Power generation

Milling with efficiency, precision and expertise

Thinking in solutions for the challenges of the Power generation industry
Pokolm Premiumtools branch power generation.

Decarbonization, climate neutrality and energy transition are frequently used buzzwords in the field of power generation.

The energy sector faces the challenge of developing new technologies and processes to reduce CO2 emissions through the transition to low-emission or emission-free energy sources. High-performance materials are increasingly being used in the manufacture of components and assemblies for wind turbines, hydroelectric power plants, gas and steam turbines and electrolysers.

These materials are characterized by high strength and high resistance to mechanical stress, withstand high temperatures and corrosive conditions, but are also difficult to machine.

Precise 5-axis milling is required in production, as the geometries of the curved blades and fine structures are often very complex. Titanium alloys also have low thermal conductivity, which means that heat builds up on the cutting edge. Nickel-based alloys, on the other hand, are tough and tend to work harden. With stainless steel, thermal expansion can lead to dimensional deviations and soft aluminum can deform during machining.

Challenges

  • Das Bild zeigt eine einzelne angefertigte Turbinenschaufel.
  • In diesem Bild ist ein Verdichterrad auf eine CNC-Maschine aufgespannt, welches gerade gefräst wurde.
  • Das Bild zeigt ein Pelton-Doppelbecher mit einer Spiegelung auf einer glatten schwarzen Fläche.

Turbine blade

Industrial gas turbines usually consist of a compressor, a combustion chamber and the actual turbine, in which the hot exhaust gases drive the turbine blades. The blades have to withstand extremely high temperatures, high pressure and strong centrifugal force. Manufacturing them is a demanding task. Materials that are difficult to machine, such as aluminum and titanium, often have to be milled at high feed rates and with complex geometric requirements to ensure that the turbine blades fit and function optimally.

Compressor wheel

A compressor wheel is a central component of a turbine. It has the task of compressing the intake air or working gas by rotating it and passing it on at increased pressure. This increases the temperature and density of the gas, which is essential for downstream processes. Compressor wheels must be able to withstand high mechanical loads, high temperatures and corrosive conditions. They are therefore made from special high-performance materials such as titanium, nickel-based alloys and steel.

Pelton turbines

Pelton turbines are constant pressure turbines for high heads and low flow rates. In the turbine, water pressure is converted by a nozzle into kinetic energy of a water jet. The water jet hits the specially shaped double buckets of the turbine runner at high speed and thus drives the turbine. The double buckets must have high strength. They are often made from difficult-to-machine materials such as titanium, stainless steel and chilled cast iron, which are tough and extremely wear-resistant.

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