Additive manufacturing system provider EOS has expanded its metals range of with the introduction of the EOS NickelAlloy HX. The heat and corrosion resistant nickel-chrome-iron-molybdenum alloy has high strength and resistance to oxidisation, even at elevated temperatures up to 1200°C.

The material is optimised for use in the company’s EOSINT M 280 system and is typically processed with a layer thickness of 20µm. Application areas include aerospace, heating elements in conveyor ovens, and industrial blast furnaces.

Andreas Graichen, Product Developer (Gas Turbines) at Siemens Energy stated, “We use EOS’ additive manufacturing process for constructing prototypes, rapid manufacturing and rapid repair. Thanks to this technology, we are able to cut repair times and reduce costs for customers that commission us to repair industrial gas turbines.”

A Siemens technician removes a gas turbine burner

that has been repaired using the EOSINT M 280

system

The material’s properties make it ideally suited to repair, as it is able to withstand the high temperatures to which gas turbines are constantly exposed. “For gas turbine burner repair, for example, instead of cutting away and discarding a large part of the burner head, we leave the structure intact, remove the top 20 mm or so, and then simply print a new combustion head. The process delivers significant savings both in terms of repair times and costs,” added Graichen.

A video describing AM repair at Siemens Energy can be viewed at: http://www.youtube.com/watch?v=zG_yZmwPhIU

Parts built from EOS NickelAlloy HX can be subsequently heat-treated to modify the characteristics of the material. Whether hardened or as originally built, parts can be finished as required and surplus unexposed material can be re used.