Metal processing

Large-scale gas turbine component: How SPALECK Manufactures Complex Welded Assemblies for the Energy Industry

SPALECK manufactured a key component for an industrial gas turbine at its Bocholt facility. The assembly places high demands on materials, welding techniques, and dimensional accuracy—all while being large in size.

Measuring 3 meters in length and 2.5 meters in diameter, this component is among the larger-scale and more technically challenging projects in metalworking.

Welded Assembly

3-meter component

Material

high-temperature-resistant

Manufacturing

Made in Germany

PROJECT PROFILE

Welded Assembly for a Gas Turbine

A challenging manufacturing project for the energy sector—carried out with a high degree of vertical integration and welding expertise at the Bocholt facility.

Industry

Power Generation / Turbine Manufacturing

Component

Large-format welded assembly

Dimensions

Approx. 3,000 mm long / 2,500 mm in diameter

Requirements

High-temperature-resistant materials, high-quality welding, dimensional accuracy

Scope of Services

Manufacturing and Machining of the Assembly

THE INITIAL SITUATION

High demands on materials, welding techniques, and dimensional accuracy

Gas turbine components are subject to extreme operating conditions. High temperatures and mechanical stresses place special demands on materials and manufacturing quality.

For manufacturing, this means:

High-performance materials with special properties
Strict requirements for welds and joints
Tight tolerances despite large component dimensions
Reliable control of warpage and component stability
At the same time, these requirements must be implemented in a reproducible manner.

Project Goal

Manufacturing of a Complex, Large-Scale Assembly

The goal was to produce a technically complex welded assembly to the highest quality standards while meeting all quality requirements.

The focus was on:

The Spaleck Solution

Manufacturing Expertise for Complex Welded Assemblies

The turbine component was manufactured at our Bocholt facility by our team of welding engineers, machining experts, and manufacturing specialists.

The key factor was the combination of:

Experience in processing challenging materials
tailored welding processes for large assemblies
Monitoring Warpage and Dimensional Accuracy During Manufacturing
Integration of Welding and Machining Processes
This made it possible to manufacture the assembly in accordance with the required technical specifications.

PROJECT RESULTS

Precision-manufactured assembly for use in power generation

The finished component meets the requirements for use in an industrial gas turbine.

COST-EFFECTIVENESS / BENEFITS FOR BUYERS

Complex assemblies from a single source

For project managers and buyers, this means:

fewer interfaces in manufacturing
Reliable implementation of complex requirements
clear accountability for the assembly
reduced coordination effort
SPALECK handles the manufacturing of complex assemblies and ensures that all process steps are coordinated.

TRANSFERABILITY for Your Processing

Relevance for High-Performance Machine and Plant Components

The project can be adapted for use in applications involving:

Discuss with our experts on welded assemblies

Discuss the next step now

Spaleck GmbH & Co KG
Robert-Bosch-Strasse 15
D-46395 Bocholt

Phone: +49 2871 2134-0