The growing consumption of oil and gas resources and the increasing difficulty of extraction have created major challenges for traditional manufacturing and maintenance, particularly in the timely supply of critical components, customized production, and complex structure fabrication. Additive manufacturing (AM) technology, with its high design freedom, precision, and rapid prototyping, provides new approaches to address these issues. However, systematic reviews of related efforts are scarce. This paper reviews the applications and progress of metal and non-metal AM technologies in oil and gas extraction and gathering engineering, focusing on the just-in-time (JIT) manufacturing of failed components, the manufacturing and repair of specialized equipment and tools for oil and gas extraction and gathering, and artificial core and reservoir geological modeling fabrication. AM applications in this field remain exploratory and face challenges with regard to their standards, supply chains, materials, and processes. Future research should emphasize developing materials and processes for extreme conditions, optimizing process parameters, establishing standards and traceability systems, and integrating AM with digital design and reverse engineering to support efficient, safe, and sustainable industry development. This work aims to provide a reference for advancing AM research and engineering applications in the oil and gas sector.

Metallic joints within tokamak devices necessitate high interface hardness and superior bonding properties. However, conventional manufacturing techniques, specifically the hot isostatic pressing (HIP) diffusion joining process, encounter challenges, including the degradation of the SS316L/CuCrZr interface and CuCrZr hardness. To address this, we explore the potential of laser powder bed fusion (LPBF) technology. To assess its viability, we fabricated 54 SS316L/CuCrZr samples and systematically investigated the impact of varied process parameters on the microhardness and tensile strength of the dissimilar metal interfaces. Through comprehensive analysis, integrating scanning electron microscopy (SEM) imagery, we elucidated the mechanisms underlying mechanical property alterations. Notably, within a laser volumetric energy density range of 60 J/mm³ to 90 J/mm³, we achieved elevated interface hardness (around 150 HV) and commendable bonding quality. Comparative analysis against traditional methods revealed a substantial enhancement of 30% to 40% in interface hardness with additive manufacturing, effectively mitigating CuCrZr hardness degradation.

In order to achieve high-quality repair of complex curved parts, a remanufacturing process method utilizing laser cladding and reverse engineering technology is proposed to be implemented by robots. This study focuses on the oscillating helical surface of a screw pump rotor. A single-pass laser cladding test is conducted using Response Surface Methodology (RSM) to construct a predictive model and identify optimal process parameters. The model’s accuracy is validated through analysis of variance (ANOVA) and index verification, while the optimal lap rate is determined through multi-pass laser cladding testing. Using reverse engineering technology, the generation of laser cladding paths for complex surfaces is explored, and the trajectory planning for the laser cladding robot is carried out. Simulations and experiments of robotic laser cladding on complex surfaces are performed, with the optimal process parameters guiding both the experiment and simulation. The optimum single-pass cladding layer, with a lap rate of 25.6%, is achieved when the laser power is 2217 W, the powder feed rate is 2.86 r/min, and the scanning speed is 400 mm/min. The study successfully plans the path for laser cladding on complex curved parts, verifying its feasibility and effectiveness, verifying that there is good metallurgical bonding between the cladding layer and the substrate, and helping to select the appropriate process parameters that are consistent with the requirements of a particular application, thus providing valuable guidance for the remanufacture of failed metal parts.

In this study, CoCrMo cuboid samples were deposited on a CuZrCr substrate using laser powder bed fusion (L-PBF) technology to investigate the influence of process parameters and laser remelting strategies on the mechanical properties and interface characteristics of multi-metals. This study found that process parameters and laser scanning strategies had a significant influence on the mechanical properties and interface characteristics. Samples fabricated with an $E_{\mathrm{V}}$ ≤ 20 J/mm³ showed little tensile ductility. As the volumetric energy density ($E_{\mathrm{V}}$) increased to a range between 40 J/mm³ and 100 J/mm³, the samples achieved the desired mechanical properties, with a strong interface combining the alloys. However, an excessive energy density could result in cracks due to thermal stress. Laser remelting significantly improved the interface properties, especially when the $E_{\mathrm{V}}$ was below 40 J/mm³. Variances in the $E_{\mathrm{V}}$ showed little influence on the hardness at the CuZrCr end, while the hardness at the interface and the CoCrMo end showed an increasing and decreasing trend with an increase in the $E_{\mathrm{V}}$, respectively. Interface characterization showed that when the $E_{\mathrm{V}}$ was greater than 43 J/mm³, the main defects in the L-PBF CoCrMo samples were thermal cracks, which gradually changed to pores with a lack of fusion when the $E_{\mathrm{V}}$ decreased. This study provides theoretical and technical support for the manufacturing of multi-metal parts using L-PBF technology.