| Abstract Scope |
The energy sector incurs significant financial costs due to mandatory shutdowns and maintenance periods, essential for equipment inspections and repairs. Unforeseen part failures compound these costs by extending the shutdown duration and increasing the loss of production time. Specialty replacement parts, such as stainless steel flanges, are often unavailable and subject to long fabrication times. Additive manufacturing could be a successful solution for rapidly producing specialized parts on demand, thereby streamlining maintenance processes, and reducing downtime. This presentation will discuss the current progress towards utilizing the Lincoln Electric Sculprint RND Machine to fabricate a flange using ER70S-6 mild steel in place of stainless steel. Following fabrication, it was milled to meet ASME B16 standards, ensuring compatibility with the specialty 18” stainless steel flange. Initially, overbuild dimensions were employed to facilitate precise milling but proved insufficient, resulting in material deficiencies and dimensional inaccuracies. Additionally, an issue with arc initiation was observed, attributed to excessive silica buildup during the printing process, resulting in frequent wire break-offs. Studying the microstructure of the test samples and conducting hardness mapper tests revealed important features for qualifying the flanges according to standard. The finished flanges will undergo testing for compliance with ASME Section II SA105 and SA350 standards, focusing on bulk mechanical properties and chemical composition. This alternative allows for the rapid production of specialized parts on demand that could ultimately decrease costs and lead times. |