Design and Manufacturing of a Metal 3D Printed kW Scale Axial Turboexpander

Abstract

Greater expansion of distributed power and process systems based on thermodynamic cycles with single to hundred kW scale power output is limited mainly there are not available cost-effective expanders. Turboexpanders have a perspective of high efficiency and flexibility concerning operating parameters even for the micro applications. However, they suffer from a high manufacturing cost and lead time in the development of traditional technologies (such as casting and machining processes). Additive manufacturing provides a possibility to overcome some of the issues. Manufacturing parts with complicated shapes by this technology, combining multiple components into a single part or rapid production by 3D printing for development purposes are among the prospective features with this potential. On the other hand, the 3D printing processes come with certain limitations which need to be overcome. This paper shows a design and manufacturing process of a 3 kW axial impulse air turbine working with isenthalpic drop 30 kJ/kg. Several samples to verify printing options and the turbine itself has been manufactured from stainless steel by the DMLS additive manufacturing method. Manufactured are two turbine variations regarding blade size and 3D printer settings while maintaining their specific dimensions. The turboexpanders testing method and rig is outlined. As the surface quality is an issue, several methods of post-processing of 3D printed stator and rotor blading to modify surface quality are suggested. Detailed experimental investigation is however subject of future work.