3D Printing
News Videos Newsletter Contact us
Home / 3D Printing Metal / Impeller Gets Laser-clad Facelift
qidi

Impeller Gets Laser-clad Facelift

June 1, 2021

Laser metal deposition (LMD) is proving more and more useful to industry, as this recent impeller repair has shown.

LMD, also known as directed energy deposition (DED) or direct metal deposition, or laser cladding, works by blowing metal particles (or feeding wire) via a nozzle into a melt pool on a part undergoing repair. The melt pool is guided around the part, building up features layer by layer.

It’s good for building parts, and it’s also great for repairing parts. We wrote about that in this previous article.

LMD is particularly useful for repairing parts with complicated geometries that may require complicated fabrication and assembly, which is why it is finding a willing friend in aerospace, marine, and oil and gas industries.

This impeller, for example, is part of a high pressure pump system for the oil and gas sector. It has been doing its job on an offshore platform somewhere off the coast of Norway.

The recirculating system is used to transform lean amine into rich amine while processing sour natural gas.

During an inspection by operator Equinor, it was found that there was cavitation damage to one of the pump impellers. Normally such a repair could be performed by machining the damaged vane surfaces down so that the cavitation damage was smoothed, but this approach was not found to be suitable with the ongoing cavitation to be expected. So rather than remove material and compromise on part strength/quality, they opted to add material with the laser cladding system.

For this repair, they sent it to Sulzer, a German engineering company. You can see the repaired impeller in the image below.

impeller laser facelift
Impeller laser facelift (Image credit: Sulzer Pumpen GmbH)

Due to the nature of the super duplex stainless steel that the impeller was manufactured from, welding the parts was not an option. The heat of the welding process can cause shifts in not only the metal properties, but in the geometry of the part itself, in the form of warping.

LMD was therefore found to be the optimal repair method in terms of lead time, cost, and in retaining the original properties of the part being repaired.

“Careful selection of consumable, control parameters and technique enables the best method to be established,” said Dr. Yogiraj Pardhi, Additive Manufacturing and Materials Specialist for Sulzer.

“In this case, for greater flexibility and access, a semi-automated process was selected using a manual wire feed and automated control of the laser head across the area being repaired. In between each pass of the LMD head, a cooling period was required to ensure the temperature of the repair site did not exceed 100 °C (212 °F).”

Lasers and energy
Lasers and energy (Image credit: Trumpf)

Most of the post processing of the impeller had been performed with hand tools and templates, mirroring the latter stages of the original part manufacturing process.

The initial laser-repair took just two weeks to fix the first impeller, but on a second repair the engineers at Sutzer’s Leeds office had managed to get that lead time reduced further still, delivering the repaired part after just one week.

The parts were returned to their homes at Equinor in Norway where they have been installed and are running just fine.

“Having established that cavitation is a feature of this application, we have decided to take a proactive approach to maintenance to ensure continued performance and reliability in the assets on our offshore platforms,” said a representative from Equinor.

“Working with Sulzer has ensured a timely repair that returns the amine pumps to their original specifications, improving durability without the expense of downtime.”

saab gripen
Related Story
Saab Tests AM for Battle Damage Repairs on Gripen Fighter
Share:
WhatsApp Twitter Facebook LinkedIn Buffer Reddit E-mail
About the author | Phillip Keane
Phillip is an aerospace engineer from UK. He is a graduate of Coventry University (UK), International Space University (France) and Nanyang Technological University (Singapore), where he studied Advanced Manufacturing at the Singapore Centre for 3D Printing.
Join our newsletter

Our newsletter is free & you can unsubscribe any time.

Latest posts

Scottish Maritime Project Shows Promise for 3D Printed Ship Components

A Scottish project using large-scale additive manufacturing for shipbuilding components has completed its second phase, demonstrating potential benefits for the maritime industry. The... read more »

News
Scottish Maritime Project Shows Promise for 3D Printed Ship Components

Navy Maintenance Center Uses 3D Printing to Replace Destroyer Pump Component at Fraction of Conventional Cost

The Southeast Regional Maintenance Center (SERMC) has successfully used 3D printing to manufacture a replacement cooling rotor for an Arleigh Burke-class guided missile... read more »

Military
Navy Maintenance Center Uses 3D Printing to Replace Destroyer Pump Component at Fraction of Conventional Cost

Rapid Fusion Launches AI Assistant for Large-Format 3D Printers

British manufacturer Rapid Fusion has introduced "Bob," an AI-powered assistant designed to optimize operations for its large-format 3D printing systems. The company developed... read more »

