additive manufacturing efforts in dnvgl › images › sridhar-am in dnvgl-overview... · ramesh...

DNV GL © 04 December 2017 SAFER, SMARTER, GREENERDNV GL ©

04 December 2017

Additive Manufacturing Efforts in DNVGL

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Narasi Sridhar

DNV GL © 04 December 2017

Why the interest in AM?

▪ Faster development to market cycles

▪ Point of use manufacturing

▪ Unique properties

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Major activities in AM

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R&I project started in 2014

Position paper and detailed reportDevelopment of

Standards

Material

Qualification

Certification/

Approval


DNVGL Model on Class Program

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DNVGL Rules, Class Guideline and Approval of Manufacturer

▪ DNVGL Class Guideline CP 0197-

November 2017-

▪ Appx 3000 download in 6 month .

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DNVGL rule allows AM Component

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Included in Offshore standard

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DNVGL-CP-0267

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Project Examples: 2018

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•Laser cladding for Turbo charge repair -

•Project completion in April 2018

•Contact Ramesh Govindaraj & Clas Jenstrup

Green ship of future- Denmark Danish Maritime Fund with

PJ Diesel Engineering, Denmark

Force Technology, Denmark

Kompressorenbau Bannewitz GmbH, KBB, Germany

•Crane Hook by Wire Arc Additive Manufacturing

•Project will start in March 2018 and expected to complete Dec 2018

•Contact: Ramesh Govindaraj/Bas WolfslagHuisman – Netherland

•Project Started for Hybrid AM Component by Powder bed Laser AM

•Project till 2019 Contact: Thorsten Lohmann/Norbert Worm,

SIGLAM German-Chinese manufacturing project

•Started

• 4 different products to be certified by DNVGL

•Contact: Harsharn Tathgar/Ramesh Govindaraj,

Joint Industry Project “ ProGRAM”

With Berenshot, Equinor (Statoil), Rolls Royce, SLM Solutions, Technip

FMC, Univ. of Strathclyde, NTNU among others

Present Project


Project Examples: 2018

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•Discussion regarding 3D welded propeller development project

•Contact DNVGL YK Lim/SK Kim, Korea and Ramesh Govindaraj, Høvik

Hyundai Heavy Industry, Ulsan

•Discussion to print one ship block

•Contact: Ramesh GovindarajAustal, Australia

•Different clients in Maritime and Oil & Gas on variety of topics in AM life cycle and certification

•New JIP program started

•Contact : Sastry Kandukuri

Global Additive Manufacturing Technology

Centre in Singapore.

•Material qualification studies at DNVGL Lab ,Ohio

•Contacts: Chris Taylor, Liu Cao, Bill KovacsJIP on AM Materials for Oil and Gas

•Maritime component

•Contact . Thorsten Lohmann/Norbert Worm, Maritimes Netzwerk –Germany

New projects


ProGRAM JIP – Qualification of AM products (Høvik)

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▪ The objective of the JIP will be to

develop requirements necessary to

introduce components made by AM for

Oil and Gas and related applications.

▪ A key deliverable will be a project

guideline that can be issued as a DNV

GL recommended practice.

▪ Participants: 11+2 (new)

▪ Still possible to join


Participating companies

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Other key references

▪ DNV GL Class Guideline DNVGL-CG-

0197

▪ Approval of Manufacture Class

program DNVGL-CP-0267 - Additive

Manufacturing issued July 2018

▪ International Standards

▪ Other guidelines

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This will form a basis for the

DNV GL approach for ProGRAM

http://rules.dnvgl.com/docs/pdf/dnvgl/cg/2017-11/dnvgl-cg-0197.pdf#search=Additive%20Manufacturing


Project period/progress

The tentative key milestones for this JIP is as follows:

▪ Kick-off (K.O.) and Steering Committee meeting 2018-01-11.

▪ Workshop 1 - MPS requirements, threat assessment. 2018-03-07 (8 weeks after K.O.).

– Over 300 failure modes identified!

