A 3D printer that prints metal. Metal is sintered into shape under the influence of a laser.
Source: iStock
Project period
01/07/2020 - 31/12/2022
Project type
Collaborative research project
Project status
Current
Description
The aim of the project MRO 2.0 - Maintenance, Repair & Overhaul is to develop new technologies for maintenance and repair activities which simultaneously mean an upgrade, i.e. an improvement in the properties of the component. Improved properties in turn lead to higher efficiency and lower emissions.
Location
Bundesanstalt für Materialforschung und -prüfung
Unter den Eichen 87
12205 Berlin
MRO 2.0 - Maintenance, Repair & Overhaul
Challenge
The use of future technologies such as digital solutions or additive manufacturing processes can lead to product and process innovations that enable the operating intervals to be extended. Within the Werner-von-Siemens Centre, components, plants and machines are no longer to be repaired in the classical way, but are to be equipped with better properties through new technologies during the repair: Upgrade instead of repair.
Methods
Maintenance, Repair and Overhaul refers to the classic maintenance and repair business used to repair components, plant and machinery. Typically, this is done through static repair process chains in which the same value-added steps are carried out continuously. After repair or maintenance, the systems and machines continue to operate with identical characteristics..
Objectives
In this project, new dynamic process chains are being developed in which the value-added steps are specified through digitisation. Each component should pass through an individual repair chain This development is to be demonstrated using the example of gas turbine blades, which can be operated at higher temperatures or longer operating intervals after repair.
In the newly built production hall of Siemens Energy, research will in future be conducted on repair and maintenance topics.
Source: Werner-von-Siemens Center
BAM's contributions
Repair of turbine blades using adaptive additive manufacturing
Division Welding Technology, Prof. Kai Hilgenberg
Damage analysis
BAM Division Experimental and Model Based Mechanical Behaviour of Materials, Dr. Jürgen Olbricht
Determination of wall thickness of turbine blades
BAM Division Acoustic and Electromagnetic Methods, Dr.-Ing. Jens Prager
Detection of cracks of turbine blades
BAM Division Thermographic Methods, Dr. Mathias Ziegler
Project coordination
Bundesanstalt für Materialforschung und -prüfung (BAM), Dr.-Ing. Jens Prager
Partners
Siemens AG
Siemens Energy
Fraunhofer-Gesellschaft, various institutes
TU Berlin, various institutes
more than 25 small and medium enterprises from Berlin and Brandenburg
Funding
The project is carried out within the Werner-von-Siemens Centre for Industry and Science. It is funded by the Investitionsbank Berlin (ProFIT) and co-financed by the European Regional Development Fund (ERDF).
Logo of the Werner-von-Siemens Centre for Industry and Science
Source: WvSC
Logo des EU European Regional Development Fund
Source: EU