Oil & Gas
Industry
New Energies
Services
Explore & Produce
Transport
Process
Our Solutions
Additive Manufacturing
Steel Construction
Automative & Transport
Mechanical Engineering
Carbon Capture, Utilization and Storage (CCUS)
Hydrogen
Solar Construction
Solutions
Solar Construction
Geothermal Energy
Bioenergy
Easy Procurement
Circular Economy
Operational Efficiency

Additive Manufacturing solutions

Vallourec has introduced new solutions to enhance the future of the metallic component value chain for various markets through Wire Arc Additive Manufacturing (WAAM).

This technology utilizes the process of additive manufacturing, which involves constructing a 3D object by adding material in successive layers. As part of the Direct Energy Deposition (DED) process family, WAAM can create shapes that are not achievable through traditional casting or forging and provides short lead times. With its versatility, the technology can cater to a wide range of applications and needs. The company’s material expertise, quality standards, and industrial framework form the foundation of this innovative offering, enabling the delivery of finished and certified parts.

Benefits
Benefits
On-demand production
Optimized design for large metallic parts
Short lead times
Faster delivery in remote locations
Cloud-based inventory
Digital warehousing
Manufacturing
Wire Arc Additive Manufacturing

For large metallic components, WAAM is the most promising and fastest 3D printing technology. With it we can design, print and fully qualify metal parts to the highest standards of quality. It offers you greater efficiency and shorter lead times, allowing you to revolutionize how you manage your assets.

How does the 3D printing work?

WAAM uses an electric arc controlled by a robotic arm to melt metal wire directly onto the surface of the base, layer by layer.

How does it impact supply chain?

WAAM does more than create a physical product, it offers the ability to create a digital warehouse so you can cut down physical storage costs and improve your supply chain efficiency by obtaining parts on demand.

How flexible is the process?

WAAM offers the opportunity to shape the part you need in a variety of materials. It provides total freedom to create new designs and new functionalities.

A one-of-a-kind-line

Designed with state-of-the-art technologies (component printing and ultrasonic inspection) capable of manufacture with short lead times (<4weeks).

Integrated

With existing traditional operations to address market requirements.

Printing area of 2m3

L=1m x l=1m x H=2m

A new technology gaining ground

  • Carbon steel components are qualified with a pressure test up to 22,500 psi
  • Quality plans are available with reference to standards and norms
  • New corrosion resistant alloys under qualification in R&D to be available soon
Warehousing
Digital Warehousing
We support your move toward digital warehousing WAAM radically changes the concept of warehouse logistics. Major O&G companies are increasingly turning to additive manufacturing to improve the agility of their supply chain, to reduce their physical stock and to establish a distributed network of manufactured parts by storing additive manufacturing digital files to be printed upon demand.
Materials
Materials
Low Properties Carbon Steel
High Properties Carbon Steel
Austenitic & Duplex Stainless Steel
Stainless martensitic steels
Nickel Base
Low Properties Carbon Steel
High Properties Carbon Steel
Austenitic & Duplex Stainless Steel
Stainless martensitic steels
Nickel Base
Characteristics and typical fields of application

Low yield stress carbon steels for energy, maritime and structural industries. Commonly used for accessories, piping and valves applications currently using grades B, LF2, S355, P265GH, F65…

Printed Product Typical Chemical Composition
Low Properties Carbon Steel
Characteristics and typical fields of application

Versatile high yield stress carbon steels, for a number of applications requiring high mechanical properties in energy, transport and structural industries. Suitable for surface components in O&G such as end fittings, bushings and circulating tools, and structural components in the industry. This material may be considered as a good mechanical alternative to carbon steel material such as 4130, grade 100, S890. Yield strengths from 100 ksi to 120 ksi without heat treatment and 110-140 ksi with heat treatment.

Printed Product Typical Chemical Composition
High Properties Carbon Steel
Characteristics and typical fields of application

Covering a very wide range of application for challenging environment for energy, maritime and structural industries using materials such as 316L, F51, X2CrNiMo22-9-3.

Printed Product Typical Chemical Composition– Duplex
Characteristics and typical fields of application

Covering a very wide range of application for challenging environment for energy, maritime and structural industries such as F6NM, 13/4.

