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<p>Metal additive manufacturing, especially arc-based directed energy deposition (DED), is being considered as an alternative for suppliers to decentralize the manufacturing sector and reduce long lead times. However, due to the lack of material standards and certification that regulate the use of parts fabricated via arc-based DED in critical applications (e.g., sour environments), this technology is yet to show full industrial market insertion. In this regard, the present work describes the fabrication route and the certification procedure of a high-volume part (flange, API 6A model BX 169) fabricated via arc-based DED (gas metal arc). To certify the additively manufactured flange (2.5%Cr–1%Mo steel), an extensive array of tests was conducted, which included a full-scale hydrostatic, tensile, impact, hardness, and four-point bending in a sour environment. The additively manufactured flange demonstrated exceptional mechanical performance, achieving higher yield strength (613 vs. 517&#xa0;MPa), ultimate tensile strength (729&#xa0;vs.&#xa0;655&#xa0;MPa), elongation (19% vs. 15%), hardness (222 vs. 197 HV10), and Charpy V-notch impact energy at −46&#xa0;°C (95 vs. 20&#xa0;J) compared to API 6A standard. Additionally, no evidence of plastic deformation or stress corrosion cracking was observed during the full-scale hydrostatic test and the four-point bending in a sour environment (NACE TM0177), respectively. These findings fully meet the API 6A requirements, underscoring the reliability of arc-based DED for fabricating critical components used in the oil and gas industry. </p>

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From CAD to part certification: 2.5%Cr–1%Mo steel flange fabricated via arc-based directed energy deposition

  • 期刊论文

  • 发表日期：

    2025年7月6日

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  • Margareth Nascimento de Souza Lira,
  • João da Cruz Payão Filho,
  • Rodrigo Rodrigues Nogueira,
  • Francisco Werley Cipriano Farias

摘要

Metal additive manufacturing, especially arc-based directed energy deposition (DED), is being considered as an alternative for suppliers to decentralize the manufacturing sector and reduce long lead times. However, due to the lack of material standards and certification that regulate the use of parts fabricated via arc-based DED in critical applications (e.g., sour environments), this technology is yet to show full industrial market insertion. In this regard, the present work describes the fabrication route and the certification procedure of a high-volume part (flange, API 6A model BX 169) fabricated via arc-based DED (gas metal arc). To certify the additively manufactured flange (2.5%Cr–1%Mo steel), an extensive array of tests was conducted, which included a full-scale hydrostatic, tensile, impact, hardness, and four-point bending in a sour environment. The additively manufactured flange demonstrated exceptional mechanical performance, achieving higher yield strength (613 vs. 517 MPa), ultimate tensile strength (729 vs. 655 MPa), elongation (19% vs. 15%), hardness (222 vs. 197 HV10), and Charpy V-notch impact energy at −46 °C (95 vs. 20 J) compared to API 6A standard. Additionally, no evidence of plastic deformation or stress corrosion cracking was observed during the full-scale hydrostatic test and the four-point bending in a sour environment (NACE TM0177), respectively. These findings fully meet the API 6A requirements, underscoring the reliability of arc-based DED for fabricating critical components used in the oil and gas industry.