| Abstract Scope |
The energy sector relies on scheduled shutdowns to maintain operational integrity, but completing these processes efficiently within time and budget constraints remains a challenge. Unexpected component failures, without readily available replacements, can significantly extend downtime and escalate costs. Wire Arc Additive Manufacturing (WAAM) is being explored as a potential solution.
This presentation showcases a case study on the fabrication and qualification process of a 2" CL150 flange using WAAM. Qualification walls were first produced in accordance with the requirements outlined in ASME Section IX, QW-600, following the procedure intended for the fabrication of the flange. The components were produced with ER70S-6 welding wire, classified under SFA 5.18. Deposition was performed using the Lincoln Electric Sculptprint RND WAAM system and its associated modeling software. Following deposition, the flange was machined to meet the geometric requirements specified in ASME B16.5 and was designed to meet the mechanical property requirements associated with SA-105 forged material specifications. However, a knowledge gap remains in how mechanical testing should be performed to reliably qualify WAAM components for pressure service applications.
Existing code frameworks separate mechanical testing requirements, particularly Charpy V-notch (CVN) impact testing, between weld metal and the heat-affected zone (HAZ) in traditional welded joints. In additive manufacturing (AM), however, the entire component consists of deposited weld metal. Despite this fundamental difference, there is currently little guidance on selecting representative mechanical test locations within WAAM components. This raises questions regarding how sampling location influences measured mechanical properties and whether conventional qualification assumptions remain valid. This work specifically examines the influence of sampling location, with particular focus on Charpy V-notch (CVN) toughness and tensile properties. This work demonstrates the qualification procedure for WAAM components, and questions conventional testing assumptions derived from traditional welding, particularly regarding Charpy notch placement. |