Benefits for the users

Potential benefits:

• reduction of lead time due to faster production
• reduction of material waste by additive manufacturing
• reduction of human errors or highly speciality (welding) skills
• manufacturing automation (vs. human labour)
• on-demand production
• on-site fabrication

 

Final demonstrator: 60 x 60 x 30 cm

Alloy: E70C 6M H4 (Metal Cored)

Weight: 30 kg printed, 87kg total weight

 

Savings: at least 80% material savings compared to CNC-manufacturing

Innovation

Current repair processes by clamps typically rely on CNC milling, specialized manual labour, or a combination of both. Each of these processes has its downsides, as CNC milling has high material waste (on average >80% of the original material) and specialized labourers are becoming more scarce.

 

Hybrid manufacturing provides a smart production solution, by combining the advantages of traditional manufacturing (such as precision machining) with the advantages of wire arc additive manufacturing (such as form freedom, high deposition rates and minimal material waste). This level of hybrid WAAM has not been shown yet at this size, flexibility and inspection requirements before.

 

The project team managed to reach a high level of assurance for the WAAM clamp demonstrator. BWI (Belgian Welding Institute) tested the materials and confirmed the printed material complied with key TEAM Industries requirements for this material. The MX3D M1 Metal AM System, facility and procedures were qualified by Lloyds Register. TiaT Europe performed non-destructive testing, such as Ultrasonic Testing (UT), Penetrant Testing (PT), Radiographic Testing (RT), showing no relevant defects. TEAM Industries has performed a pressure test, which ran until the maximum pressure of the test installation (i.e. > 60 Bar) without any failure.

Risks and limitations

Further testing and extensive inspection is required to achieve the full certification of this hybrid WAAM pipeline clamp application. As the material (wire), process (with the M1 Metal AM System) and DPS (deposition procedure specification) has been certified already, it is likely that the certification of the full application can be achieved. Furthermore, although the hybrid WAAM has been shown on various size and diverse shapes (including straight pipe and curved pipe), it is to be determined whether is achievable for more size, shapes and materials.

Technology readiness level

7 - System model in operational environment

Sectors of application

Oil & Gas Industry, Chemicals Industry.

Potential sectors of application

Hybrid WAAM can be extended to other industries where a combination of traditional manufacturing and 3D metal printing can be put to good use. Any industry that is using casting, CNC-milling, sheet metal fabrication, or robotic welding could be interested in this application.

Hardware / Software

Hardware:

MX3D M1 Metal AM System: Turn-key solution for the hybrid WAAM process

MX3D MetalXL Control System: to monitor and control the hybrid WAAM process

CNC-machine: to pre-manufacture the sidebars and flange

Software:

CAD program: To design a new clamp shape or edit an existing design

MX3D MetalXL software: To prepare, control and log the hybrid WAAM process

Video

WAAM Clamp, a Hybrid Wire Arc Additive Manufacturing to reduce production lead time for the oil and gas industry

https://youtu.be/J5zEzMvoqbE