The Styrian specialist manufactures complex components for stationary gas turbines in the USA. During the first phase of the project, around 168 of the turbine blades designed for maximum load will be manufactured by this autumn. In the long term, more than 2,500 components will be shipped from the headquarters in Ilz to Texas by 2031. Production has already begun.
Thanks to the multi-billion-dollar economic stimulus package known as the ‘Inflation Reduction Act’ (IRA), the expansion of renewable energy in the US has gained significant momentum. The sector expects annual growth of 14 per cent up to 2028. Last year alone, solar power systems with a capacity of 33 gigawatts were installed in the US. Paradoxically, it is the expansion of renewable energy, of all things, that is leading to a boom in small, stationary, gas-fired power stations: converted, ageing aircraft engines, in particular, are set to stabilise the US electricity grid during periods of low generation. Modifying the turbines therefore requires extensive aeronautical expertise as well as a thorough understanding of the materials involved: these specific requirements led the US group, which was entrusted with the project, all the way to Ilz in Eastern Styria, to M&H.
A sum in the tens of millions
The Styrian 3D printing pioneer has established itself – despite high-calibre international competition – as a strategic partner in the transformation of gas turbines: During a pilot phase running until this autumn, 168 additively manufactured turbine blades – which are used in the exhaust system of the turbine unit – will be delivered to Texas via various other locations, primarily the Netherlands. If the project is successful, the framework agreement will be extended until 2031 to cover over 2,500 components. M&H also provides the relevant engineering services. “For our company, this long-term contract with our partner marks a real milestone. This collaboration not only highlights our expertise in the field of 3D metal printing, but also strengthens our position in the international market. This is made possible above all by our exceptional staff – every single one of them is making a significant contribution to what is, for us, a historic success,” says M&H Managing Director Patrick Herzig. The contract is worth a total of tens of millions, and the first components have already been delivered to the “full satisfaction of the customer”.
Expertise in working with complex materials
Specifically, M&H supplies complex, hollow structural components made from the heat-resistant material Inconel 718. The nickel-chromium alloy not only makes machining complex, but also requires a process known as ‘pre-deforming’: ‘During the manufacturing process, materials such as Inconel 718 can be deformed by heat or mechanical forces. This technique pre-shapes the material so that it retains the correct shape and size after the machining steps,’ explains Herzig. Decision-makers attribute the fact that a 3D printing specialist from Styria is being brought in for this major project in the US to the company’s extensive expertise in working with the alloy and its state-of-the-art machinery. “With the first prototypes we delivered, we were immediately able to demonstrate the quality of our products and surpass existing best-in-class performance in terms of precision and rigidity. This is also because, with our SLM800, we have one of the largest 3D metal printers in Austria,” says Jochen Wagner, Sales Manager at M&H.
“We are on track”
According to M&H Managing Director Herzig, the contract also includes extensive component testing. These include, for example, material analyses carried out after manufacture, chemical tests, tensile tests, density cube tests and crack tests. Herzig emphasises: “These tests are crucial to ensuring that all requirements, which are based on aviation industry standards, are met and that component quality remains high.” Here, they have also benefited from experience gained in other sectors – such as the quality-focused aviation industry, where such tests “are part of standard procedure”, says Herzig. Or from the world of motor racing, particularly Formula 1, where the Ilzer company is now on board as a partner to various teams. “We’ve got some real momentum at the moment, which is enabling us to weather the still challenging market conditions. We’re right on track,” said Herzig.