Trials of the combined 5-axis CNC milling and laser metal deposition head
Starting with a forging , the core of the impeller can be machined using a 5-axis milling machine . Then further material is added to the outside of the impeller using laser metal deposition .
The use of milling tools means that the internal hydraulic surfaces have a very high-quality finish , much better than those achieved with a casting process . The process of adding material and machining is repeated until the complete impeller emerges . The whole process , which can be completed in a matter of days , is much quicker than casting a new component , which can typically take 15 – 20 weeks .
The greatly reduced build time for a new impeller means that , in the event of a pump needing a new component , the standby pump can be brought online while the new part is manufactured and delivered . Although this time could be reduced further if necessary , the consensus is that a few days is sufficient for the majority of applications .
PROVING THE THEORY The development work has now been put into practice and applied to a real-world application . Chevron has a CPT pump from Sulzer operating with a corrosive fluid , an application that requires specific material properties to ensure the durability of the pump . The impeller was identified for replacement and an
An example of the complex geometry that can be achieved
ideal subject for the new manufacturing process .
Using the original design drawings , a 3-dimensional model was fine-tuned and a final set of coded instructions for the hybrid manufacturing machine was generated . Within a few hours the new impeller had been created and was ready to be installed .
The new impeller was installed in the pump and tested at Sulzer first . It has now been operating successfully since its installation on site in 2019 . Both Sulzer and Chevron are confident in the performance and durability of the new component .
Robert Rettew , Program Manager , Materials Technology Development at Chevron , comments : “ We have worked closely with Sulzer to develop the technology and systems required to achieve hybrid manufacturing and now Chevron is the first customer to benefit from this cutting-edge solution . There is considerable opportunity to increase the applications and widen the scope of materials used in the process .”
Chevron has a strategic plan to take advantage of new and innovative technologies that can offer improvements for its operations and improve efficiency . One of these is additive manufacturing . This process is also very important for components that are now obsolete , enabling parts for heritage assets to be sourced with a short lead time .
Charles Soothill concludes : “ For Sulzer , the goal is to offer customers the best possible service and , when time is of the essence , deliver the solution with the shortest lead time , while maintaining the highest quality standards . In addition to receiving a new part quickly , customers also benefit from the latest design standards that have benefitted from decades of experience in designing and manufacturing pumps .”
For further information , please visit www . sulzer . com
Issue 49 PECM 59