Long-Term Lifetime Validation of Hot Turbine Guide Vanes Manufactured by Laser Powder Bed Fusion

Abstract The advent of additive manufacturing (AM), specifically laser powder bed fusion (LPBF), has revolutionized the production of gas turbine components. This paper presents a comprehensive study on the application of LPBF in serial production of turbine guide vanes (GVs), which are critical for the efficient performance of gas turbines. The guide vanes manufactured using LPBF have been subjected to rigorous verification and validation in commercial engine conditions, spanning operational intervals of 27,000–30,000 h, to assess their performance and durability. An in-depth analysis of the condition of these parts postoperation is conducted to compare their actual performance against the expected outcomes, particularly in areas known for stress concentration. Furthermore, the paper evaluates the condition of the printed cooling channels after extended use. Another aspect covered in the paper is the behavior of the printed components under local overheating conditions, which can occur due to various operational anomalies. Understanding how these components react to such extreme conditions is crucial for ensuring their reliability and safety in the field. The findings presented in this paper highlight the robustness of LPBF-manufactured gas turbine guide vanes, showcasing their capability to withstand both design and off-design operational conditions. The accumulation of operational experience with these components is a significant step toward the widespread adoption of additive manufacturing technologies in the production of gas turbine parts.