CASE STUDY
Pioneering additive manufacturing for sour-service valves
Written By IMI Publications
May 29, 2026
When TotalEnergies Denmark identified valve passing issues in their anti-surge systems, they required a replacement solution that could withstand the demanding conditions of a sour-gas (H₂S) environment, preferably one that was 3D printed.
With H₂S partial pressures reaching up to 3.3 kPa, the challenge wasn’t just about performance; it was also about corrosion resistance, reliability, and qualification for use in such a sour service.
This project became the first time TotalEnergies would install additively manufactured Ni-based alloy components in a sour-gas environment. Together with IMI’s Retrofit3D team, the goal was to prove that 3D-printed components could perform as well as, if not better than, conventionally manufactured parts while passing all the tests needed to sustain a well in the field.
Anti-surge valve installed in the field, incorporating additively manufactured nickel alloy trim qualified for sour gas conditions
The challenge
While a Ni-based alloy is a well-known alloy in oil and gas applications, there was little to no track record of its use in H₂S service. Previous industry studies showed inconsistent corrosion performance, making qualification a critical step before deployment.
Together with the engineering team at TotalEnergies, we focused jointly on the requirements of the service, and together had to:
Qualify the additive material through DNV-ST-B203 (Det Norske Veritas
AMC Level 3) standards, including Build Process Qualification (BPQ) and full production testing.
Benchmark 3D-printed a Ni-based alloy directly against conventionally wrought material through ASTM A262 (intergranular corrosion) and ASTM G61 (pitting resistance) tests.
Develop a new heat treatment process to improve the corrosion and mechanical performance of the printed material.
Provide data-backed confidence to both IMI and TotalEnergies that the material could survive long-term exposure to sour service without failure.
The solution
We worked closely with TotalEnergies to develop a structured qualification programme that combined material science, simulation, and testing.
Using Laser Powder Bed Fusion (LPBF) technology, a full set of Ni-based alloy coupons and production disk-stack parts (ranging from 5.88” to 9.75” OD) were printed and tested under DNV supervision. The images below illustrate a few key steps in the process, from 3D printing to the completion of the final component.
From powder bed to finished component, the Laser Powder Bed Fusion process used to produce nickel alloy valve trims for sour service applications
1. Developing an advanced IMI-TotalEnergies customised heat treatment
We then create a customised heat treatment sequence designed to optimise both strength and corrosion resistance. This process includes:
Higher hardness (~50 Rockwell hardness Scale C) compared to conventional Ni-based alloy,
Improved impact strength than previously observed results with F3055-H (at 23 J),
Stable microstructure and balanced ductility, and
Better pitting resistance under Potentiodynamic testing.
2. Extensive testing and validation
The qualification programme covered a wide range of tests:
ASTM A262 (methods A &E): After 15 hours of exposure,
no cracking or fissures
were detected on either AM or wrought samples, confirming excellent resistance to intergranular attack.
ASTM G61: Potentiodynamic polarisation tests showed comparable pitting potential between AM and conventional NI-BASED ALLOY (around +398 mV vs +373 mV SCE).
Mechanical Testing: Tensile, yield, and elongation values were on par — or slightly better — for the AM material compared to conventional samples. This marked the first-ever IMI additive trim qualified for sour-service operation.
3. DNV qualification (Det Norske Veritas qualification)
All parts successfully passed DNV-ST-B203 AMC3 process qualification and production testing, including:
tensile,
impact,
hardness,
microstructure,
and porosity checks.
4. Finite element validation (FEA)
FEA was performed to analyse stress distribution and directional loading on the printed disk stacks.
Findings confirm uniform stress dispersion comparable to conventional trim designs, validating AM geometry integrity.
Finite element models used to assess stress distribution and structural integrity of additively manufactured valve trim designs
Results
The outcome of this collaboration marked a transformative milestone for both IMI and TotalEnergies, underscoring the successful integration of additive manufacturing into mainstream oil and gas applications and reinforcing the strength of our global innovation partnership. This achievement goes beyond a single project — it represents a pivotal step in reshaping how critical service components are designed, qualified, and deployed across the industry.
As TotalEnergies’ Head of Additive Manufacturing, Bertrand Levaché commented,
What started as a collaborative effort to tackle valve reliability challenges in a demanding H₂S environment has evolved into an actual demonstration of how innovation can flourish through partnership. IMI’s deep engineering expertise and proactive approach to applying additive manufacturing were instrumental in delivering results that fully meet our expectations.”
Through months of testing, data analysis, and joint reviews with the TotalEnergies team, we delivered a solution that:
Met all mechanical and corrosion requirements under ASTM A262 and G61, proving full equivalence between AM and wrought Ni-based alloy.
Successfully achieved DNV-ST-B203 AMC Level 3 qualification; the highest standard for additive components with mechanical properties, validating our additive process for sour-service applications.
Introduced a new proprietary heat treatment that improved impact toughness and pitting resistance while maintaining exceptional hardness and strength.
Demonstrated that our additive engineering and heat-treatment expertise could overcome one of the most critical barriers in deploying 3D-printed components in oil & gas operations.
As a result, TotalEnergies approved the installation of seven anti-surge valves equipped with our additive Ni-based alloy disk stacks. The first one was installed in June 2025, marking the first-ever deployment of this kind to undergo comprehensive qualification, including G61, ASTM A262, and DNV certification, ensuring complete suitability for a sour-service environment.
Our success also gave TotalEnergies the technical confidence to expand additive manufacturing into future applications across its global network.
For IMI, the project reaffirmed our position as an industry leader in metal additive manufacturing, combining deep materials knowledge, advanced process control, and a customer-focused mindset to turn complex problems into proven solutions.
Conclusion
This project demonstrates what is possible when deep materials expertise meets close customer collaboration. By combining additive design, innovative heat treatment, and independent third-party validation, IMI and TotalEnergies have demonstrated that 3D-printed Ni-based alloys can operate in one of the most challenging environments in the oil and gas sector.
It is not just a qualification milestone for IMI; it’s a clear signal that additive manufacturing is ready for critical service in the real world.
