MX3D是金属电线弧添加剂制造（WAAM）技术的开发商，已公布其新的3D印刷的“ WAAM夹”。
这hybrid industrial part is an example of a pipeline clamp, a component used to seal high-pressure leaks in the chemical and oil and gas sectors. Pipeline clamps are a crucial part of pipeline repair, and also serve to improve the service life of an installation before maintenance is required.
在欧盟Horizon 2020计划的支持下，3D打印的WAAM夹在生产和测试。Team Industrial Services和TIAT - 工业管系统维护的两名专家。这BWI（比利时焊接研究所）also performed material testing, while劳埃德的登记册辅助MX3D具有零件认证过程。
Thomas Van Glabeke, Project Lead and R&D Manager at MX3D, said, “Hybrid additive manufacturing combines both the advantages of conventional manufacturing such as precision and high production speed of ‘simple’ parts, with the advantages of additive manufacturing, such as geometrical freedom, production speed, and minimal material waste. The WAAM Clamp quality and complexity showcase the potential of the technology developed by MX3D.”
Up to €1 million a day
In the oil and gas sector, short lead times are crucial due to their implications for production downtime and minimizing human, environmental, and safety risks. As it stands, the lead time of a pipeline repair project can be as long as three weeks, with a potential value loss of up to €1M a day for the affected company.
现代维修项目中使用的管道夹通常依赖于常规的制造工艺，例如CNC加工，不幸的是，该工艺还带有高材料废物（有时超过原始材料块的80％）。操作这些机器还倾向于需要一支专业的劳动力，这是数字化时代的减少资源。
桥接传统和添加剂制造
In a bid to address these issues, the hybrid WAAM Clamp combines both conventional and additive manufacturing. The component was partly fabricated using anMX3DM1 Metal AM 3D printer, with some of the simpler sections CNC machined for precision.
WAAM夹子的重量为87公斤（3D印刷），用2.1 kg/hr的材料沉积速率花了45小时才能制造。该项目合作伙伴选择了ASME IIA SA-516-70作为基础材料 - 一种通常用于石化应用的钢。通过BWI执行材料测试，劳埃德的登记册有资格，并监督该零件的非破坏性测试，该财团能够达到WAAM夹具的高水平保证。
Finally, Team Industrial Services validated the build with a pressure test, confirming that the WAAM Clamp was able to withstand the maximum test pressure of 60 Bar without fatigue or fracture.
通过采用混合WAAM方法，合作伙伴利用3D打印的几何自由来利用CNC加工的尺寸精度，同时消除了由于WAAM的高沉积率而消除了后处理并大大减少了交货时间。作为奖励，还将物质废物保持在最低限度，这对制造成本和环境都是有益的。
弗勒·马斯（Fleur Maas）, Managing Director of the BWI, concludes, “WAAM produced components can offer a real advantage for the production of bespoke elements, for example in piping or for petrochemical industries. The alternative production methods of these (sizeable) components tend to be relatively costly, and not always able to deliver parts quickly.”
This certainly isn’t the first time additive manufacturing has been leveraged for petrochemical applications. Earlier this year, oil and gas firmVallourec通过设计和3D printing a safety-critical water bushing component for the very first time。Designed for French oil majorTotal, the part is reportedly the first ever pressure-containing component to be 3D printed using the WAAM process.
在其他地方，一个由ABS,Sembcorp Marine, and3D Metalforgerecently fitted aConocoPhillips polar oil tanker with end-use 3D printed parts。印刷的零件包括功能性离心泵轴，组合的盐水/空气喷油器喷嘴和一个废水泵耦合设备，每个设备都通过了严格的安全检查。
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Featured image shows the WAAM Clamp being 3D printed on the MX3D M1 Metal AM System. Photo via MX3D.