News
Rapid Fusion Launches AI Assistant for Large-Format 3D Printers

Creality Submits IPO Prospectus for Hong Kong Stock Exchange Listing

Shenzhen-based 3D printer manufacturer Creality has submitted a prospectus to the Hong Kong Stock Exchange for a main board listing. The company began... read more »

News
Creality Submits IPO Prospectus for Hong Kong Stock Exchange Listing

Graphjet Technology Partners with Malaysian University on 3D-Printed Heat Sink Development

Graphjet Technology has entered into a collaboration agreement with the Centre for Materials Engineering and Smart Manufacturing (MERCU) at Universiti Kebangsaan Malaysia (UKM).... read more »

News
Graphjet Technology Partners with Malaysian University on 3D-Printed Heat Sink Development

Humtown drives US Manufacturing Comeback with Additive Sand Casting

Humtown Products, an Ohio-based company, is positioning itself to serve manufacturers looking to bring production back to the United States. The company specializes... read more »

News
Humtown drives US Manufacturing Comeback with Additive Sand Casting

Oak Ridge National Laboratory Releases Advanced Dataset for 3D Printing Quality Monitoring

Oak Ridge National Laboratory has released a comprehensive dataset for its Peregrine software, which monitors and analyzes parts created through powder bed additive... read more »

News
Oak Ridge National Laboratory Releases Advanced Dataset for 3D Printing Quality Monitoring

Creality Expands Flagship Lineup with K2 and K2 Pro 3D Printers

Creality has announced the launch of the K2 and K2 Pro, two new additions to its high-end K series. Built on a rigid... read more »

3D Printers
Creality Expands Flagship Lineup with K2 and K2 Pro 3D Printers

Farsoon and Stark Future Complete KLINGA Project, Producing Over 1,000 Titanium Parts

Farsoon Europe GmbH and Stark Future have completed the KLINGA Project, a collaborative engineering initiative that produced more than 1,000 titanium parts using... read more »

3D Printing Metal
Farsoon and Stark Future Complete KLINGA Project, Producing Over 1,000 Titanium Parts

Swiss Steel Group’s Ugitech Introduces Custom Wire for 3D Metal Printing

Swiss Steel Group and its French subsidiary Ugitech have launched UGIWAM wire, a new product designed for wire arc additive manufacturing (WAAM). The... read more »

3D Printing Metal
Swiss Steel Group's Ugitech Introduces Custom Wire for 3D Metal Printing

Social

  • Facebook Facebook 3D Printing
  • Linkedin Linkedin 3D Printing
Join our newsletter

Our newsletter is free & you can unsubscribe any time.

Featured Industries

  • Automotive
  • Aerospace
  • Construction
  • Dental
  • Environmental
  • Electronics
  • Fashion
  • Medical
  • Military
  • QIDI Plus4

    • - Print size: 305 x 305 x 280 mm
    • - print temperature of 370°C
    More details »
    $799.00 QIDI Store
    Buy Now
  • QIDI Tech X-Max 3

    • - Print size: 325 x 325 x 315 mm
    • - fully enclosed
    More details »
    $799.00 QIDI Store
    Buy Now
  • QIDI Tech Q1 Pro

    • - Print size: 245 x 245 x 245 mm
    • - 600mm/s max speed
    More details »
    $449.00 QIDI Store
    Buy Now
  • Snapmaker Artisan Premium 3-in-1

    • - Print size: 400 x 400 x 400 mm
    • - comes with enclosure
    More details »
    $2,999.00 Snapmaker
    Buy Now

Company Information

  • What is 3D Printing?
  • Contact us
  • Join our mailing list
  • Advertise with us
  • Media Kit
  • Nederland 3D Printing

Blog

  • Latest News
  • Use Cases
  • Reviews
  • 3D Printers
  • 3D Printing Metal

Featured Reviews

  • Anycubic Photon Mono M5s
  • Creality Ender 5 S1
  • The Mole 3D Scanner
  • Flashforge Creator 3 Pro

Featured Industries

  • Automotive
  • Aerospace
  • Construction
  • Dental
  • Environmental
  • Electronics
  • Medical
  • Military
  • Fashion
  • Art
2025 — Strikwerda en Dehue
  • Home
  • Join our mailing list
  • Contact us
Blog
  • Latest News
  • Use Cases
  • Reviews
  • 3D Printers
  • 3D Printing Metal
Featured Industries
  • Automotive
  • Aerospace
  • Construction
  • Dental
  • Environmental
  • Electronics
  • Medical
  • Military
  • Fashion
  • Art
Company Information
  • What is 3D Printing?
  • Contact us
  • Join our mailing list
  • Advertise with us
  • Media Kit
  • Nederland 3D Printing