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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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DNV GL © 04 December 2017
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
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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
DNV GL © 04 December 2017
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
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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
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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
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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
DNV GL © 04 December 2017
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
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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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DNV GL © 04 December 2017
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