Multi-material robotic hybrid additive wire arc manufacturing for the energy industry

该提案的首要目标是“开发一个完全集成、经过实验验证、支持传感器融合的增材减材数字工具链，该工具链集成了增材制造 (AM) 策略的设计，同时结合了通过线弧增材制造工艺处理的材料特性及其制造限制。”通过这项提案，该大学的申请人和 Syncrude Canada Ltd 之间将建立联盟，以研究和推进增材制造技术的应用，通过改进工艺、设备和/或组件可靠性来改善 Syncrude 在艾伯塔省油砂行业的运营。该项目合作伙伴关系将推进以下领域的研究和开发：1- 为石油和天然气领域的多轴无支持先进定向能量沉积系统开发与平台无关的数字工具链，重点关注基于脉冲的冷金属传输电弧机器人增材制造技术2- 了解针对采矿和能源行业特定需求的材料系统的机器人电弧增材制造 (RWAAM) 的凝固-微观结构-几何相互作用，包括碳钢和低合金钢、不锈钢、司太莱钢和WC-Ni MMC。 3- 使用 RWAAM 制造的基于晶格结构的复合材料，开发和实施增材制造策略的重新设计、装配整合和打印大型零件。4- 使用传感器融合进行原位和内联几何和材料沉积质量评估，并集成层内和层间混合制造策略。

The overlying objective of the proposal is to "Develop a fully integrated, experimentally validated, sensor fusion enabled additive-subtractive digital toolchain that integrates design for additive manufacturing (AM) strategies while incorporating material characteristics processed through wire arc AM process and its manufacturing constraints." Through this proposal, an alliance will be developed between the applicants at the university and Syncrude Canada Ltd to investigate and advance the application of AM technologies for improving Syncrude's operations in the oil sands industry in Alberta by improving the process, equipment, and/or component reliability. This project partnership will advance research and development in the following areas:1- Development of a platform-agnostic digital toolchain for multi-axis support free advanced directed energy deposition systems for oil and gas with a focus on pulse-based cold metal transfer wire arc robotic AM technology2- Understanding of solidification-microstructure-geometry interaction for robotic wire arc AM (RWAAM) of material systems specific to the needs of the mining and energy industry, including carbon and low alloy steels, and stainless steels, Stellite's, and WC-Ni MMC's. 3- Develop and implement a design for AM strategy for redesign, assembly consolidation, and printing of large-scale parts using RWAAM manufactured lattice structure-based composites.4- Using sensor fusion for in-situ and inline geometric and material deposition quality assessment with integrated intralayer an interlayer hybrid manufacturing strategy.