27/08/2020

A 3D printer that prints metal. Metal is sintered into shape under the influence of a laser.

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.

MRO Indoor Panorama

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

Logo of the Werner-von-Siemens Centre for Industry and Science

Source: WvSC

Logo

Logo des EU European Regional Development Fund

Source: EU