Project MRO 2.0 - Maintenance, Repair & Overhaul - phase 2

25/09/2023

• Challenge
• Objectives
• Methods
• Partners

Components in gas turbines, e.g., the turbine blades, are subject to constant wear due to corrosion and oxidation. They are regularly removed, repaired, and then operated again with the same running times or - after certain intervals - replaced altogether.

In the project, new dynamic process chains are being developed in which the value creation steps are specified through digitization. Each component is to pass through an individual repair chain. This development will be demonstrated using the example of gas turbine blades, which can be operated at higher temperatures or with longer operating intervals after repair.

The use of future technologies such as additive manufacturing processes and digital twins can result in product and process innovations that enable operating intervals to be extended. In addition, improved properties can contribute to greater efficiency and lower emissions.

Siemens Energy Global GmbH & Co. KG
Technische Universität Berlin
Fraunhofer Institute for Production Systems and Design Technology
KleRo GmbH Roboterautomation
GESTALT Robotics GmbH
YOUSE GmbH
Datalyze Solutions GmbH
SERVITIZE UG
CONTACT Software GmbH

Review: MRO 2.0 - Maintenance, Repair & Overhaul – phase 1

The "MRO 2.0 - Maintenance, Repair & Overhaul" project began in 2020. The first phase (01.07.2020 - 31.12.2022) focused on developing new technologies for maintenance and repair activities that simultaneously represent an upgrade, i.e. an improvement in the properties of the component. Improved properties in turn lead to higher efficiency and lower emissions.

The use of future technologies such as digital solutions or additive manufacturing processes can lead to product and process innovations that enable longer operating intervals. Within the framework of the Werner von Siemens Centre, components, systems and machines will no longer be repaired in the classic way, but will be equipped with better properties through new technologies during the repair process: Upgrade instead of Repair. Maintenance, Repair and Overhaul refers to the classic maintenance and repair business with which components, systems and machines are overhauled. Typically, this is done through static repair process chains in which the same value-adding steps are carried out continuously. After repair or maintenance, the plant and machinery continues to operate with identical characteristics.

BAM's contributions in phase 2

CAx chain for the repair of moving blades by wire arc process
Dr. Andreas Pittner, Welding Technology Division

Water vapor resistance of ceramic materials for combustion chambers
Artur Göbel, Materialography, Fractography and Ageing of Engineered Materials Division

Development of a quality tool for in-situ process monitoring of additive manufacturing in the powder bed processes
Dr.-Ing. Kai Hilgenberg, Additive Manufacturing of Metallic Components Division

Damage and measure prediction
Dr. Jürgen Olbricht, Experimental and Model Based Mechanical Behaviour of Materials Division

Determination of wall thickness of turbine blades
Dr.-Ing. Jens Prager, Acoustic and Electromagnetic Methods Division

Detection of cracks of turbine blades
Dr. Mathias Ziegler, Thermographic Methods Division

Project coordination

Dr.-Ing. Jens Prager, Bundesanstalt für Materialforschung und -prüfung (BAM)

Partners

Siemens Energy Global GmbH & Co. KG
Technische Universität Berlin
Fraunhofer Institute for Production Systems and Design Technology
KleRo GmbH Roboterautomation
GESTALT Robotics GmbH
YOUSE GmbH
Datalyze Solutions GmbH
SERVITIZE UG
CONTACT Software GmbH

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).