Grant: Alliance Grants
University of Alberta
$116,000.00
Sustainable hybrid additive-subtractive inspection and remanufacturing processes for high chrome white iron machinery in the energy industry
FY 2024-25
Summary
Wear is a technical and expensive challenge in the oilsands industry, where replacement of parts includes
loss of production time and incurred costs for components and associated labor. Extreme temperatures,
pressures, aggregate impacts, and corrosive substances can contribute to wear damage. Equipment such as
pumps, valves, impellers, and piping are often exposed to highly abrasive fluids and gases where damage
manifests itself in a multitude of ways; for example, in the volute casing of a pump or on impeller
surfaces. Incurred damage of components has significant economic consequences, with replacement costs
approaching ~150K-200K CAD each. Furthermore, consistent replacement of components impacts the oil
sands' operational sustainability since component replacement has a high carbon and energy footprint due
to production and supply chain logistics.
This proposal will develop a novel hybrid, additive-subtractive repair process for repairing localized
wear on complex geometric surfaces for operational equipment. An advanced automated manufacturing
(AM) cell with 3D vision and hybrid AM capabilities will be designed and tested along with a wear-resistant
material compatible with Chrome White Iron (CWI, ASTM 532 IIIA) or similar. This system will enable
quick and precise inspections of equipment geometry and surface and subsurface cracks, identifying
potential issues. The hybrid AM capabilities will allow efficient on-site repairs to be made, reducing
costly and time-consuming equipment replacements. Implementing this solution would result in a 50%
decrease in cycle time, a 60% decrease in material costs, and significant carbon and energy footprint
reduction. Furthermore, an increased efficiency and accuracy of the system would improve safety by
reducing the risk of accidents and equipment failures, and enabling precision repairs. Developing and implementing this manufacturing cell is critical in addressing the challenges the oil and gas industry faces and ensuring the sector's long-term sustainability.
Program
Alliance Grants
Recipient
Location
Alberta, Canada
Recipient Type
Academia
Type
Grant
Source
NSERC's Awards Data
As published
Application id
592691-2024
Name nom
Qureshi, Ahmed Jawad AJ
Department département
Mechanical Engineering
Organization id
9
Institution établissement
University of Alberta
Province en
Alberta
Province fr
Alberta
Country en
CANADA
Country fr
CANADA
Fiscal year exercice financier
2024
Competition year année de concours
2024
Award amount
116000
Program id
ALLRP
Program name en
Alliance Grants
Program name fr
Subventions Alliance
Group en
RESEARCH PARTNERSHIPS
Group fr
PARTENARIATS DE RECHERCHE
Committee code
96
Committee name en
RPP Internal Decision Cttee
Committee name fr
Cté de décision interne - PPR
Area of application code
500
Area of application group en
Manufacturing processes and products
Area of application group fr
Procédés et produits industriels
Area of application en
Manufacturing processes and products
Area of application fr
Procédés et produits industriels
Research subject code
1702
Research subject group en
Design and manufacturing
Research subject group fr
Conception et fabrication
Research subject en
Advanced manufacturing
Research subject fr
Méthodes de fabrication avancées
Field of research list names en
Not available
Field of research list names fr
Non disponible
Socioeconomic objective list names en
Not available
Socioeconomic objective list names fr
Non disponible
Application title
Sustainable hybrid additive-subtractive inspection and remanufacturing processes for high chrome white iron machinery in the energy industry
Keywords
additive manufacturing; high chrome white iron; hybrid manufacturing; metal 3d printing; multi scale non contact metrology; plasma transfer arc am
Application summary
Wear is a technical and expensive challenge in the oilsands industry, where replacement of parts includes
loss of production time and incurred costs for components and associated labor. Extreme temperatures,
pressures, aggregate impacts, and corrosive substances can contribute to wear damage. Equipment such as
pumps, valves, impellers, and piping are often exposed to highly abrasive fluids and gases where damage
manifests itself in a multitude of ways; for example, in the volute casing of a pump or on impeller
surfaces. Incurred damage of components has significant economic consequences, with replacement costs
approaching ~150K-200K CAD each. Furthermore, consistent replacement of components impacts the oil
sands' operational sustainability since component replacement has a high carbon and energy footprint due
to production and supply chain logistics.
This proposal will develop a novel hybrid, additive-subtractive repair process for repairing localized
wear on complex geometric surfaces for operational equipment. An advanced automated manufacturing
(AM) cell with 3D vision and hybrid AM capabilities will be designed and tested along with a wear-resistant
material compatible with Chrome White Iron (CWI, ASTM 532 IIIA) or similar. This system will enable
quick and precise inspections of equipment geometry and surface and subsurface cracks, identifying
potential issues. The hybrid AM capabilities will allow efficient on-site repairs to be made, reducing
costly and time-consuming equipment replacements. Implementing this solution would result in a 50%
decrease in cycle time, a 60% decrease in material costs, and significant carbon and energy footprint
reduction. Furthermore, an increased efficiency and accuracy of the system would improve safety by
reducing the risk of accidents and equipment failures, and enabling precision repairs. Developing and implementing this manufacturing cell is critical in addressing the challenges the oil and gas industry faces and ensuring the sector's long-term sustainability.
