Recovery of Hydro Turbines: From Welding to Additive Manufacturing

Abstract:

This work describes the advances in manufacturing for the recovery of hydraulic turbines. One of the key components in the operation of hydraulic turbines is the blades; as they are part of the impeller, they are in constant motion and directly receive all the loads produced by the impact of the water and the abrasive effects caused by sediment. The interaction between abrasion, cavitation, and corrosion accelerates the wear of these components, so it is necessary to apply coatings to prolong their useful life. When these elements lose their hydrodynamic profile, they must be submitted to a recovery process; typically, welding is used. However, due to the advancement of additive manufacturing (AM) and the development of new materials, AM appears as a disruptive technology capable of recovering the dynamic profile and improving surface properties such as hardness and wear resistance. The results show the effectiveness of the wire and arc additive manufacturing technology for the recovery of hydraulic turbines, increasing surface hardness from 285 to 325 HB.

• Periodical: Solid State Phenomena (Volume 338)
• Pages: 55-62
• DOI: https://doi.org/10.4028/p-lx8uye
• Online since: October 2022
• Authors: Germán Omar Barrionuevo*, Marcelo Toapanta, José Luis Mullo, Lorena Camacho-Játiva
• Keywords: Additive Manufacturing, Coating, Hydro Turbines, Recovery, Stainless Steel, Welding

References

[1] L. A. Teran et al., Analysis of economic impact from erosive wear by hard particles in a run-of-the-river hydroelectric plant,, Energy, vol. 113, p.1188–1201, (2016).

DOI: 10.1016/j.energy.2016.07.072

[2] L. A. Teran et al., Failure analysis of a run-of-the-river hydroelectric power plant,, Eng. Fail. Anal., vol. 68, no. December 2014, p.87–100, (2016).

[3] P. P. Gohil and R. P. Saini, Coalesced effect of cavitation and silt erosion in hydro turbines - A review,, Renew. Sustain. Energy Rev., vol. 33, p.280–289, (2014).

DOI: 10.1016/j.rser.2014.01.075

[4] R. kumar and S. K. Singal, Operation and Maintenance Problems in Hydro Turbine Material in Small Hydro Power Plant,, Mater. Today Proc., vol. 2, no. 4–5, p.2323–2331, (2015).

DOI: 10.1016/j.matpr.2015.07.284

[5] V. K. Singh and S. K. Singal, Operation of hydro power plants-a review,, Renew. Sustain. Energy Rev., vol. 69, no. August 2016, p.610–619, (2017).

[6] C. P. Jawahar and P. A. Michael, A review on turbines for micro hydro power plant,, Renew. Sustain. Energy Rev., vol. 72, no. October 2015, p.882–887, (2017).

DOI: 10.1016/j.rser.2017.01.133

[7] G. O. Barrionuevo, B. A. Guerrero, and M. Walczak, Computational Fracture Mechanics: Evaluation of the Structural Integrity in a Penstock Applying the BS7910 Standard and Finite Element Analysis,, IOP Conf. Ser. Mater. Sci. Eng., vol. 925, no. 1, (2020).

DOI: 10.1088/1757-899x/925/1/012023

[8] X. Liu, Y. Luo, and Z. Wang, A review on fatigue damage mechanism in hydro turbines,, Renew. Sustain. Energy Rev., vol. 54, p.1–14, (2016).

[9] P. J. Dunstan and S. C. Li, Cavitation enhancement of silt erosion: Numerical studies,, Wear, vol. 268, no. 7–8, p.946–954, (2010).

DOI: 10.1016/j.wear.2009.12.036

[10] B. S. Thapa, B. Thapa, and O. G. Dahlhaug, Current research in hydraulic turbines for handling sediments,, Energy, vol. 47, no. 1, p.62–69, (2012).

DOI: 10.1016/j.energy.2012.05.014

[11] R. Ahmed and M. Hadfield, Mechanisms of fatigue failure in thermal spray coatings,, J. Therm. Spray Technol., vol. 11, no. 3, p.333–349, (2002).

