Fused filament fabrication (FFF) for oil sands applications

适用于油砂应用的熔丝制造 (FFF)

• 批准号: 537171-2018
• 负责人: Henein, Hani
• 金额: $ 4.94万
• 依托单位: University of Alberta
• 依托单位国家: 加拿大
• 项目类别: Collaborative Research and Development Grants
• 财政年份: 2021
• 资助国家: 加拿大
• 起止时间: 2021-01-01 至 2022-12-31
• 项目状态: 已结题
• 来源: https://www.nserc-crsng.gc.ca/ase-oro/Details-Detailles_eng.asp?id=720237
• 关键词: Fused; filament; fabrication; FFF; oil

Maintenance of oil sands facilities is exceedingly expensive with Syncrude for example spending over $1.7 Billion annually on these tasks. It is imperative to have reliable and improved metal-ceramic composites for wear applications. Additive Manufacturing (AM, also known as 3D printing) is a recent innovation that holds much promise for the industry. It allows components to be redesigned for greater efficiency, lighter parts, and functionally more efficient. Numerous AM processes have been developed and tested. This project will utilize Fused Filament Fabrication (FFF) process as it is at least an order of magnitude cheaper than laser based systems. Using FFF, a metal and ceramic powder can be embedded into the polymer matrix fiber and the component built layer by layer. Subsequently, the polymer can be removed and the metal-ceramic composite sintered to final shape. This approach also has the advantage over laser based systems of not melting the metal powders, a very expensive raw material, as well as eliminating the issue of powder recycling. This proposal is, therefore, composed of four (4) interdependent tasks. The first is the fabrication of polymer filaments having optimum high loading of metal and ceramics powders. The second will address experiments and modeling of the printing process. Task 3 will address the important aspect of debinding and sintering the 3D printed samples. It is critical to determine sintering approaches and parameters that will yield fully dense samples. The fourth and final task will integrate the knowledge generated from the previous three Tasks to print a sample component and test its wear characteristics. This project will be carried out using the expertise of four colleagues in a collaborative manner. By combining the expertise in materials, modelling and manufacturing, we will identify the optimum conditions for applying FFF to metal matrix applications for wear resistance. Over this four year project, we estimate that between 4 and 6 graduate students will be trained in a multi-disciplinary field. The benefits to Canada will stem from improved wear resistant parts for the oil sands operation, new markets for a Canadian SME, and increased HQP trained in AM.

Syncrude 的油砂设施维护极其昂贵，例如每年在这些任务上花费超过 17 亿美元。必须有可靠且改进的金属陶瓷复合材料用于磨损应用。增材制造（AM，也称为 3D 打印）是一项最新的创新，为行业带来了巨大的希望。 它允许重新设计组件，以提高效率、减轻部件重量并提高功能效率。许多增材制造工艺已被开发和测试。该项目将采用熔丝制造（FFF）工艺，因为它比基于激光的系统至少便宜一个数量级。 使用FFF，可以将金属和陶瓷粉末嵌入聚合物基体纤维和逐层构建的组件中。随后，可以去除聚合物并将金属陶瓷复合材料烧结成最终形状。 与基于激光的系统相比，这种方法还具有不熔化金属粉末（一种非常昂贵的原材料）的优点，并且消除了粉末回收的问题。 因此，该提案由四 (4) 项相互依赖的任务组成。 第一个是制造具有最佳高负载金属和陶瓷粉末的聚合物长丝。第二个将讨论印刷过程的实验和建模。 任务 3 将解决 3D 打印样品脱脂和烧结的重要问题。 确定能够产生完全致密样品的烧结方法和参数至关重要。 第四个也是最后一个任务将整合前三个任务生成的知识来打印样本组件并测试其磨损特性。该项目将利用四位同事的专业知识以协作方式进行。 通过结合材料、建模和制造方面的专业知识，我们将确定将 FFF 应用于金属基体应用以提高耐磨性的最佳条件。 在这个为期四年的项目中，我们估计将有 4 到 6 名研究生接受多学科领域的培训。 加拿大的利益将来自油砂作业耐磨部件的改进、加拿大中小企业的新市场以及接受增材制造培训的总部人员的增加。