Rotating Machinery Services (RMS) stands at the forefront of industrial rotating equipment operations, playing a pivotal role in sectors like energy and petrochemical. But their vision goes beyond the status quo. Recently, RMS produced a Ø 10.7” (272 mm) Inconel® 718 shrouded impeller using metal additive manufacturing (AM), eliminating the need for traditional internal support structures.
This ambitious endeavor bore fruit as the impeller not only met but exceeded industry benchmarks, withstanding speeds up to 25,000 rpm. Yet, RMS’s vision extended further. They aspired to craft even larger impellers; a task made daunting by the constraints of typical metal 3D printers.
This challenge found its match in Velo3D’s large-format Sapphire XC metal 3D printer, recognized as the market leader in 600 mm metal AM. Along with the printer’s impressive c apabilities, the prowess of Velo3D’s application engineering team was invaluable. Together, they undertook the task of producing a 483 mm diameter impeller with intricate features.
However, innovation is seldom a straightforward path. The team confronted an unexpected issue—melt pool instabilities (MPIs) on the impeller. These unwanted formations jeopardized the impeller’s quality. To overcome these challenges, Velo3D’s engineers innovated a novel support strategy. By leveraging tapered pin supports, they were able to maintain the impeller’s surface quality and facilitate easier post-production processes.
Benjamin Wagner, Engineering Manager at RMS, encapsulated the experience stating, “We’ve explored various systems for our application needs, but Velo3D stood out as the best fit. Not only did their technology perfectly align with the complexities of developing a large impeller, but the level of support we received from the Velo3D team was unparalleled. They were with us every step of the way, ensuring that the project was executed to the highest standards.”
By tackling challenges associated with large-scale parts over 400 mm in diameter, Velo3D and RMS not only advanced the boundaries of metal AM but also demonstrated tangible benefits in efficiency, reduced lead times, and cost savings.
Read the complete case study to learn more about RMS’ large-format impeller.
