BAM and Werner-von-Siemens Center research highly efficient gas turbines

The Federal Institute for Materials Research and Testing (BAM) is intensifying its research on gas turbines at the Werner-von-Siemens Center for Industry and Science (WvSC). With the support of the State of Berlin and the European Union, research is being carried out with the aim of revolutionizing the maintenance, repair and development process of gas turbine blades through innovative additive manufacturing processes.

Gas turbines are a key component of modern power generation systems, and their efficiency and sustainability are crucial to reducing greenhouse gas emissions. Faced with the challenges of corrosion and increasingly extreme operating conditions, the research projects focus on the use of advanced additive manufacturing processes and digital technologies to increase productivity and performance in gas turbine construction.

A central aspect of the research is the MRO 2.0 project, which focuses on improving the repair process for turbine blades. Automated and digitalized processes, supported by AI algorithms, are intended to enable efficient and precise repairs. New inspection methods for assessing damage and the development of digital twins are further steps towards optimizing the process.

At the same time, the HTA 2.0 project is investigating sustainable additive manufacturing processes for high-temperature components. By using laser beam melting processes and developing strategies for material reuse, the project addresses economic and ecological challenges in gas turbine construction.

Ten partners, including Siemens Energy, several Fraunhofer Institutes and the Technical University of Berlin, are involved in the research. The projects not only offer the opportunity to improve the performance and sustainability of gas turbines, but also to further expand BAM’s expertise in the areas of material characterization, additive manufacturing processes and material behaviour at high temperatures.