Green-TUrbine - Sustainable Manufacturing and Lifecycle Optimization for Pelton Runners through Wire-Arc Additive Manufacturing

The Green-TUrbine project investigates the integration of WAAM technology into the lifecycle of Pelton turbines to enhance their sustainability. The principles of "Rethink, Reduce, Reuse" are applied to optimize manufacturing, resource consumption, and the reuse of the runners. A comprehensive LCA will evaluate the ecological and economic impacts.

Short Description

As climate change progresses and its consequences become more apparent, rethinking sustainable actions becomes increasingly important. Hydropower, as a renewable energy source, significantly contributes to CO2-free electricity production in Austria, thus aiding the energy transition. However, it is essential not only to focus on green electricity itself but also on the sustainable manufacturing of components and technologies necessary for electricity generation and their lifecycle.

The Green-TUrbine project addresses this by examining the integration of "Wire Arc Additive Manufacturing" (WAAM) technology into the entire lifecycle of a Pelton turbine. Systematically, the sustainability elements "Rethink, Reduce, Reuse" are applied to the lifecycle of a turbine runner.

Under the motto Rethink, a hybrid process chain consisting of additive and subtractive technologies, is investigated as a more sustainable alternative for Pelton runner manufacturing. In terms of Reduce, the use of WAAM can lower resource consumption in the manufacturing process, thereby saving energy. Reuse refers to the reutilisation of turbine runners through automated repair processes using WAAM technology. The investigations focus particularly on the use of multi-material WAAM applications. By selectively using more noble and wear-resistant materials, the lifespan of turbines can be extended.

The machines and robot programs required for these complex manufacturing, repair, and multi-material applications in the project are supported by innovative CAD/CAM modules. The potential impact of the optimizations developed in the project are finally evaluated through a comprehensive life cycle assessment (LCA) of the Pelton manufacturing process, both ecologically and economically.

Project Partners

Projektleitung

DI Gernot Mauthner
TU Wien - Institut für Fertigungstechnik und Photonische Technologien

Projektpartner

Fronius International GmbH
Global Hydro Energy GmbH
ModuleWorks GmbH

Contact Address

DI Gernot Mauthner
TU Wien - Institut für Fertigungstechnik und Photonische Technologien
Getreidemarkt 9/E311 1060 Wien
Tel.: +43 1 58 801-31101
E-Mail: mauthner@ift.at
Web: www.tuwien.at/mwbw/ift