Additive Flange Build on ODS Pipes Without Hoop Strength Loss
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Solution Overview
Problem
Conventional welding techniques disrupt the oxide distribution in oxide dispersion strengthened (ODS) and precipitation strengthened nickel-based alloys, leading to significant reductions in strength and toughness, particularly along the hoop direction of piping components.
Innovation Solution
The use of additive manufacturing processes, such as directed energy deposition or powder bed fusion, to construct a flange on the outer surface of a pipe, thereby maintaining the mechanical and metallurgical properties of the ODS or nickel-based alloy without causing microstructural changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional welding methodologies are used to join pipe sections or attach flanges, then joining is achieved, but the distribution of oxides within the metal matrix is disrupted resulting in significant reduction in strength and toughness
Solution Approach 1:
The patent extracts the harmful welding process from the joining operation and replaces it with additive manufacturing. By removing the welding step entirely and using directional solidification to create a single-crystal or near-single-crystal structure that extends through the wall thickness, the disruption of oxide distribution is eliminated while maintaining joining capability through flange attachment.
Solution Approach 2:
The patent changes the manufacturing parameter from conventional welding to additive manufacturing with directional solidification. This parameter change transforms the microstructure formation process, allowing control over crystal orientation and oxide distribution to maintain strength while achieving the joining function.
2Ease of manufacture
If welding is used to attach flange to pipe, then flange connection is achieved, but microstructure change occurs through entire thickness of pipe resulting in reduction of mechanical properties
Solution Approach 1:
The patent removes the welding process from the flange attachment operation. Instead, flanges are attached using mechanical fastening methods (bolts, screws) to the pipe ends, which have been processed through directional solidification to maintain their microstructure. This extraction of the welding step prevents through-wall microstructure degradation.
Solution Approach 2:
The patent applies preliminary directional solidification processing to the pipe sections before flange attachment. This creates a controlled microstructure with optimized oxide distribution and crystal orientation in advance, so that subsequent flange attachment does not require welding that would degrade the properties.
3Strength
If additive manufacturing is used to build flange on pipe, then mechanical and metallurgical properties are retained, but manufacturing complexity increases
Solution Approach 1:
The patent segments the manufacturing process into distinct steps: directional solidification of pipe sections, separate flange manufacturing, and mechanical assembly. This segmentation allows each component to be optimized independently while maintaining overall simplicity, avoiding the need for complex integrated welding processes.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method allows for the retention of mechanical properties like hoop strength, hardness, and tensile strength, enabling the use of these alloys in high-temperature piping applications without degrading their performance.
Implementation Method 1
The flange can be constructed using such as directed energy deposition, powder bed fusion, friction-stir, or diode laser cladding additive manufacturing processes
Implementation Method 2
The flange can be constructed using such as directed energy deposition, powder bed fusion, friction-stir, or diode laser cladding additive manufacturing processes
Implementation Method 3
By using additive manufacturing, the mechanical and metallurgical properties of the ODS or nickel-based alloy material can be retained after constructing the flange on the pipe
Data Source
AI summary
The present invention is directed to methods for constructing a flange on a pipe using an additive manufacturing process, such as directed energy deposition, powder bed fusion, friction-stir, or diode laser cladding. The flange can be constructed on a pipe comprising an oxide dispersion strengthen or nickel-based alloys, in particular a precipitation strengthened nickel-based alloy, such that the pipe maintains its inherent mechanical and metallurgical properties, including hardness, tensile strength, yield strength, fracture toughness, creep strength, fatigue, which would otherwise be reduced based upon typical welding of a flange to the end of the pipe. The flange can be constructed around the exterior of a pipe at the end of the pipe to allow use of the flange in connecting the pipe via bolting to other piping components, such as another pipe with a corresponding flange, a valve flange, a pump flange, or any other type of flange.