Energy transformation Ready for take-off

3D sand printing competence center of voestalpine Foundry Group. photo credits: voest alpine Foundry Group

Hydropower is an efficient and sustainable way of generating electricity and, at around 60%, accounts for by far the largest share of Austrian electricity generation. In the hydro power segment, the voestalpine Foundry Group has been a longtime partner of many well-known turbine manufacturers. In the last five years alone, a total of 130 projects have been successfully implemented at the Linz and Traisen sites. With the new 3D sand printing technology the competitiveness in this area will further increase.

In recent months in particular, a clear upward trend has been noticeable in the industry. The growing focus on decarbonization is reflected in the increasing number of many new projects in the international arena. In addition, many existing plants are currently being revitalized, thus ensuring sustainable power generation for the next decades. In the hydro energy segment, the voestalpine Foundry Group, a subsidiary in the Steel Division of the voestalpine Group, supplies essential components for the energy infrastructure, such as blades or guide vanes or even entire runners made from a single casting. These are used in a wide variety of turbine types, such as Kaplan, Francis or Pelton. All weight ranges can be covered, from a few kilograms to 50 tons and more. Highest quality of castings as well as reliable delivery times are important aspects in a well-functioning customer partnership. Especially in the case of power plants, security of supply is a prerequisite to ensure unrestricted power supply. The voestalpine Foundry Group can look back on many years of expertise in this area and works only with the highest-quality metallurgical equipment. The wide range of materials complies with all standards and norms of the hydro power industry and is characterized above all by its special durability.

TRADITION MEETS INNOVATION

The traditional manufacturing process is supported by 3D sand printing technology, especially for complex geometries or time-critical spare parts. In addition to design freedom, this innovative process also enables optimization of the production steps, which has a positive effect on the delivery time to the customer.

Francis blade 3.000 kg:

During the process, a 3D printer uses CAD data to directly produce sand molds into which liquid steel is poured. The sand molds are created by the repeated application of 300-micrometer-thick layers of chemically bonded silica sand.

More information about this technology you can find here:

STEEL DVISION

As a global manufacturer of high-quality steel products, the Steel Division of the voestalpine Group is a driving force toward a clean future worth living. It has been setting environmental benchmarks in steel production for years, working simultaneously on future hydrogen-based options to help bring about steelmaking routes low in CO2. The Steel Division is the first point of contact for major automotive manufacturers and suppliers worldwide when it comes to high-quality steel strip. It is also one of the most important partners to the European white goods and mechanical engineering industries. The Steel Division produces heavy plates for applications under the most extreme conditions in the energy sector, supporting the oil & gas industry and renewable energy generation with custom solutions. It operates the world’s most advanced direct reduction plant in Corpus Christi, Texas, USA, producing high-quality pre-materials (HBI) used in steel production for both Group companies and external entities alike. In the business year 2020/21, the Steel Division generated revenue of EUR 4.2 billion, reported an operating result (EBITDA) of EUR 487 million, and had around 10,500 employees worldwide.