and materials development. To close the design and manufacturing process chain, it is also critical to ensure that the full AM potential is accessible in design stages. In this article, a DFAM framework is proposed to drive the design paradigm shift to AM. In the framework, a complete DFAM process is defined based on existing studies of Siemens gas turbine applications. By integrating a set of DFAM methods, tools and considerations into the current gas turbine design processes, the AM-driven product design is enabled. We use Siemens large gas turbine applications to demonstrate the development and industrialization of AM using the frameworks. The benefits in reducing cost, expediting time to market, improving component performance and enabling new design freedom will be highlighted.

Modelling combustor turbine interaction is to be performed in an integrated simulation of a combustion chamber and the nozzle guide vane of a jet engine. Starting with an incompressible pressure based combustion CFD code, two steps are required to obtain a code that is suitable for performing such calculations. Firstly, the SIMPLE algorithm needs to be extended to all-Mach-number flows. Secondly the solution algorithm needs to be modified to deal with combustion. This paper presents the first of these steps. A solver has been developed which is capable of computing both incompressible and transonic flows. Validation of modelling compressible viscous flow is performed using experimental data. The suitability of the algorithm to highly complex geometry is demonstrated on real engine nozzle guide vane geometry and results are compared to the results of other solvers.