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51317--9667-Additive Manufacturing for Sour Service: an Experimental Investigation

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The overall goal was to determine if a set of additive manufacturing (AM) parts could comply with the testing requirements of wrought or welded materials for sour service as outlined in NACE MR0175 / ISO 15156-3:2015. Recommendations for a qualification pathway for AM parts in sour service are included.

 

Product Number: 51317--9667-SG
ISBN: 9667 2017 CP
Author: William Kovacs
Publication Date: 2017
Industry: Materials Selection and Design
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Additive manufacturing (AM) commonly referred to as 3D printing offers advantages compared to more traditional production methods including quick prototyping short production runs and intricate thin section microfluidic variable composition and low-waste designs. These exciting features are accompanied by new challenges including higher costs variable quality and inherently anisotropic properties etc. To utilize the benefits of AM in sour service environments new qualification and materials testing requirements will be required. There are possible corollaries envisioned for the application of AM to sour service with the (additive) technique of welding. In this work the relative SSC resistance of 17-4PH stainless steel produced by AM (powder bed fusion) was compared with welded and wrought parts of the same alloy utilizing NACE TM0177-2005 Method A. The chemistry microstructure mechanical properties including hardness and electrochemical behavior of these materials were examined to explain the results observed and to seek predictors for AM suitability for sour service. The overall goal was to determine if AM parts can comply with the testing requirements of wrought or welded materials for sour service as outlined in NACE MR0175 / ISO 15156-3:2015. Recommendations for a qualification pathway for AM parts in sour service are included.

Key words: Additive manufacturing, SSC resistance, NACE MR0175 qualification, UNS S17400

Additive manufacturing (AM) commonly referred to as 3D printing offers advantages compared to more traditional production methods including quick prototyping short production runs and intricate thin section microfluidic variable composition and low-waste designs. These exciting features are accompanied by new challenges including higher costs variable quality and inherently anisotropic properties etc. To utilize the benefits of AM in sour service environments new qualification and materials testing requirements will be required. There are possible corollaries envisioned for the application of AM to sour service with the (additive) technique of welding. In this work the relative SSC resistance of 17-4PH stainless steel produced by AM (powder bed fusion) was compared with welded and wrought parts of the same alloy utilizing NACE TM0177-2005 Method A. The chemistry microstructure mechanical properties including hardness and electrochemical behavior of these materials were examined to explain the results observed and to seek predictors for AM suitability for sour service. The overall goal was to determine if AM parts can comply with the testing requirements of wrought or welded materials for sour service as outlined in NACE MR0175 / ISO 15156-3:2015. Recommendations for a qualification pathway for AM parts in sour service are included.

Key words: Additive manufacturing, SSC resistance, NACE MR0175 qualification, UNS S17400

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Mechanical and electrochemical rapid screening techniques for UNS(4) S17400 (AM) material were evaluated in comparison to sour tests of the same materials. Effects of the as-deposited surface were explored, in addition to the influence of build orientation.
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The main scope of this work is to explore different process configurations to understand the corrosion response of additive manufactured alloys and to suggest the parameters to be controlled for future qualification in sour environment.
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Additive manufacturing can manufacture components that were previously impossible - without compromising strength, ductility and corrosion resistance. The pitting corrosion resistance of a selective laser melted Nickel alloy has been evaluated by electrochemical methods. 
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