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Canada's oil sands are the third largest deposit of crude oil in the world, and consist of a mixture of sand, water, and bitumen. Due to an aggressive operating environment that includes abrasive sands and corrosive chemicals, oil sands equipment and process piping often experience severe wear and erosion-corrosion, which can lead to the risk of equipment failures, plant downtime or, even worse, environmental leaks [1]. For more than half a century, oil sands producers have collaborated with materials suppliers, equipment fabricators, and technology providers to develop wear technologies to reduce downtime and improve operational reliability.
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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.
Direct energy deposition processes that utilize wire feedstock have been deployed to deposit and fabricate near net shape functional metal parts at high deposition rates. Is this just multi-pass welding or is there more to it? Should the material requirements for additive be the same as those defined for welding? Is weld quality the same as part quality? A large metal additive part fabricated using a robotic wire arc additive system will be used to demonstrate the similarities and identify critical differences between essential variables for welding and additive manufacturing. The opportunities for both welding and additive manufacturing to learn and leverage one another to develop unique and novel materials, process controls and further fundamental understanding of metal deposition processes will be outlined.
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.