Additive Manufacturing for Oil & Gas Summit

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Glossary

1

Additive manufacturing (AM)

A family of processes that build parts layer by layer from a digital model, rather than removing material from a billet or casting. In oil and gas, AM is used for complex geometries, spare parts and repair.

2

Laser powder bed fusion (LPBF)

A metal AM process in which a laser melts thin layers of metal powder in a build chamber. It is used for fine-feature components such as downhole tool parts, heat exchangers and valve internals.

3

Directed energy deposition (DED)

An AM process that feeds metal powder or wire into a focused heat source, often a laser or arc, to build or repair parts. DED is suited to large components, cladding and repair of worn surfaces.

4

Wire arc additive manufacturing (WAAM)

A DED variant that uses an electric arc as the heat source and metal wire as feedstock. It is attractive for large steel or nickel-alloy structures where deposition rate matters more than fine detail.

5

Electron beam melting (EBM)

A powder bed process that uses an electron beam in a vacuum to melt metal powder. It can reduce residual stress in reactive alloys such as titanium, but the vacuum chamber limits part size.

6

Binder jetting

An AM process that deposits a liquid binder into a powder bed to form a green part, which is then cured and sintered. It can be faster and less costly for certain geometries, but shrinkage and density require process control.

7

Metal feedstock

The powder or wire consumed by an AM process. Alloy chemistry, particle size distribution, oxygen content and morphology affect flow, melt behaviour and final properties.

8

Hot isostatic pressing (HIP)

A post-processing step that applies high temperature and gas pressure to close internal porosity and improve fatigue performance. It is often specified for safety-critical oil and gas AM parts.

9

Post-processing

All operations after the build, including stress relief, HIP, heat treatment, machining, surface finishing and inspection. In oil and gas, post-processing often determines whether a part meets pressure-boundary and corrosion requirements.

10

Qualification and certification

The evidence and approvals needed to show an AM part is fit for a defined service. It typically covers feedstock, process parameters, mechanical testing, NDT, traceability and a qualified production route.

11

Build simulation

Software that predicts distortion, residual stress and support requirements before a build. It helps engineers choose orientation and process parameters, especially for thin-walled or large oilfield components.

12

Topology optimization

A design method that removes material where loads are low to create lightweight, organic shapes. AM can produce these geometries, but the design must still pass pressure, corrosion and fatigue checks.

13

Near-net shape

A part produced close to final dimensions so that only limited machining is needed. AM near-net shapes can reduce material waste for expensive nickel or titanium alloys.

14

Deposition rate

The amount of material deposited per unit time. High deposition rate processes such as WAAM or DED suit large parts, while LPBF trades speed for fine resolution.

15

Porosity

Voids or gas pockets trapped in a built part. Porosity and lack-of-fusion defects are key inspection targets because they can reduce fatigue life and pressure integrity.

16

Maintenance, repair and overhaul (MRO)

The process of restoring worn or damaged equipment to service. AM is used in MRO for cladding, rebuilding worn seals, impellers and valve seats, and for producing obsolete spares.

17

Corrosion-resistant alloy (CRA)

An alloy selected for resistance to harsh oilfield environments, such as duplex stainless steel, super duplex, Inconel or titanium. AM process parameters must be qualified for each CRA and service condition.