Method for modifying the dimensions of a cast iron pump part

Abstract

A method for modifying a dimension of a cast iron pump part features placing a cast iron pump part on a base plate of a directed energy deposition (DED) machine; selecting a metal deposition procedure for depositing a metal having a combination of one or more Nickel Alloys or Nickel powders on the cast iron pump part; and depositing the metal on the cast iron pump part to modify the dimension of the cast iron pump part, based upon the metal deposition procedure selected. The selecting of the metal deposition procedure includes forming the metal by mixing metal powders that include a Nickel Alloy “A” in a specified mixed ratio with a pure Nickel powder “B” for depositing on the cast iron pump part.

1 - 20 . (canceled) 
     
     
         21 . A cast iron pump component/part made or manufactured using steps in a method for modifying a dimension of a cast iron pump part, comprising steps for
 placing a cast iron pump component/part on a base plate of a directed energy deposition (DED) machine;   selecting a metal deposition procedure for depositing a metal having a combination of one or more Nickel Alloys or Nickel powders on the cast iron pump component/part; and   depositing the metal on the cast iron pump component/part to modify the dimension of the cast iron pump component/part, based upon the metal deposition procedure selected.   
     
     
         22 . A cast iron pump component/part according to  claim 21 , wherein the selecting of the metal deposition procedure comprises forming the metal by mixing metal powders that include a Nickel Alloy “A” in a specified mixed ratio with a pure Nickel powder “B” for depositing on the cast iron pump part. 
     
     
         23 . A cast iron pump component/part according to  claim 22 , wherein the Nickel Alloy “A” comprises a High Nickel Alloy “A” that includes Inconel 625 or Inconel 718. 
     
     
         24 . A cast iron pump component/part according to  claim 22 , wherein the specified mixed ratio of the Nickel Alloy “A” and the pure Nickel powder “B” includes percentages ranging from 50-75/25-50, including where the percentage of Nickel Allow “A” is in a range of 50-75 percent, and the percentage of the pure Nickel powder “B” is in a range of 25-50 percent. 
     
     
         25 . A cast iron pump component/part according to  claim 21 , wherein the selecting of the metal deposition procedure comprises forming the metal by mixing metal powders that include a Nickel powder “B” and a Nickel Alloy “A” at different ratios for depositing on the cast iron pump part. 
     
     
         26 . A cast iron pump component/part according to  claim 25 , wherein the different ratios include mixtures of the Nickel powder “B” and the Nickel Alloy “A” at powder/Alloy percentages ranging from 50-75/25-50, including where the percentage of Nickel powder “B” is in a range of 50-75 percent, and the percentage of Nickel Alloy “A” is in a range of 25-50 percent. 
     
     
         27 . A cast iron pump component/part according to  claim 21 , wherein the selecting of the metal deposition procedure comprises using a multiple material layer construction that includes a Nickel power “B” and a Nickel Alloy “A”, including depositing the Nickel power “B” over a grey cast iron to create a metallurgical bond with the Nickel Alloy “A”. 
     
     
         28 . A cast iron pump component/part according to  claim 27 , wherein the Nickel Alloy “A” is a High Nickel Alloy “A”. 
     
     
         29 . A cast iron pump component/part according to  claim 27 , wherein the method comprises preheating the grey cast iron of the cast iron pump part. 
     
     
         30 . A cast iron pump component/part according to  claim 29 , wherein the preheating of the grey cast iron of the cast iron pump part includes a low temperature preheating of up to 450° C. 
     
     
         31 . A cast iron pump component/part according to claim  9 , wherein the preheating of the grey cast iron of the cast iron pump part includes a localized high temperature preheating of up to 800° C. on the skin of the surface of the grey cast iron. 
     
     
         32 . A cast iron pump component/part according to  claim 21 , wherein the method comprises selecting a low heat input deposition pattern that includes selecting a honeycomb structure. 
     
     
         33 . A cast iron pump component/part according to  claim 32 , wherein the method comprises depositing the honeycomb structure using a skip pattern for depositing the metal on the cast iron pump part. 
     
     
         34 . A cast iron pump component/part according to  claim 21 , wherein the method comprises selecting a deposition sequencing procedure that includes selecting a skip pattern for depositing the metal on the cast iron pump part. 
     
     
         35 . A cast iron pump component/part according to  claim 34 , wherein the skip pattern selected comprises using multiple passes that include:
 a first pass for depositing individual clusters of the metal separated by a first distance D 1  along a first axis on the cast iron pump part, and depositing the individual clusters of the metal separated by a second distance D 2  along a second axis on the cast iron pump part, the first axis being orthogonal to the second axis; and   one or more skip passes for depositing one or more skip individual clusters of the metal separated by a corresponding first distance D 1  along the first axis on the cast iron pump part, and depositing the one or more skip individual clusters of the metal separated by the second distance D 2  along the second axis on the cast iron pump part.   
     
     
         36 . A cast iron pump component/part according to  claim 21 , wherein the method comprises removing the cast iron pump part from the DED machine. 
     
     
         37 . A cast iron pump component/part according to  claim 21 , wherein the method comprises using a heat treatment procedure for providing stress relief to the cast iron pump part, including where the heat treatment procedure include transferring the cast iron pump part to a furnace for heat treatment. 
     
     
         38 . A cast iron pump component/part according to  claim 21 , wherein the method comprises implementing the method on cast iron pump parts that include a pump volute or a pump impeller, including a broken blade of the pump impeller or a leading edge of the pump impeller. 
     
     
         39 . A cast iron pump component/part according to  claim 21 , wherein the method comprises forming the combination from the one or more Nickel Alloys alone, the one or more Nickel powder alone, or a Nickel Alloy/powder combination. 
     
     
         40 . A cast iron pump component/part according to  claim 21 , wherein the method comprises forming the one or more Nickel alloys from Nickel mixed with one or more other elements.