A review of additive manufacturing capabilities for potential application in offshore renewable energy structures

Offshore renewable energy structures are subject to harsh environments with loading from wind, wave, and tides which introduce fatigue damage in corrosive and erosive environments. An effective approach that has been found to improve mechanical and fatigue resistance of engineering structures is employment of Additive Manufacturing (AM) technology. However, little research has been conducted for implementation of AM technology in offshore renewable energy structures. This study aims to collate and critically discuss the advantages that AM technology can offer to enhance the lifespan of offshore renewable energy structures. In addition to fatigue life improvement, the potential of AM technology to enhance corrosion and erosion resistance in offshore renewable energy structures has been explored. It has been found in this study that among the existing AM techniques, Wire Arc Additive Manufacturing (WAAM) offers promising potentials for life enhancement of offshore wind turbine and tidal turbine support structures. Early research into the potential of using WAAM to create corrosion resistance coatings and components highlights many benefits achieved from this new emerging manufacturing technology, but further research is required to justify the use of the processes for commercial applications. In terms of erosion and wear resistance even less research has been conducted but initial findings show that AM has the potential to add a great level of resistance compared to the wrought material. This study presents the key advantages that AM technology offers to enhance the design life and integrity of offshore renewable energy structures as a first step towards unlocking the great potentials of AM for consideration and implementation in the energy transition roadmap.