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AM brings significant benefits in better performance, inventory management, and lifecycle cost reduction to the Oil & Gas industry. Both manufacturers and users are working towards AM qualification and standardization in order to realize and sustain these benefits. Starting at the product level, the goal is to ensure the product is sound in its form, fit, and function, and free from macroscopic (surface, sub-surface, internal) anomalies deleterious to its performance. Product qualification is supported by a foundational metallurgical or AM material qualification.1
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Cemented carbides have been widely used to make parts for wear applications due to the excellent combination of hardness and toughness. Cemented carbides represent a group of composite materials containing hard metal carbides, such as tungsten carbide (WC), bonded by ductile metallic binder agents, such as cobalt (Co), nickel (Ni), or iron (Fe).1 By varying WC grain size, weight fraction of metallic binder, and processing parameters, a wider range of microstructure and mechanical properties can be achieved.
Stainless steel 316L (316SS) has been widely applied in relevant commercial fields (e.g. chemical, petrochemical, pharmaceutical, biomedical, and manufacturing industries) due to its excellent properties in corrosion and abrasion resistance, antioxidation, and service life. It is considered an austenitic material, non-magnetic, and thermally nonhardenable. The 316SS can be produced via powder by different methods such as: self-combustion, high-temperature synthesis (SHS), electron beam radiation, laser surface melting, plasma spray synthesis, mechanical alloying and casting methods among others.
Additive manufacturing is a term that encompasses a number of technologies that manufacture structures by building material up, layer by layer, and which are attractive due to a number of factors, such as the ability to rapidly produce complex components with controlled microstructures in a single step with reduced post processing requirements. Laser-powder bed fusion (L-PBF) is an additive manufacturing technique where a laser continuously melts successive layers of powder material, building up from a horizontal build plate.
Alloy UNS N07718 (hereafter abbreviated as 718) is one of the most versatile precipitation-hardened nickel-based corrosion-resistant alloys (CRAs) used for both surface and sub-sea components in oil and gas production service. API 6ACRA provides heat treatment windows and acceptance criteria for 718 in these oil and gas production environments, in which the heat treatment is intended to homogenize the microstructure and obtain the correct microstructure for targeting the desired mechanical properties. For fabricating high temperature materials via additive manufacturing (AM), alloy 718 is a primary focus due to its widespread applications in the past 60 years and excellent weldability in either age hardened or annealed condition.
Over the past twenty years, additive manufacturing (AM) has gradually emerged as an important commercial manufacturing technology for the production of components, particularly complex and highvalue metallic components. AM enables the layer-by-layer rapid manufacturing of near-net shapes using 3D computer-aided design data and typically minimizes raw-material wastes.
Alloy UNS N07718 (hereafter abbreviated as 718) is one of the most versatile precipitation-hardened nickel-based corrosion-resistant alloys (CRAs) used for both surface and sub-sea components in oil and gas production service. API 6ACRA1 provides heat treatment windows and acceptance criteria for 718 in these oil and gas production environments, in which the heat treatment is intended to obtain high strength and to minimize the formation of δ-phase at grain boundaries. As pointed out in NACE MR0175 Part 32 (Table 1), field failures of 718 components in sour service are primarily related to stress corrosion cracking (SCC) at elevated temperatures and hydrogen embrittlement in the lower temperature range. The latter is specifically called galvanically induced hydrogen stress cracking (GHSC or GIHSC), which is typically caused by atomic hydrogen uptake from galvanic corrosion or cathodic protection (CP) when 718 is used with steel components in a seawater environment. CP is normally used to protect steel component from corrosion in subsea environments.
Parts produced via additive manufacturing (AM) are being adopted broadly among many industries andused in an array of applications. AM parts are attractive to these industries for several reasons. Complexgeometries that cannot be manufactured using traditional, subtractive methods can be producedadditively.
3D Printing revolutionizes the production of engineered parts, enabling manufacturers and Oil & Gas plant owners to prototype or replace any part, regardless of geometrical complexity. The disruptive nature of this technology impacts most industries today, from medical equipment manufacturers to Oil & Gas companies, allowing for logistical flexibility and full independence in the manufacturing of components that will allow the repair of existing assets and re-commissioning of obsolete equipment.
For any company, becoming independent from a supply chain grants a unique strategic position that allows for better prediction and control of product output.