The DNV GL-led consortium that develops a guideline for the qualification of parts made by additive manufacturing for the O&G and maritime industries, has now grown to include 16 companies. The participating companies represent the entire value chain: Equinor, Saudi Aramco, Siemens, Kongsberg Maritime, Voestalpine, Guaranteed, IMI CCI, Kongsberg Ferrotech, Addilan, BMT Aerospace, FIT AG, and Howco Group are joined by ImphyTek Powders, Intertek, XDM3D and ExOne. The project is still open for new partners.
This Joint Innovation Project (JIP) is now in the second phase of the “ProGRAM JIP” which ultimately led to the new standard for metal additive manufacturing in the oil & gas sector, DNVGL-ST-B203. The standard, focusing on WAAM and PBF-LB is now being extended to incorporate more AM technologies.
The JIP kicked off in May 2020 and is now working on laser powder bed fusion (PBF LB) with electron beam melting (PBF EB), laser metal deposition, metal binder jetting and wire arc additive manufacturing on part-substrate,, extending the application of the O&G standard for AM. Each of these technologies has unique advantages and challenges, which need to be addressed both in the part selection and the development of the qualification framework.
A very important part of the project is the part production. This not only provides essential learnings to the partners but also a testbed for the new qualification framework that is being defined in the JIP. By actually printing parts the partners are testing the framework to see if it is practical and adding value.
Over the course of the summer, the partners have provided insights and suggestions to what parts they would like to see printed and what material to use. The selection is be based on the respective inventories, and the business potential if a part is printed instead of manufactured conventionally. The JIP has concluded with the following parts;
Among the test cases reported, Equinor had an impeller successfully printed by PBF-LB in the first phase. The JIP is now looking at how might the same impeller perform when printed with PBF-EB technology. Kongsberg Maritime’s crank disc was also printed in the first phase. The team is now looking at reducing cost and increasing efficiency by feature addition with WAAM, utilizing conventional material for the bulk.
Saudi Aramco’s wear ring can be improved by adding material with different properties where it is needed and the technology under consideration is laser metal deposition (LMD). Siemens’ small part size fuel swirlers are perfect for metal binder jetting. The JIP is looking to develop a framework suitable for such small and complex parts
Finally, with greater complexity comes greater challenges when it comes to inspection, and inspection is important. In many cases conventional inspection methods may fall short when AM parts are to be controlled. This challenge will also be addressed in the JIP.