EUROTURBINE

The Company is an independent,

engineering and service provider for the
Gas & Steam turbine industry
worldwide
Turbine parts
design
Gas turbine New Parts
GE Nozzles and labyrinths
Investment Casting
The Lost Wax Investment Casting Process

FPI
X-Ray

14
 Casting Capabilities

Production of cast blades

Production of cast vanes

Air cast capability

Vacuum cast capabilities

Engineering capabilities
WAX PATTERN
Casting tooling
BLADE CERAMIC CORE
GE MS9001E stage 1 blade
 Inspection and production

Core and wax production / Shelled waxes

inspection and dipping

Cut-out of ABB 1st

Cut-
stage blade
• Individual wax patterns
are welded onto sprue
system to form the
cluster

• The cluster is designed

to optimise the flow of
the molten metal and
the cooling required to
obtain a good casting
GE MS9001E stage 1 blade
GE MS9001E stage 2 vane
The ceramic mold is
created by dipping
or investing the
cluster in the
ceramic slurry
followed by coating
it with refractory
sands
PREFIRING OF THE CERAMIC MOLD BEFORE POURING
 Pouring Weight = 40kg (88lb) to 90kg (198lb)

Turbine Casting 28
Proprietary
GE MS9001E stage 1 vane
 EQ Vacuum Casting Furnace
CAPACITY : Pouring Weight = 35kg to 180kg Size = Ø900 x 1000mm

30
The final cast structure
depends upon a variety of
factor as e.g.the cross-
section size of the part,the
gating system,the pouring
temperature,the mould
temperature and ,mainly,
the thermal insulation used
to control the cooling
rate.The desired structural
and mechanical properties
of the casting are achieved
by optimising all these
factors
Post Casting H.I.P.
Treatment

The desired
metallurgical and
mechanical properties
can be obtained by
subjecting the parts to
suitable heat treatment
after casting
Dimensional
inspection in
production

Gages
Several casted blades and vanes from GE 6001, 9001,
ABB and Westinghouse/MHI
Turbine Parts Machining
 Machining Capabilities

Non conventional machining such as

Electro-Discharge Machining (EDM)
Stem-Drilling
Creep feed grinding

Precision machining such as

5 axis milling
5 axis fast drilling
Turning , and Grinding

Welding and Joining such as

TIG welding

Inspections processes such as

Fluorescent Penetrant Inspection, FPI
3-D and CMM measurements.
Flow test , Moment weight etc
 EDM Stem drilling Creep feed grinding

15 machines ONA and Agie Used for very precise root area
Max. tank size: 250 x 150 x 80 cm grinding for turbine blades
Machining space 160x50x65 cm
Deep hole drilling
technique using
electricity and acids
 ECD
Holes up to 0,5 mm Ø and
400 mm long inside Buckets.
Turbulated Holes
4 units currently +6 other
machines function of the
market.
We can go even in a higher
position inside our building
up to 20 machines if
requested.
 ECD

Blade tooling

Turbulated Cooling Holes

ECD
 Creep
Feed
Grinding
GRINDING
 5-axis milling 5-axis fast drilling TIG Welding

Tungsten inert gas

low heat input
local melting
CNC milling of super-
super-alloys high quality
no oxidation
blades, vanes
sub--assemblies for TP
sub
other gas turbine components

MAKINO EBV86
conditioned set-up
stroke: 80 x 60 x 50 cm
part size: 140x98x57 cm
part weight: 100 kg
FPI inspection CMM inspection Projection
Projector inspection for root
grinding
Using Fluorescent
inspection techniques
under UV-light to
detect cracks and
other faults

Other available
techniques:
air-flow, moment weight,
Full 3-D measuring ultra-sonic and ferric
facility in controlled etching
environment
GE MS9001E Components
Machining Tooling
Turbine stator components
GE MS9001E 1st, 2nd and 3rd stage shroud blocks
 Turbine Detailed parts
Through laser cutting, press forming, welding,
assembly, CNC machining, coating etc. many
different sub-assemblies and finished parts are
manufactured
Examples

• Installation harware
• Compressor & Steam turbine blades
• Combustion liners, Transition pieces and Bull horns
• Fuel nozzles, Swirlers, Cross fire tubes
• Brackets
• Very large silo type Combustors and Casings
Compressor blades
GE MS5001, 6001, 7001, 9001 IGV’s
• GE MS9001FA combustion hardware
GE FR 9 EA 3rd stage vane locking hardware
Combustor and
Casing
Fabrication
 Fuel Nozzle assembly
Bracket transition piece in fixture

Transition Piece and Combustion Liner

Assembly hardware
Combustor components
Siemens V93.1 casing
Siemens V94.2 Inner casing
Siemens V94.2 Combustor System
Coating Services
Powders Plasma HVOF

Wire Powder
Electric Arc Combustion Combustion
Wires
Technical Features of Thermal Spray
iLow temperature processing

i Low to high temperature service

i Relatively thin to very thick

coatings possible

i Good adhesion to substrate

i Coarse to smooth finish –

post machining possible

i Components can often be recoated –

provides additional service life

i Independent of component shape and

size

i Both external and internal surfaces

 Coating Purposes

• Metallic : Oxidation resistant

• Metallic : Type I Hot Corrosion resistant
• Metallic : Type II Hot Corrosion resistant
• Metallic : Bondcoating for TBC
• Ceramic : Insulating TBC (thermal barrier coating)
• Carbides : Fretting resistant
 Coating Application Technology
• Metallic : Galvanic Deposition
• Metallic : CVD (diffusion)
• Metallic : Pack Cementation (diffusion)
• Metallic : VPS / Low Pressure Plasma Spraying
• Metallic : Plasma Spraying
• Ceramic : Plasma Spraying
• Ceramic : Electron Beam Physical Vapour
• Carbides : Plasma Spraying
 Thank You

for your attention