Deposition and Repair of High Temperature Materials Using Additive Manufacturing

In this section

Back to Core Research Programme AMorph – 4D Printing for Field Morphing Structures Automation of Composite and Hybrid Joining Process Coaxial Wire Additive Manufacturing Processes and In-Line Monitoring Tools Development of Coded Excitation Technique for Non-Metallic Pipes Inspection Development of Digital Twin technology as a demonstrator for real-time integrity assessment of crack growth in tensile specimens Development of Friction Stir Welding (FSW) for Hydrogen Fuel Storage Tanks Development of Leak-Before-Break Hydrogen Storage Composite Pressure Vessels With Polymeric Liner Establishing Assessment Methods for Determining Safe Service Limits of High-Temperature Materials in Extreme Environments Fracture toughness in aggressive environments: effect of crack monitoring techniques on test results In-process detection and non-destructive testing of electron beam weld imperfections Internal Bore Coatings for Applications in Corrosion and Hydrogen Environment Joining of Additively Manufactured Materials Long term behaviour of polymeric liner materials/coatings in hydrogen service Techniques for High Temperature Ultrasonic Inspection of Arc Welding Ultimate Leverage Fund

Project Code: 32881

Start date and planned duration: February 2019, 36 months

Objectives

Develop an additive manufacturing (AM) process for the deposition of high temperature materials, including repair of failed components.
Progress inspection techniques for AM deposited high temperature materials particularly in repaired locations.
Characterise high temperature properties, microstructure and macrostructure of AM parts made from high temperature materials.
Understand the stresses present in the AM repairs in order to estimate and optimise the service life of repaired components.

Project Outline

The project will develop an AM process suitable for depositing high-temperature materials such as Alloy 800HT or 310 stainless steel, extending TWI’s current AM capabilities to new materials. The processes developed will include repairing existing complex thermally aged components. The deposited material will then be inspected using NDT techniques to develop understanding of possible inspection regimes for the deposited ‘virgin’ AM material and the parent-AM interface in repaired components. Inspection will include definition and detection strategies for the unique new defect types produced by AM deposition of these materials. The microstructures and high temperature properties of the deposited materials will be characterised in detail, including high temperature thermomechanical testing such as creep and high temperature tensile tests. This will advance TWI knowledge of AM deposits and the influence of AM deposition processes on complex parent materials during repair/manufacturing processes. This material property and microstructural characterisation will be complemented by finite element analysis (FEA) and computational fluid dynamics (CFD). The latter will be used to understand the heat fluxes experienced by the repaired part and the former will consider the combined thermo-mechanical stresses acting on the component. Together, this will allow for the thermal stresses developed in the repaired components during high temperature service to be analysed. The FEA will particularly focus on the thermal stresses which may develop at the interface of ‘virgin’ AM material and repaired components. The wire plus arc AM (WAAM) process is considered to be most appropriate for repair of large components.

Industry Sectors

Construction and Engineering
Electronics and Sensors
Oil and Gas
Power
Equipment, Consumables and Materials

Benefits to Industry

The outcomes of the project will allow industry to evaluate AM technologies as a means of repairing complex, high value components. The process parameters developed will enable the repair of high-temperature components, reducing non-operating time or costs associated with maintaining stock of spares. NDT investigations combined with associated characterisation and testing will enable industry to more clearly define NDT assessment strategies for AM deposits/repairs.

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