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, HaniH
• 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: 2022
• 资助国家: 加拿大
• 起止时间: 2022-01-01 至 2023-12-31
• 项目状态: 已结题
• 来源: https://www.nserc-crsng.gc.ca/ase-oro/Details-Detailles_eng.asp?id=746820
• 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.

维持油砂设施的维护非常昂贵，例如，Syncrude每年在这些任务上花费超过17亿美元。必须具有可靠且改进的金属陶瓷复合材料，以用于磨损。添加剂制造（AM，也称为3D打印）是最近的一项创新，对该行业充满希望。 它允许重新设计组件以提高效率，更轻的零件，并在功能上更有效。已经开发和测试了许多AM过程。该项目将利用融合细丝制造（FFF）过程，因为它至少比基于激光的系统便宜。 使用FFF，可以将金属和陶瓷粉末嵌入聚合物基质纤维中，并逐层构建组件。随后，可以去除聚合物，并将金属陶瓷复合材料烧结到最终形状。 这种方法还比基于激光的系统具有优势，即不熔化金属粉末，这是一种非常昂贵的原材料，并消除了粉末回收的问题。 因此，该建议由四（4）个相互依存的任务组成。 首先是制造具有最佳高负载金属和陶瓷粉末的聚合物丝。第二个将解决打印过程的实验和建模。 任务3将解决删除和烧结3D打印样品的重要方面。 确定将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从前三个任务中生成的知识，以打印样品组件并测试其磨损特性。该项目将以协作的方式使用四个同事的专业知识进行。 通过结合材料，建模和制造的专业知识，我们将确定将FFF应用于金属矩阵应用程序的最佳条件以进行耐磨性。 在这个四年的项目中，我们估计将在多学科领域接受4至6名研究生的培训。 加拿大的好处将源于油砂运营的耐磨零件，加拿大中小型企业的新市场以及在AM培训的HQP增加。