GE Oil & Gas is bringing the future of automation to its Talamona, Italy plant with a EUR 10 million investment.
A new nozzle production line is the first to be completely automated for the company and a new additive manufacturing line will use laser technology to 3D print end burners for gas turbine combustion chambers.
The new nozzle line includes two anthropomorphic robots capable of employing 10 different technologies, including electrical discharge machining, measurement and laser beam welding.
The new technology will allow GE Oil & Gas to produce components formerly bought from outside suppliers.
After extensive validation of additive during prototyping of the NovaLT16 gas turbine, GE decided to move the technology into full production, leveraging the design enhancement capabilities, cycle time reduction and improved product quality.
Software schedules activities, but also supports predictive maintenance.
“The use of automated production and new techniques like additive manufacturing allow us to develop parts and products more efficiently, precisely and cost-effectively, accelerating the speed at which we can bring product to market," said Davide Marrani, general manager of manufacturing for business turbomachinery solutions at GE Oil & Gas.
"Our investment in these technologies at this site reflects our ongoing commitment to combine cutting edge technology and new manufacturing processes to lower cost and accelerate the innovation, speed and performance of industrial products," Marrani continued.
“Our commitment to ongoing research and innovation is key to meet our clients’ ever-changing needs.”
GE has made a serious effort to bring additive technology into mass production of mission an safety critical parts for gas turbine engines. GE R&D sites include Bangalore (India), Niskayuna (Japan), Michigan (United States), Shanghai (China) and Munich (Germany).
Applications include the use of cobalt-chromium alloys for jet engines that were originally used for joint replacements and dental implants.
GE Oil & Gas opened an additive lab in Florence, Italy in 2013 with the installation of the first Direct Metal Laser Melting (DMLM) machine. Since then, the Laboratory has grown its capabilities thanks to the addition of two further machines for the development of turbomachinery components and special alloys.
Collaborations with GE Aviation and GE Global Research Centre have significantly accelerated the development of the technology within GE.
“The opportunities for the application of additive manufacturing and 3D printing in the oil and gas industry are only just starting to be explored, and it will require an ongoing rethink of component design and production approach,” said Massimiliano Cecconi, GE Oil & Gas Materials & Manufacturing Technologies Executive.
“GE Oil & Gas is fostering the development of this technology to produce complex components for gas turbines, while cutting costs, boosting performance and reducing emissions.”
The new production lines are already working and will be fully operational by 1Q 2017.