DOI: 10.1361/105996302770348727

[12] A. HAMILTON, A. SHARMA, and U. PANDEL, SOLID PARTICLE EROSION RESISTANCE OF HVAF-SPRAYED WC-10Co-4Cr COATING ON CA6NM STEEL,, Surf. Rev. Lett., vol. 24, no. Supp01, p.1850011, (2017).

DOI: 10.1142/s0218625x18500117

[13] B. S. Mann and V. Arya, Abrasive and erosive wear characteristics of plasma nitriding and HVOF coatings: Their application in hydro turbines,, Wear, vol. 249, no. 5–6, p.354–360, (2001).

DOI: 10.1016/s0043-1648(01)00537-3

[14] L. Thakur, N. Arora, R. Jayaganthan, and R. Sood, An investigation on erosion behavior of HVOF sprayed WC-CoCr coatings,, Appl. Surf. Sci., vol. 258, no. 3, p.1225–1234, (2011).

DOI: 10.1016/j.apsusc.2011.09.079

[15] J. Y. Yu, D. W. Shi, Z. Li, S. Y. Yu, and Y. Zhang, Experimental study on repairing large modulus rack cracks by argon arc welding,, Mater. Sci. Forum, vol. 943 MSF, p.8–13, (2018).

DOI: 10.4028/www.scientific.net/msf.943.8

[16] R. De Paula Silva, M. I. S. T. Faria, L. F. C. B. De Almeida, C. A. Nunes, D. Vieira, and W. Borges, Microstructure and mechanical properties of ASTM A743 CA6NM steel welded by FCAW process,, Mater. Res., vol. 20, no. 6, p.1622–1629, (2017).

DOI: 10.1590/1980-5373-mr-2017-0468

[17] G. O. Barrionuevo, S. Ríos, S. W. Williams, and J. A. Ramos-Grez, Comparative Evaluation of Machine Learning Regressors for the Layer Geometry Prediction in Wire arc Additive manufacturing,, in 12th International Conference on Mechanical and Intelligent Manufacturing Technologies, 2021, p.186–190.

DOI: 10.1109/icmimt52186.2021.9476168

[18] M. Karmuhilan and A. K. Sood, Intelligent process model for bead geometry prediction in WAAM,, Mater. Today Proc., vol. 5, no. 11, p.24005–24013, (2018).

DOI: 10.1016/j.matpr.2018.10.193

[19] J. Liu, Y. Xu, Y. Ge, Z. Hou, and S. Chen, Wire and arc additive manufacturing of metal components: a review of recent research developments,, Int. J. Adv. Manuf. Technol., vol. 111, no. 1–2, p.149–198, (2020).

DOI: 10.1007/s00170-020-05966-8

[20] J. L. Z. Li, M. R. Alkahari, N. A. B. Rosli, R. Hasan, M. N. Sudin, and F. R. Ramli, Review of wire arc additive manufacturing for 3d metal printing,, Int. J. Autom. Technol., vol. 13, no. 3, p.346–353, (2019).

DOI: 10.20965/ijat.2019.p0346

[21] J. Xiong, Z. Yin, and W. Zhang, Closed-loop control of variable layer width for thin-walled parts in wire and arc additive manufacturing,, J. Mater. Process. Technol., vol. 233, p.100–106, (2016).

DOI: 10.1016/j.jmatprotec.2016.02.021

[22] G. O. Barrionuevo, P. M. Sequeira-Almeida, S. Ríos, J. A. Ramos-Grez, and S. W. Williams, A machine learning approach for the prediction of melting efficiency in wire arc additive manufacturing,, Int. J. Adv. Manuf. Technol., no. 0123456789, (2022).

DOI: 10.1007/s00170-022-08966-y

[23] J.-H. Lee, C.-M. Lee, and D.-H. Kim, Repair of damaged parts using wire arc additive manufacturing in machine tools,, J. Mater. Res. Technol., vol. 16, p.13–24, (2022).

DOI: 10.1016/j.jmrt.2021.11.156

[24] S. M. Yusuf and N. Gao, Influence of energy density on metallurgy and properties in metal additive manufacturing,, Mater. Sci. Technol. (United Kingdom), vol. 33, no. 11, p.1269–1289, (2017).

DOI: 10.1080/02670836.2017.1289444