cold spray additive manufacturing for new …
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COLD SPRAY ADDITIVE MANUFACTURING FOR NEW PIPELINE FABRICATION IN LIVE, NATURAL GAS DISTRIBUTION MAINSPI: Dr. Farah Singer, ULC Technologies, LLCCO-PI: Dr. Baiyang Ren, ULC Technologies, LLC Subcontractor: Mr. Anthony J. Naccarelli, PSU ARLSubcontractor: Dr. Alessandra Colli, BNL
We are developing a novel, cost-effective Cold Spray additivemanufacturing process for rehabilitating aging gas distribution pipelines,using methane as the carrier gas of the process.
Total Project Cost: $1.25MLength 12 mo.
Project Vision
ARPA-E REPAIR Kickoff Meeting – January 6 & 7
INNOVATION
Next-generation Process For Rehabilitating Aging Gas Distribution Pipelines
Operates in live natural
gas pipes
COLD SPRAY ADDITIVE MANUFACTURING FOR NEW PIPELINE FABRICATION IN LIVE, NATURAL GAS DISTRIBUTION MAINSJanuary 12, 2021
Does not require
pipe pre-cleaning
Remote robotics
operation
Faster than SOA
3D printers
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INNOVATION
ARPA-E REPAIR
Cold Spray Structural Stainless Steel Coatings
Minimal reliance on aging host
pipe substrate
Anticipated >50 years
life expectancy
Standard for H2
transport and
storage
COLD SPRAY ADDITIVE MANUFACTURING FOR NEW PIPELINE FABRICATION IN LIVE, NATURAL GAS DISTRIBUTION MAINSJanuary 12, 2021
Simplified Robotic Concept for Material Deposition
Nozzle
Aging pipe
SS deposit
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ADVANTAGES and IMPACT
COLD SPRAY ADDITIVE MANUFACTURING FOR NEW PIPELINE FABRICATION IN LIVE, NATURAL GAS DISTRIBUTION MAINSJanuary 12, 2021
State-of-the-art Technologies‣ Excessive Excavation for replacing pipe‣ Gas service disruptions‣ $1-10 million per mile cost‣ Environmental implications
Economics‣ Cost-effective process: < $1 million per mile‣ Drastically-reduced excavation costs‣ Positive impact on U.S. economy‣ New U.S. manufacturing jobs
Environment & Safety‣ Eliminate need for pipes cleaning/eliminate
need for hazardous waste disposal‣ Significant reduction in number of
leaks/reduced methane (greenhouse gas)emissions into atmosphere
Energy‣ Enhanced reliability of energy delivery
Social‣ No disruption of gas service to customers‣ Minimal Excavation sites
ULC’s REPAIR Technology
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THE TEAM
4COLD SPRAY ADDITIVE MANUFACTURING FOR NEW PIPELINE FABRICATION IN LIVE, NATURAL GAS DISTRIBUTION MAINSJanuary 12, 2021
Team member
Location Competencies Role in project
ULC Technologies, LLC (Prime Recipient)
NY ‣ Robotics R&D and RaaS.
‣ ME, EE and SE.‣ Systems design,
fabrication and testing.
‣ Cold spray processdevelopment.
‣ Testbench development.‣ Experimental testing and
validation.PSU Applied Research Lab (Sub)
PA ‣ Cold spray R&D.‣ Microstructural
characterization.‣ Material development.
‣ Cold spray parametersdevelopment.
‣ SS material selectionand characterization.
Brookhaven National Lab (Sub)
NY ‣ Material science and characterization.
‣ Data analytics approaches to advance metal AM.
‣ Deposited materialcharacterization.
‣ Physical/mechanicalproperties testing.
OBJECTIVES and TIMELINE‣ Objectives: Demonstrate the feasibility of fabricating a new high-quality SS pipes inside a
live aging gas pipes, using a cost-effective custom cold spray process.‣ Final Deliverables: A custom cold-spray system using methane as a carrier gas, and
capable of depositing uniform SS coatings inside 16”-20” pipes.
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TECHNOLOGY-TO-MARKET STRATEGY‣ Techno-economical (TEA) analysis‣ Cost target: < $1million/mile.‣ Early/continuous communications with industry/utility stakeholders and TTSP
– Define 1st, 2nd and 3rd markets– Develop road maps for the technology’s early commercialization– Facilitate technology adoption by regulators and operators
‣ Deployment of the technology as a service, licensing, leasing equipment, and sales ofequipment and associated training.
