Focus first published in the September/October 2021 issue of 3D ADEPT Mag, in collaboration with Guaranteed. Roles, capabilities and examples reflect that period.
Once you have decided to go down the Metal Additive Manufacturing (AM) route, the next step is at least equally important. While “value for money” is often the most analysed criterion, the truth is, working with a solutions provider must go beyond this important argument. Indeed, not only is the market filled with companies offering AM services, but also confusion can quickly arise when one realizes there is also a wide range of metal AM technologies. What criteria should you use to favour one technology over another? And most importantly, how should/do you envision the future of your production with that Metal AM solution?
Metal additive manufacturing has developed beyond prototyping, with production applications in sectors including medical, aerospace and automotive. Its suitability depends on the part and the selected process.
Part size imposes constraints on build volume, productivity and cost. Powder-based processes are not restricted to small parts, however: powder bed fusion must be distinguished from directed energy deposition, which can use wire or powder feedstock.
Choosing a process for large parts
In oil and gas, maritime, energy, transport or heavy industry, some large parts are cast or forged in steel, nickel-based alloys or titanium. Complex geometry, low volumes or long supply lead times can prompt a comparison with additive manufacturing.
All of these constraints often lead manufacturers to explore manufacturing processes which could best meet these requirements.
“The combination of component size and functional complexity makes a compelling case for the wire based DED-processes (CMT and plasma) offered as a one-stop-shop manufacturing service by Guaranteed as it allows parts up to 10 x 5 x 6 meters and up to 20 tons to be produced near-net-shape within short lead times at a competitive cost. Currently the material database is already well populated (steel, stainless, Inconel, titanium, aluminium, bronze …), but it can easily be expanded at the request of our customers”, Joachim Antonissen, CEO Guaranteed comments.
These dimensions and weight are the capabilities Guaranteed reported in this interview. WAAM refers here to wire deposition using an electric arc; CMT and plasma are approaches offered by the supplier.
Wire cost and availability can favour some WAAM projects. High density does not automatically remove the need for hot isostatic pressing or other post-processing: the process route must meet material, property and part-qualification requirements.
Depositing onto an existing component can enable hybrid manufacture or local repair. Potential material, transport and storage savings must be compared with the preparation, inspection and finishing required.
Include qualification from the outset
Service and certification requirements form part of the economic assessment. Quality control can limit rework and scrap, but itself requires procedures, testing and inspection.
Guaranteed presents its process-control software as a way to reduce trial-and-error and improve process control. The supplier reports participating in qualification work for oil and gas, maritime, rail and mining. Requirements depend on the component and applicable standard. The research described on deposition speed and mechanical properties represents development goals, not evidence of general superiority over forged parts.
“Born from innovation, we use state of the art unique simulation, monitoring and inspection tools to guarantee first time right zero-defect production. Being raised in Industry, we guarantee one-stop-shop industrial reliability”, Sander Plasschaert, CTO Guaranteed states.
This wording expresses the supplier’s commercial commitment; it does not replace process qualification and part acceptance criteria.
Is the best spare part a virtual one?
As installations operate in increasingly challenging environments, there is a larger likelihood of essential parts breaking down, becoming obsolete due to technological changes or changes to standards or going out of production before their end of life. The small series sizes and short life cycles of parts relative to the installations present a challenge in inventory management and further strengthen the case for the deployment of large size metal AM.
Stocks of rarely ordered parts tie up resources and can become obsolete. For selected parts, on-demand production can reduce this need. A digital inventory nevertheless requires qualified files, the relevant usage rights and production capacity available within the required lead time.
The benefit must be quantified using actual part costs, stock turnover, equipment criticality and replacement lead times. On-demand manufacturing does not eliminate every inventory requirement.
In 2021, Guaranteed reported participating in digital-warehouse ecosystems in oil and gas, rail and maritime.
“AM supports our operations with shorter lead-time because it creates a shift towards buying parts just-in-time as opposed to just-in-case. The traditional way of buying spare parts at the onset of installing new equipment, may no longer be necessary if we can print the parts with the same or improved quality. Spare parts stored in a warehouse require proper storage and preservation which comes at a cost and does not provide agility when operating conditions change and the original spare parts may no longer be suitable. We believe that printing spare parts just-in-time eventually reduces the costs of sourcing specific parts, especially those that are critical for business operations”, A. Goh, Shell points out.
Value the future, upgrade the past
Ageing installations can make replacement difficult when a part becomes obsolete or requirements change. The aim is to restore a compliant function while limiting equipment downtime.
Guaranteed offers reproduction, repair or refurbishment, including one-off parts. Any design or material change must be justified and validated for the intended use; improved service life cannot be assumed for every repair.
For some parts that are difficult to move, Guaranteed also described a mobile WAAM repair service in 2021. Feasibility depends on intervention conditions, material and the inspection that can be performed on site.
Assessing resource savings
Repairing a part or making it closer to its point of use can reduce some material and transport needs. Environmental benefit nevertheless depends on energy, consumables, treatments and achieved service life for an equivalent function.
“AM and digital parts libraries will result in cost savings through smaller inventory volumes and reducing costs and risks of late life and obsolescence. As Equinor moves to zero carbon and increases its renewables presence, reducing the environmental impact of equipment production and the transport of parts through the supply chain will become increasingly important”, Brede Laerum – Equinor adds.
Guaranteed reported a comparative life-cycle analysis conducted with Cranfield University and WAAM3D. The illustrations present its estimates for production, repair and refurbishment cases. Because this Focus does not provide the full study boundary and underlying data, the results cannot be generalised to all parts or facilities.
The supplier also reported funding from a Booster fund of the European Institute of Innovation and Technology. This support does not itself constitute independent validation of every performance claim.
Comparing options case by case
Guaranteed explains that it examines repair, refurbishment and on-demand manufacture with customers. Depending on the case, potential gains concern obsolete-part replacement, inventory or working capital. They must be assessed against qualification costs and operating constraints.
Provider selection therefore needs to combine manufacturing capability, quality control, lead times, and a documented economic and environmental assessment. Guaranteed’s examples illustrate this approach for its WAAM applications.
This content has been created in collaboration with Guaranteed.
Initially published in the 2021 September/October edition of 3D ADEPT Mag.
Contact details:
All images: courtesy of Guaranteed
+32 473 30 19 28 | info@guaranteed.be
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