Process Setup for Manufacturing of a Pump Impeller by Selective Laser Melting

Huber, Marc; Ess, Jonas; Hartmann, Martin; Würms, Andreas; Rettberg, R.J.; Kränzler, Thomas; Löffel, Kaspar

doi:10.1007/978-3-319-66866-6_24

Cited by 12 publications

(5 citation statements)

References 8 publications

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“…An important step in developing a closed impeller prototype using additive manufacturing technology was made by Sulzer [ 15 ], studying different orientations and support designs in order to avoid material deposition in inaccessible areas. Even if this AM component was not meant for space applications, it can be considered an excellent model of good practice and the results represent a step forward in the development of closed impellers for the space industry [ 16 ].…”

Section: Introductionmentioning

confidence: 99%

A Study on Using the Additive Manufacturing Process for the Development of a Closed Pump Impeller for Mechanically Pumped Fluid Loop Systems

et al. 2021

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The efficiency of a centrifugal pump for mechanical pump fluid loops, apart from the design, relies on the performance of the closed impeller which is linked to the manufacturing process in terms of dimensional accuracy and the surface quality. Therefore, the activities of this paper were focused on defining the manufacturing process of a closed impeller using the additive manufacturing technology for mechanically pumped fluid loop (MPFL) systems in space applications. Different building orientations were studied to fabricate three closed impellers using selective laser melting technology and were subjected to dimensional accuracy and surface quality evaluations in order to identify the optimal building orientation. The material used for the closed impeller is Inconel 625. The results showed that both geometrical stability and roughness were improved as the building orientation increased, however, the blade thickness presented small deviations, close to imposed values. Finishing processes for inaccessible areas presented significant results in terms of roughness, nevertheless, the process can be further improved. Abrasive flow machining (AFM) post-processing operations have been considered and the results show major improvements in surface quality. Thus, important steps were made towards the development of complex structural components, consequently increasing the technological readiness level of the additive manufacturing process for space applications.

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Section: Introductionmentioning

confidence: 99%

A Study on Using the Additive Manufacturing Process for the Development of a Closed Pump Impeller for Mechanically Pumped Fluid Loop Systems

et al. 2021

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“…Over the past decade, the Selective Laser Melting (SLM) technique, which belongs to the Additive Manufacturing (AM) metal technologies [1], has emerged as one of the most robust AM techniques for producing metal parts. It stands out as a prevalent technique under the umbrella of Powder Bed Fusion (PDF) processes, according to ISO/ASTM 52900-15 standards [1], leading to extensive exploration across various industries for the manufacturing of complex geometries and advanced design features [2][3][4][5]. SLM offers the versatility of processing a wide range of materials [6], including Al, Ti, Ni, Co, Cu, and Fe [7,8].…”

Section: Introductionmentioning

confidence: 99%

On the Effect of Volumetric Energy Density on the Characteristics of 3D-Printed Metals and Alloys

Pechlivani,

Melidis,

Pemas

et al. 2023

Metals

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Selective Laser Melting (SLM) is a specific 3D printing technique under Additive Manufacturing (AM) metal technologies. SLM is considered to be a precise rapid AM process combined with a powder bed system for producing customized metal products with a tailored microstructure and shape. Differences in the printing parameters can lead to differences in the surface as well as macroscopic mechanical characteristics of the manufactured parts and components. This work aims at quantifying the effect of the Volumetric Energy Density (VED) used in the SLM processing of various metals and alloys. Metallic specimens printed with different VED values were subjected to surface characterization as well as tensile deformation. Their surface roughness, yield stress and toughness were subsequently used to verify a linear relationship between roughness and VED, and a linear behavior between yield stress/toughness and VED was proposed. Predictive models were formulated for estimating the roughness/yield stress/toughness of the produced specimens with respect to the VED used in their production. The models’ predictions will provide insight into the 3D printing parameters, thus minimizing the cost and effort of the 3D printing procedure, in applications where surface quality and strength are important.

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“…Sulzer (Winterthur, Switzerland) is developing an impeller manufacturing process, which combines Laser Metal Deposition (LMD) with subtractive 5 Axis CNC Milling. Additionally, Sulzer presented different orientations and support structure designs in order to avoid material deposition in inaccessible areas for a LPBF closed impeller [7]. Consequently, efforts were made by Yanghi et al [8] towards optimizing the manufacturing process of a closed impeller using Laser Powder Bed Fusion (L-PBF), in order to mitigate the distortions of the part by applying the finite element method (FEM).…”

Section: Introductionmentioning

confidence: 99%

“…Multiple research studies have aimed to perfect and understand the various additive manufacturing techniques, expand the type of materials and parts that are used, and explore the manufacture of a complex, integrated system. Huber et al [9] described the LPBF manufacturing of an already existing closed impeller design at the lower limit of castability, and the purpose was to find the optimal building direction as well as to design a proper support structure. The results show that LPBF processed prototype closed impeller, obtained through a heuristic and iterative process, fulfilled all geometrical requirements.…”

Section: Introductionmentioning

confidence: 99%

Manufacturing of Closed Impeller for Mechanically Pump Fluid Loop Systems Using Selective Laser Melting Additive Manufacturing Technology

et al. 2021

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In the space industry, the market demand for high-pressure mechanically pumped fluid loop (MPFL) systems has increased the interest for integrating advanced technologies in the manufacturing process of critical components with complex geometries. The conventional manufacturing process of a closed impeller encounters different technical challenges, but using additive manufacturing (AM) technology, the small component is printed, fulfilling the quality requirements. This paper presents the Laser Powder Bed Fusion (LPBF) process of a closed impeller designed for a centrifugal pump integrated in an MPFL system with the objective of defining a complete manufacturing process. A set of three closed impellers was manufactured, and each closed impeller was subjected to dimensional accuracy analysis, before and after applying an iterative finishing process for the internal surface area. One of the impellers was validated through non-destructive testing (NDT) activities, and finally, a preliminary balancing was performed for the G2.5 class. The process setup (building orientation and support structure) defined in the current study for a pre-existing geometry of the closed impeller takes full advantages of LPBF technology and represents an important step in the development of complex structural components, increasing the technological readiness level of the AM process for space applications.

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Process Setup for Manufacturing of a Pump Impeller by Selective Laser Melting

Cited by 12 publications

References 8 publications

A Study on Using the Additive Manufacturing Process for the Development of a Closed Pump Impeller for Mechanically Pumped Fluid Loop Systems

A Study on Using the Additive Manufacturing Process for the Development of a Closed Pump Impeller for Mechanically Pumped Fluid Loop Systems

On the Effect of Volumetric Energy Density on the Characteristics of 3D-Printed Metals and Alloys

Manufacturing of Closed Impeller for Mechanically Pump Fluid Loop Systems Using Selective Laser Melting Additive Manufacturing Technology

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