6COLD SPRAY ADDITIVE MANUFACTURING FOR NEW PIPELINE FABRICATION IN LIVE, NATURAL GAS DISTRIBUTION MAINSJanuary 12, 2021
2021 2026
- Develop CSAM process for rehabilitating gas
distribution steel pipelines- Explore market requirements/
commercialization potential
2022 2023
- Adapt the process equipment for compact robotic applications
- Develop a complementary structural health monitoring system
- Demonstrate early robotics prototype- Facilitate technology adoption by regulators and
operators
- Develop commercial cold spray robotic system- Launch service for natural gas pipelines- Conduct field tests and demonstrations
- Target other markets: crude oil and petroleum product pipes, and steam distribution pipes
CONVENTIONAL COLD SPRAY
‣ Cold spray process: particles of metal powder are propelled through a nozzle using heated, pressurized gas to accelerate them to supersonic speeds
– Relatively a bulky system‣ He or N2 gas: typical carrier gases‣ Applications: repairs, deposit metals on sensitive or difficult-to-weld surfaces, etc.
7COLD SPRAY ADDITIVE MANUFACTURING FOR NEW PIPELINE FABRICATION IN LIVE, NATURAL GAS DISTRIBUTION MAINSJanuary 12, 2021
Restored B737 nose wheel steering actuator barrel via Cold Spray Remanufacturing (Ref:
Cold Spray Coatings, Pasquale Cavaliere)Comparison between damaged and cold sprayed components: (a) AH-64
helicopter mast support, (b) F18-AMAD gearbox, and (c) front frame of T-700 engine (Ref: Cold Spray Coatings, Pasquale Cavaliere)
CHALLENGES and RISKS
Challenges ‣ Use Methane as carrier gas‣ Successfully scale down the system dimensions‣ Achieve targeted process costs: impact of SS powder price and process
speedRisks
‣ Undeposited SS powder: carryover in live pipes
Approach to overcome risks/challenges‣ ULC+PSU+BNL collective 20+ years of experience‣ Custom engineered systems‣ Initial concept validation using Nitrogen‣ Early industry communications‣ Cooperation with TTSP
8COLD SPRAY ADDITIVE MANUFACTURING FOR NEW PIPELINE FABRICATION IN LIVE, NATURAL GAS DISTRIBUTION MAINSJanuary 12, 2021
POTENTIAL PARTNERSHIPS
‣ We are open to collaborate with REPAIR teams, by providing our robotics and engineering expertise.
‣ We are open to collaborate with entities interested in future deployment of our CSAM technology.
9COLD SPRAY ADDITIVE MANUFACTURING FOR NEW PIPELINE FABRICATION IN LIVE, NATURAL GAS DISTRIBUTION MAINSJanuary 12, 2021
SUMMARY
‣ ULC and its partners PSU and BNL will develop a custom Cold Spray AdditiveManufacturing (CSAM) process for rehabilitating aging gas distribution pipelines
‣ The CSAM process will:– Create structural SS coatings that do not rely on the aging host pipe substrate– Use Methane as the carrier gas: run inside live natural gas pipelines– Require minimal excavation– Cost <$1million/mile– Have multiple social and environmental advantages over SOA technologies
‣ ULC will cooperate with TTSP for technology regulation
‣ ULC will identify technology commercialization paths and markets through earlycommunication with industry and utility stakeholders
‣ ULC’s envisioned timeline of milestones:– 2021: A developed custom CSAM system using methane as a carrier gas and capable
of depositing uniform SS coatings inside 16”-20” pipes– 2023: Complete demonstrations of early robotics CSAM prototype– 2026: Commercial robotic CSAM system launched service for natural gas pipelines;
other markets are targeted (crude oil and petroleum product pipes, and steamdistribution pipes)
10COLD SPRAY ADDITIVE MANUFACTURING FOR NEW PIPELINE FABRICATION IN LIVE, NATURAL GAS DISTRIBUTION MAINSJanuary 12, 2021
Thank you!
Farah Singer, PhDAssociate Project Manager
ULC Technologies, LLCOffice: 631-667-9200
Cell: 443-905-0295Email: [email protected]
LinkedIn: FarahSinger/LinkedInProfileWebsite: https://ulcrobotics.com
COLD SPRAY ADDITIVE MANUFACTURING FOR NEW PIPELINE FABRICATION IN LIVE, NATURAL GAS DISTRIBUTION MAINSJ anuary 12, 2021