Have a look at our pump impeller manufacturing process
First of all, What is an impeller?
Impellers are hydraulic components usually used in pumps. They are used to make fluids flow through the machine, increasing the pressure of the liquid. This makes them essential parts for the efficient performance of hydraulic machinery.
The way impellers work is by converting kinetic energy into pressure energy. This can only be possible thanks to their specific shape and components, which are combined into a single, highly efficient component.
The impeller is implemented into the shaft of the hydraulic pump with a bore, and transports liquid through its channels. Once the fluid has entered the impeller, the vanes do the rest of the work as they convert mechanical energy into pump output power.
Types of impellers
Impellers have many specifications that are tailored to the machine they are going to be implemented into, so it is very difficult to cover all kinds of impellers in a single article. However, it can be said that all these types fall into three basic categories, which are the following:
- Open impellers: They lack vane support on both sides, which makes them structurally weaker. They are typically used in smaller and cheaper pumps because of their reduced diameter.
- Semi-open impellers: The vanes are enclosed in only one side, which adds mechanical strength and efficiency to the piece. They are fit for medium diameter pumps.
- Closed impellers: The vanes are enclosed completely between two discs in a single piece. Their improved efficiency makes them fitter for larger pumps, which makes them the most popular type of impeller in the market.
Main challenges we face as impeller casting manufacturers
Impeller casting manufacturers supply to industrial markets with highly demanding technical and legal requirements. Our clients ask for the highest performance, efficiency and quality, and we provide it to them. This need usually translates into complex and innovative designs, which pose special challenges for us manufacturers.
One of the most difficult parts of being a pump impeller manufacturer is getting the hydraulic opening right. It being the outlet area where the fluid exits the impeller, it is extremely important that it is up to its task. Controlling this part of the impeller geometrically is critical to the performance of the equipment, so it becomes a challenge for us to get it right. Impeller manufacturers must also take into account the relation between the part and the hydraulic opening, adding another layer of difficulty to the task.
The number of blades of each impeller, along with their thickness and angle,also complicates the impeller manufacturing process, as getting these specifications right can mean the difference between a quality piece and a flawed one.
If we mix in the different treatments and processes that should be applied to the material, we can confidently say that the task at hand is not easy.
What makes us fit for the impeller manufacturing process?
Freeze cast is an impeller manufacturer, specialized in casting hydraulic pieces in stainless steel. We have extensive experience in the manufacturing process of impellers and diffusers, which has been improved by our constant compromise with innovation. We have incorporated the latest machinery in the sector to make us more competitive in impeller manufacturing, and when that wasn’t enough, we invented our own processes to go beyond what any foundry could do.
Why are we the perfect impeller pump manufacturers?
- We use ceramic moulds instead of sand moulds . This makes our impeller better, more efficient and durable. It also means that we are able to reduce secondary processes, making the piece cheaper.
- Because our in-house developed HHPS® process, we are able to achieve the best surface qualities in our impellers. This makes our parts more efficient and cost effective than most in the market.
- Our Instant Casting process makes us the fastest impeller manufacturer in the market, delivering parts in a matter of two weeks. Because of this, we are able to respond to urgent needs of spare parts faster.
- Our machinery and experienced teams have managed to come up with clever solutions to the limitations of the traditional casting process. Because of this, we have managed to overcome the weight and size limitations we previously had, manufacturing 300kg and 400 kg parts regularly.
- Our improved processes and machinery also make us fit better with the complex shapes of the designs that our clients provide us. With our Ad Hoc service, our team can face any innovation that can be introduced into an impeller.
- We have incorporated 3D printing machines never before seen in the Spanish market, which enhances the whole process, from the design to the manufacturing process.
- On top of it all, we have implemented a highly demanding quality policy, which incorporates non destructive and destructive methods to ensure that our impellers are in perfect shape.