Printed Product Typical Chemical Composition
Characteristics and typical fields of application

Nickel based alloys, widely used in aerospace, chemical, petrochemical and marine industries for its superior corrosion resistance properties under various harsh environement including salt water condition. This material has excellent strength from room temperature to elevated temperature. Available production data for 625 material:

References
WAAM Part Examples
Waterbushing
Safety Hook
Anti-return Valve
Sealing Ring
Repair Clamp
Anchor Flange
Waterbushing
Safety Hook
Anti-return Valve
Sealing Ring
Repair Clamp
Anchor Flange

Safety piece for well control
Dimensions: 1072 x 360 x 360 mm
Weight: 236 kg
Grade: X90

Safety braking hook
Dimensions: 320 x 170 x 50 mm
Weight: 12kg
Grade: X65

Maintenance part
Dimensions: 280 x 280 x 120 mm
Weight: 17kg
Grade: X65

Sealing ring for hydroelectric valve
Dimensions: 900 mm Ø
Weight: 180 kg
Grade: 13Cr-4Ni

On-stream leak sealing clamp for refineries and petrochemical plants
Dimensions: 700 x 400 mm
Weight: 40 kg
Grade: Carbon steel (Grade B)

Component used to anchor the pipeline in order to contrast thrust forces.
Dimensions: 2500 x 470 mm
Weight: 330 kg
Grade: X65

Resources
Documents & Resources
  • World Oil Tech Session “Powering Ahead: Using Additive Manufacturing in the Development of Large Metallic Components for O&G” 
    > View the session now!

 

  • Webcast “Thermal Spray & Wire Arc Additive Manufacturing” 
Contact
Contact us

Smartengo

Access our Product Configurator and get an instant quote & lead-time for your needs.

Need to contact us?

A specific project? Let’s talk about it
Our teams will be happy to discuss with you about your challenges and your projects.

More Videos

Videos

Discover the AM Team
Learn more about Thermal Spray Solution
More information about Additive Manufacturing
Stories
Customer Story
Safety-critical Sealing Ring for EDF Hydro’s Hydroelectric Facilities
Vallourec has manufactured the first safety-critical sealing ring using Wire Arc Additive Manufacturing for EDF Hydro’s hydroelectric facilities. This component, manufactured in martensitic stainless steel, is 1-meter long in diameter and weighs approximately 100kg. “Today, we have proved the benefits and the process of this technique and now we would like to scale up production and benefit from this new supply method in our facilities, which will involve thousands of components.” Sylvain Guyot, Additive Manufacturing Lead at EDF Hydro.
3D-Printed Lifting Plug Deployed in Timor Sea
Vallourec has recently produced 2 lifting plugs using Wire Arc Additive Manufacturing (WAAM) meeting Weatherford’s urgent operational demands. The 3D-printed safety-critical components weighed 175kg each with a tailor-made diameter of 50cm and were designed for load carrying applications of around 100 metric tons. “We were extremely happy with the finished product and will look to Vallourec and this method for future requirements.” Shane Ferguson - Project Manager for Weatherford
3D-Printed Waterbushing with TotalEnergies
Vallourec has equipped TotalEnergies with a 3D printed waterbushing for the EIG well in the North Sea. “This is the first time that a safety-critical component has been created using additive manufacturing in the Energy industry. It was essential for us to have the right partner and a good business case. Vallourec, as a longstanding partner, provided us with that confidence.” Edwige Ravry, Additive Manufacturing Lead at TotalEnergies
X-over production with DNV GL
The objective of the project was to perform a full-size physical component test in order to assess the performance of a WAAM manufactured product. The test has been successfully conducted with Internal Pressure (15,000 psi) combined with Tension, Compression loads (400 kips) and elevated temperature up to 130°C. Ultimately, concluding with a burst test with a pressure up to 30,000 psi without failure (50% above plastic deformation). Participating companies: BP, Equinor, Shell, Total - Contractors: SLM Solutions, TechnipFMC, IMI Critical Engineering, Kongsberg, Siemens - Fabricators: Vallourec, ArcelorMittal, voestalpine, ivaldi, Aidro Hydraulics, Additive industries, Immensa, Sandvik, HIPtec, Quintus & the Advanced Forming Research Centre of the University of Strathclyde.

Discover our OCTG Solutions

More information