Fused filament fabrication (FFF) for oil sands applications

适用于油砂应用的熔丝制造 (FFF)

• 批准号: 537171-2018
• 负责人: Henein, HaniH
• 金额: $ 4.94万
• 依托单位: University of Alberta
• 依托单位国家: 加拿大
• 项目类别: Collaborative Research and Development Grants
• 财政年份: 2022
• 资助国家: 加拿大
• 起止时间: 2022-01-01 至 2023-12-31
• 项目状态: 已结题
• 来源: https://www.nserc-crsng.gc.ca/ase-oro/Details-Detailles_eng.asp?id=746820
• 关键词: Fused; filament; fabrication; FFF; oil

Maintenance of oil sands facilities is exceedingly expensive with Syncrude for example spending over $1.7 Billion annually on these tasks. It is imperative to have reliable and improved metal-ceramic composites for wear applications. Additive Manufacturing (AM, also known as 3D printing) is a recent innovation that holds much promise for the industry. It allows components to be redesigned for greater efficiency, lighter parts, and functionally more efficient. Numerous AM processes have been developed and tested. This project will utilize Fused Filament Fabrication (FFF) process as it is at least an order of magnitude cheaper than laser based systems. Using FFF, a metal and ceramic powder can be embedded into the polymer matrix fiber and the component built layer by layer. Subsequently, the polymer can be removed and the metal-ceramic composite sintered to final shape. This approach also has the advantage over laser based systems of not melting the metal powders, a very expensive raw material, as well as eliminating the issue of powder recycling. This proposal is, therefore, composed of four (4) interdependent tasks. The first is the fabrication of polymer filaments having optimum high loading of metal and ceramics powders. The second will address experiments and modeling of the printing process. Task 3 will address the important aspect of debinding and sintering the 3D printed samples. It is critical to determine sintering approaches and parameters that will yield fully dense samples. The fourth and final task will integrate the knowledge generated from the previous three Tasks to print a sample component and test its wear characteristics. This project will be carried out using the expertise of four colleagues in a collaborative manner. By combining the expertise in materials, modelling and manufacturing, we will identify the optimum conditions for applying FFF to metal matrix applications for wear resistance. Over this four year project, we estimate that between 4 and 6 graduate students will be trained in a multi-disciplinary field. The benefits to Canada will stem from improved wear resistant parts for the oil sands operation, new markets for a Canadian SME, and increased HQP trained in AM.

油砂设施的维护费用非常昂贵，例如Syncrude每年花费超过17亿美元用于这些任务。因此，迫切需要可靠和改进的金属陶瓷复合材料用于磨损应用。增材制造（AM，也称为3D打印）是最近的一项创新，为行业带来了很大的希望。 它允许重新设计组件，以提高效率，减轻部件重量，并提高功能效率。已经开发和测试了许多AM工艺。该项目将采用熔丝制造（FFF）工艺，因为它至少比基于激光的系统便宜一个数量级。 使用FFF，可以将金属和陶瓷粉末嵌入聚合物基质纤维中，并逐层构建部件。随后，可以去除聚合物，并将金属-陶瓷复合材料烧结成最终形状。 与基于激光的系统相比，这种方法还具有不熔化金属粉末（一种非常昂贵的原材料）以及消除粉末回收问题的优点。 因此，本提案由四（4）项相互依存的任务组成。 第一个是具有最佳高负载的金属和陶瓷粉末的聚合物长丝的制造。第二部分将讨论印刷过程的实验和建模。 任务3将解决脱脂和烧结3D打印样品的重要方面。 关键是要确定烧结方法和参数，将产生完全致密的样品。 第四个也是最后一个任务将整合前三个任务生成的知识，打印样本组件并测试其磨损特性。该项目将利用四名同事的专门知识以协作方式开展。 通过结合材料，建模和制造方面的专业知识，我们将确定将FFF应用于金属基体应用的最佳条件，以提高耐磨性。 在这个为期四年的项目中，我们估计将有4到6名研究生在多学科领域接受培训。 对加拿大的好处将来自于油砂作业耐磨部件的改进、加拿大中小企业的新市场以及在AM方面接受培训的HQP的增加。