▪ Workshop 2 – Essential variables and test requirements 20-22 weeks after K.O. Held on 11-12

June at SLM solutions in Lubeck - Germany

▪ Workshop 3 – Draft Guideline 38-40 weeks after K.O. Planned 1-2 October (week 40)

▪ Final guideline Within 18 months after K.O. (June 2019)

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▪ Name/owner: Propeller blade / Rolls Royce

▪ Size: 375*200*320

▪ Material: ??

▪ Process partner: SLM

▪ Process: PBF

▪ Redesign: Light weighted at SLM

▪ Status: Ready to print in SLM 800. Waiting for available slots.

Expect to print in September/October. Designing tests for class

vessel validation

Parts & processes (Overview)

▪ Name/owner: Flange / TechnipFMC

▪ Size: 240ø * 95

▪ Material: SS (316L?)

▪ Process/partner: talks with Strathclyde, Arcelor, RamLab

▪ Process: WAAM

▪ Redesign at TFMC

▪ Status: Looking into business case and production strategies?

▪ Name/owner: Impeller / Equinor

▪ Size: 250ø * 70

▪ Material: Inconel 625 (SLM) and Ti (AI)

▪ Process/partner: SLM & Add. Industries

▪ Process: PBF

▪ Redesign at Eureka & Ivaldi

▪ Status: SLM and AI validated printing strategy, waiting on test

specimen designs, new quote and quote approval.

▪ Name/owner: Cross-over / BP

▪ Size: 140ø * 1170

▪ Material: inconel, Superduplex

▪ Process/partner: Strathclyde, Ramlab

▪ Process: WAAM

▪ Redesign at Strathclyde/ Dutch universities

▪ Status: Determining section to be manufactured, waiting for WAAM

availability.

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Roll Royce Turbine

Blade

Jip Partners External partners

Core teams Equinor BP RR TFMC Arcelor Ivaldi Voest. Strathclyde SLM AI Ramlab Eureka

Crossover (BP) Part owner Expert Producer Producer

Turbine Blade (RR) Part owner Producer

Pump Impeller (Equi) Part owner Expert Producer Producer Expert

Companion Flange (TFMC) Part owner Producer Producer Expert

Equinor

Impeller


Feedbacks from partners

▪ Rolls-Royce Marine: “Many of our components and products have to be approved by Classification

Societies. In this JIP project, we can test if the 3D printed components can be produced according

to our and the class societies requirements.”

▪ Equinor: The diversity and differences in competence fields within the core teams is important to

arrive at good results. In the process together we also learn a lot and get insight from each

other.

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DNV GL – Thought Leader in AMEstablishment of Global AM Centre of Excellence in Singapore

- Thought Leadership

- Joint Development/Industry Projects

- Development of Certification Schemes for

Personnel, Equipment and Products

- Laboratory Testing

- Training Centre

▪ >6000 hours of AM direct customer engagement / project execution / activities

▪ Offering services in AM value chain / Eco-system from End-to-End

▪ Equipped with dedicated AM expert and team of 10 people


Various ongoing /oncoming customer projects @AM CoE Singapore

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Ongoing JIPs in Singapore on repair & new build

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JIP on AM 718 (Columbus, Ohio)

▪ To evaluate the performance of AM 718 in representative oil and gas production environments

and compare it to conventional 718 using the same tests

– High temperature sour service

– Sea water CP

– Completion/packer fluids

▪ To understand the microstructural differences between the conventional and AM 718 after

straining using advanced SEM techniques

– Identify the role of inclusions on cracking

– Identify the role of second phase precipitates (carbides, γ", γ‘, δ)

▪ To understand the electrochemical corrosion differences between conventional and AM 718 in

acids and sea water

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Benefits of the program

▪ The project will identify whether AM 718 can meet the same sour service requirements as

conventional 718. This will provide guidance on further improvements needed.

▪ The microstructural characterization using advanced electron microscopy techniques will help us

understand what processing conditions (e.g., powder quality, deposition parameters, post-

deposition treatments) are likely to improve AM performance

▪ The test program will help inform future guidance to test and qualification procedures

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Summary

▪ AM parts will occupy an increasing role in various components (initially non-critical, but

increasingly critical)

▪ Qualification and approval of AM parts present unusual challenges due to the extended supply

chains

▪ DNVGL has initiated internal as well as external projects to develop deep knowledge of AM

materials and parts and guidelines and rules for approving them.

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