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

该提案的首要目标是“开发一种完全集成的、经过实验验证的、支持传感器融合的加减法数字工具链，它集成了加法制造设计(AM)策略，同时纳入了通过焊丝弧形AM工艺及其制造约束处理的材料特性。”通过这项提案，该大学的申请者将与辛克鲁德加拿大有限公司结成联盟，以调查和推进AM技术的应用，通过改善工艺、设备和/或组件的可靠性来改善辛克鲁德在艾伯塔省油砂行业的运营。这一项目伙伴关系将推动以下领域的研究和开发：1-开发平台无关的数字工具链，用于多轴无支撑先进的石油和天然气定向能沉积系统，重点是基于脉冲的冷金属转移丝弧机器人AM技术2-了解采矿和能源行业特定需要的材料系统的凝固-微观结构-机器人丝弧AM(RWAAM)的几何交互作用，包括碳钢和低合金钢以及不锈钢、钨铬钴合金和WC-Ni MMC。3-开发和实施AM的设计战略，用于重新设计、组装加固、使用RWAAM制造的基于点阵结构的复合材料用于大型零件的印刷和印刷。4-使用传感器融合进行原位和在线几何和材料沉积质量评估，并采用集成的层内混合制造策略。

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.