Evaluating the erosion-corrosion-fatigue properties of WAAM built components and how to optimise them for the marine environment

随着人们对向净零排放绿色转型的兴趣日益浓厚，海上可再生能源正成为许多国家关注的焦点。数以百计的海上风力涡轮机即将结束其25-30年的生命周期，许多开发商正在寻找延长寿命的选择，以最大限度地利用他们的资产。海上可再生能源的结构受到世界上一些最恶劣的环境的影响，在腐蚀性和侵蚀性的环境中受到风、浪和潮汐的负荷。增材制造（AM）在海洋环境中显示出巨大的应用前景。然而，该技术在该行业的研究或应用很少。腐蚀被认为是海上结构的最大威胁之一，并且随着侵蚀的存在而加速。增材制造有可能混合不同的材料，以改善终端部件的性能。电弧增材制造（WAAM）由于能够在较短的交货时间内制造大型部件，与传统制造工艺相比，几乎没有缺陷，因此显示出巨大的前景。与传统的供应链路线相比，该流程可以在离岸站点附近的港口或船厂轻松制造，因此有可能以更短的交货时间制造组件。早期对使用WAAM制造耐腐蚀涂层和组件的潜力的研究已经强调了该工艺的许多优点，但需要进一步的研究来证明该工艺在商业应用中的应用。在耐磨性方面，甚至很少进行研究，但初步发现表明，与锻造材料相比，有更大的阻力。本研究的目的是全面回顾AM用于工程结构抗侵蚀和耐腐蚀的最新进展，重点是海上可再生能源结构。本研究的结果有助于确定未来研究的知识差距，以实现增材制造在海上工业中的商业化应用。

With the increasing interest in a green transition to Net Zero, offshore renewable energy is becoming a big focus for many countries. There are hundreds of offshore wind turbines which are coming to the end of their 25-30-year lifecycle and many developers are looking into life extension options to maximise their assets. The structures for offshore renewables are subject to some of the harshest environments in the world, with loading from wind, wave, and tides in a corrosive and erosive environment. Additive Manufacturing (AM) has shown great promise for use in the marine environment. However, little research or application of the technology has been done within the sector. Corrosion is seen as one of the biggest threats to offshore structures and can be accelerated with the presence of erosion. AM has the potential to mix different materials to improve the properties of the end part. Wire Arc Additive Manufacturing (WAAM) has shown great promise due to the ability to create large components, in short lead times, with little defects compared to traditional manufacturing processes. The process allows for easy manufacture at ports or yards near offshore sites and therefore has the potential to create components with shorter lead times compared to traditional supply chain routes. Early research into the potential of using WAAM to create corrosion resistance coatings and components has highlighted the processes' many benefits but further research is required to justify the use of the processes for commercial applications. In terms of wear resistance even less research has been conducted but initial findings show that there is a greater resistance compared to the wrought material. The aim of this study is to thoroughly review the state-of-the-art on the use of AM for erosion and corrosion resistance of engineering structures with the focus on offshore renewable energy structures. The findings from this study help to identify the gap in the knowledge for future research to commercialise the AM application within the offshore industry.