Heavy Machining & Fabrication for Gas Turbines
Gas turbines operate under extreme conditions—subjected to immense thermal stress, high-pressure environments, and intense rotational forces. The large-scale structural and casing components that house these turbines require absolute metallurgical integrity, flawless welding, and micron-level machining precision.
Openex is a trusted contract manufacturing partner for the global power generation sector. Utilizing our massive facility footprint, 250-ton lifting capacity, and state-of-the-art 5-Axis CNC gantry mills, we fabricate and machine the heaviest, most complex stationary components for heavy-duty industrial gas turbines (IGTs) and aeroderivative turbines.
Key Turbine Components We Manufacture
Turbine Casings & Shells
Massive upper and lower turbine half-shells. We perform precision boring, horizontal milling, and split-line flange machining to ensure a perfect, pressure-tight seal upon assembly.
Exhaust Diffusers & Plenums
Fabricated from heat-resistant stainless steels and superalloys. We handle the heavy plate rolling, complex structural welding, and thermal stress relief required for exhaust structures.
Stator Frames & Rings
Large diameter ring forgings and stator fabrications. Machined on our massive Vertical Turning Lathes (VTLs) up to 8 meters in diameter to achieve strict concentricity tolerances.
Combustion Chamber Housings
Precision 5-Axis milling of complex burner and combustion chamber mounting geometries, ensuring exact alignment for critical internal components.
Manufacturing Capacities & Specs
We custom build turbine components directly to OEM blueprints. Below are our general facility capacities for power generation equipment:
| Max Component Weight | Up to 250 Tons (Single Assembly) |
|---|---|
| Max Machining Dimensions | Gantry Milling up to 25m Long | Vertical Turning up to Ø 8m |
| Materials Processed | High-Temp Carbon Steels, Stainless Steels (304, 316, 310S), Inconel, Hastelloy, and specialized Cr-Mo alloys. |
| Heat Treatment | On-site massive Post-Weld Heat Treatment (PWHT) and stress relief furnaces. |
| Quality & Inspection | 100% NDT (UT, MT, PT, RT), Large-Scale Laser Tracker CMM Inspection, ASME Compliance. |
The Openex Quality Advantage
Welding massive turbine casings introduces heavy thermal stresses. We strictly control heat input and utilize massive welding positioners to maintain dimensional stability before the component ever reaches the machining center.
Turbine casings are cast or fabricated in halves. Our heavy-duty boring mills allow us to clamp and machine these massive half-shells with near-zero vibration, ensuring the split lines mate together flawlessly under operating pressure.
Using FARO Laser Trackers and large-scale CMMs within our climate-controlled inspection rooms, we verify that every bore, bolt pattern, and surface flatness perfectly matches your 3D CAD model.