An evaluation of additive manufacturing of MMCs for oil sands applications

该项目将解决等离子体转移弧工艺在石油和天然气行业增材制造（PTA-AM）应用中的使用问题。由于油砂的高磨损和腐蚀作用，金属基复合材料（MMC）需要用于油砂作业。通常，NiCrSiB合金粉末与碳化钨（WC）粉末混合，并通过喷嘴送入由惰性气体保护的等离子体中，然后沉积在基材上。对于PTA-AM应用，我们建议逐层构建Syncrude感兴趣的两个部分，并针对其操作，法兰管和注射喷嘴头。这将是加拿大首次采用PTA工艺进行AM研究，也可能是世界上第一个MMC应用研究。该项目将涉及来自阿尔伯塔大学和InnoTech阿尔伯塔的四名研究人员的合作。通过结合这两个群体的专业知识，这种方法的可行性AM可以充分探讨。正如我们所预期的成功，我们与InnoTech阿尔伯塔的合作将确保技术向工业界和未来的规模扩大研究的良好转移。在这个项目中，材料加工、Henein、PTA操作、Wolfe、AM应用PTA的重新设计、Qureshi和AM样品的冶金分析等专业知识的结合，提供了跨学科专业知识的独特组合。这种专业知识的结合也将为高素质人才（HQP）的培训提供独特的氛围。我们计划在四年的时间里每年有三个学生参与这个项目。一个研究助理的50%的时间也需要，以提供日常的监督ofstudents使用实验室设施，如差示扫描量热法。为了便于将来扩大规模，实验测试将在位于InnoTech阿尔伯塔的PTA装置进行。访问费用包括在提案中，以及来自InnoTech阿尔伯塔的实物捐助，以支持这一合作。Syncrude正在提供现金和实物捐助，详见下文。

This project will address the use of the Plasma Transfer Arc process for Additive Manufacturing (PTA-AM)applications in the oil and gas industry. Due to the high wear and corrosion action of oil sands, metal matrixcomposites (MMCs) are required for use in oil sands operations. Typically a NiCrSiB alloy powder is mixedwith tungsten carbide (WC) powders and fed through a nozzle into a plasma protected by inert gas anddeposited onto a substrate. For PTA-AM applications, we propose to build layer by layer two parts of interestto Syncrude and specific to their operations, a flanged pipe and an injection nozzle head. This will be the firstresearch study of AM using the PTA process in Canada and likely the first in the world for MMC applications.This project will involve a collaboration between four researchers from the University of Alberta and InnoTechAlberta. By combining the expertise of both groups, the feasibility of this approach to AM can be fullyexplored. As we anticipate success, our collaboration with InnoTech Alberta will ensure excellent transfer oftechnology to industry and for future scale-up studies. For this project, the combined expertise of materialsprocessing, Henein, the operation of the PTA, Wolfe, the re-design of PTA for AM applications, Qureshi, andthe metallurgical analysis of the AM samples, Li, offers a unique combination of interdisciplinary expertise.Such a combination of expertise will also provide a unique atmosphere for the training of Highly QualifiedPeople (HQP). We plan to have three students working on this project each year of its proposed four yearduration. A 50% time of a Research Associate is also required in order to provide day to day supervision ofstudents using laboratory facilities such as Differential Scanning Calorimetry. In order to facilitate futurescale-up the experimental tests will be carried out at the PTA unit located at InnoTech Alberta. Costs of accessare included in the proposal as well as in-kind contributions from InnoTech Alberta in support of thiscollaboration. Syncrude is providing both cash and in-kind contributions as outlined in detail.