Undetected and undesired microstructural variations in components produced by laser powder bed fusion are a major challenge, especially for safety-critical components. In this study, an in-depth analysis of the microstructural features of 316L specimens produced by laser powder bed fusion at different levels of volumetric energy density and different levels of inter layer time is reported. The study has been conducted on specimens with an application relevant build height (>100 mm). Furthermore, the evolution of the intrinsic preheating temperature during the build-up of specimens was monitored using a thermographic in-situ monitoring set-up. By applying recently determined emissivity values of 316L powder layers, real temperatures could be quantified. Heat accumulation led to preheating temperatures of up to about 600 °C. Significant differences in the preheating temperatures were discussed with respect to the individual process parameter combinations, including the build height. A strong effect of the inter layer time on the heat accumulation was observed. A shorter inter layer time resulted in an increase of the preheating temperature by more than a factor of 2 in the upper part of the specimens compared to longer inter layer times. This, in turn, resulted in heterogeneity of the microstructure and differences in material properties within individual specimens. The resulting differences in the microstructure were analyzed using electron back scatter diffraction and scanning electron microscopy. Results from chemical analysis as well as electron back scatter diffraction measurements indicated stable conditions in terms of chemical alloy composition and austenite phase content for the used set of parameter combinations. However, an increase of the average grain size by more than a factor of 2.5 could be revealed within individual specimens. Additionally, differences in feature size of the solidification cellular substructure were examined and a trend of increasing cell sizes was observed. This trend was attributed to differences in solidification rate and thermal gradients induced by differences in scanning velocity and preheating temperature. A change of the thermal history due to intrinsic preheating could be identified as the main cause of this heterogeneity. It was induced by critical combinations of the energy input and differences in heat transfer conditions by variations of the inter layer time. The microstructural variations were directly correlated to differences in hardness.
A study group of 376 Clinton Sand wells in Ohio provided data to determine the historic frequency of the problem of abnormal production declines in stripper gas wells and the causes of the abnormal production decline. Analysis of the historic frequency of the problem indicates over 70% of the wells experienced abnormal production decline. The most frequently occurring causes of abnormal production declines were determined to be fluid accumulation (46%), gas gathering restrictions (24%), and mechanical failures (23%). Data collection forms and decision trees were developed to cost-effectively diagnose the abnormal production declines and suggest corrective action. The decision trees and data collection sheets were incorporated into a procedure guide to provide stripper gas well operators with a methodology to analyze and correct abnormal production declines. The systematic methodologies and techniques developed should increase the efficiency of problem well assessment and implementation of solutions for stripper gas wells.This final technical progress report provides a summary of the deliverables completed to date, including the results of the remediations, the procedure guide, and the technology transfer. Due to the successful results of the study to date and the efficiency of the methodology development, two additional wells were selected for remediation and included into the study. Furthermore, the remediation results of wells that were a part of the study group of wells are also described.
The goal of this research program is to develop and deliver a procedure guide of low cost methodologies to analyze and correct problems with stripper wells experiencing abnormal production declines.
The goal of this research program is to develop and deliver a procedure guide of low cost methodologies to analyze and correct problems with stripper wells experiencing abnormal production declines.A study group of wells will provide data to determine the historic frequency of the problem of abnormal production declines in stripper gas wells and the historic frequency of the causes of the production problems. Once the most frequently occurring causes of the production problems are determined, data collection forms and decision trees will be designed to cost-effectively diagnose these problems and suggest corrective action. Finally, economic techniques to solve the most frequently occurring problems will be researched and implemented. These systematic methodologies and techniques will increase the efficiency of problem assessment and implementation of solutions for stripper gas wells.This seventh quarterly technical progress report further describes the data reduction and methodology to develop diagnostic tools to evaluate the cause of declines in problem wells, specifically addressing the methodology to analyze the group of wells where recent problems have occurred utilizing the data gathering forms. This report also describes the methodology to select the two wells with the greatest potential for increase and also having the most frequently occurring problem. Finally, this report describes the preliminary results of the remediation applied to the two wells selected.Two wells selected and analyzed from a twenty-four well study group indicated that their current abnormal production decline was attributable to fluid build-up in the wellbore. Subsequent remediation work of putting both wells on pump to reduce fluid build-up in the well bore decreased the flowing bottom hole pressure and increased gas production dramatically.A procedure guide and summary report that will also evaluate the results of the methodology and implemented procedures will be completed by August 31, 2001.
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