1

CHAPTER 1

INTRODUCTION

A pump that has been widely used in industry is the most typical type
of fluid machinery that transforms machinery energy into fluid pressure and kinetic
energy via impellers. A centrifugal pump, the most common type of pumps, has
been used in industrial areas, such as water, sewage, drainage, and the chemical
industry. Accordingly, numerous studies have been performed for the designs of
various models of centrifugal pumps. Due to the needs of the industry,
optimization using mechanical concepts has recently been studied in order to make
higher-efficiency pumps with higher heads. An impeller, among all of the
components of the pump, has the biggest influence on performance, since fluid
flow in the pump generates energy through it. Therefore, an accurate analysis is
essential to optimize variables that affect the performance of the pump.
1.1 CENTRIFUGAL PUMP

Centrifugal pumps are a sub-class of dynamic axisymmetric work-

absorbing turbo machinery. Centrifugal pumps are used to transport fluids by the
conversion of rotational kinetic energy to the hydrodynamic energy of the fluid
flow. The rotational energy typically comes from an engine or electric motor. The
fluid enters the pump impeller along or near to the rotating axis and is accelerated
by the impeller, flowing radially outward into a diffuser or volute chamber
(casing), from where it exits. Common uses include air, water, sewage, petroleum
and petrochemical pumping. The reverse function of the centrifugal pump is
a water turbine converting potential energy of water pressure into mechanical
rotational energy.
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1.1.1 Working of centrifugal pump

General explanation: Like most pumps, a centrifugal pump converts
rotational energy, often from a motor, to energy in a moving fluid. A portion of the
energy goes into kinetic energy of the fluid. Fluid enters axially through eye of the
casing, is caught up in the impeller blades, and is whirled tangentially and radially
outward until it leaves through all circumferential parts of the impeller into the
diffuser part of the casing. The fluid gains both velocity and pressure while passing
through the impeller. The doughnut-shaped diffuser, or scroll, section of the casing
decelerates the flow and further increases the pressure.

Fig 1.1 Parts of a centrifugal pump

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1.2 IMPELLER

An impeller is a rotating component of a centrifugal pump, usually

made of iron, steel, bronze, brass, aluminum or plastic, which transfers
energy from the motor that drives the pump to the fluid being pumped by
accelerating the fluid outwards from the center of rotation. The velocity achieved
by the impeller transfers into pressure when the outward movement of the fluid is
confined by the pump casing. Impellers are usually short cylinders with an open
inlet (called an eye) to accept incoming fluid, vanes to push the fluid radially, and
a splined, keyed or threaded bore to accept a drive-shaft.

Fig 1.2 Impeller

The impeller made out of cast material in many cases may be

called rotor, also. It is cheaper to cast the radial impeller right in the support it is
fitted on, which is put in motion by the gearbox from an electric motor, combustion
engine or by steam driven turbine. The rotor usually names both the spindle and
the impeller when they are mounted by bolts.
 4

Impellers in agitated tanks are used to mix fluids or slurry in the tank.
This can be used to combine materials in the form of solids, liquids and gas. Mixing
the fluids in a tank is very important if there are gradients in conditions such as
temperature or concentration.

There are two types of impellers, depending on the flow regime created

 Axial flow impeller

 Radial flow impeller

Radial flow impellers impose essentially shear stress to the fluid, and
are used, for example, to mix immiscible liquids or in general when there is a
deformable interface to break. Another application of radial flow impellers are the
mixing of very viscous fluids.

Axial flow impellers impose essentially bulk motion, and are used on
homogenization processes, in which increased fluid volumetric flow rate is
important.

Impellers can be further classified principally into three sub-types

 Propellers
 Paddles
 Turbines

1.3 FATIGUE OF MATERIAL

In materials science, fatigue is the weakening of a material caused by

repeatedly applied loads. It is the progressive and localized structural damage that
occurs when a material is subjected to cyclic loading. The nominal maximum
stress values that cause such damage may be much less than the strength of the
material typically quoted as the ultimate, or the yield stress limits.

Fatigue occurs when a material is subjected to repeat loading and

unloading. If the loads are above a certain threshold, microscopic cracks will begin
 5

to form at the stress concentrators such as the surface, persistent slip bands (PSBs),
and grain interfaces. Eventually a crack will reach a critical size, the crack will
propagate suddenly, and the structure will fracture. The shape of the structure will
significantly affect the fatigue life; square holes or sharp corners will lead to
elevated local stresses where fatigue cracks can initiate. Round holes and smooth
transitions or fillets will therefore increase the fatigue strength of the structure.

1.3.1 Characteristics of fatigue

 In metal alloys, when there are no macroscopic or microscopic discontinuities,

the process starts with dislocation movements, which eventually form
persistent slip bands that become the nucleus of short cracks.
 Macroscopic and microscopic discontinuities as well as component design
features which cause stress concentrations (holes, keyways, sharp changes of
direction etc.) are common locations at which the fatigue process begins.
 Fatigue is a process that has a degree of randomness (stochastic), often showing
considerable scatter even in well controlled environments.
 Fatigue is usually associated with tensile stresses but fatigue cracks have been
reported due to compressive loads.
 The greater the applied stress range, the shorter the life.
 Fatigue life scatter tends to increase for longer fatigue lives.
 Damage is cumulative. Materials do not recover when rested.
 Fatigue life is influenced by a variety of factors, such as temperature, surface
finish, metallurgical microstructure, presence of oxidizing, presence
inert chemicals, residual stresses, scuffing contact (fretting), etc.
 Some materials (e.g., some steel and titanium alloys) exhibit a
theoretical fatigue limit below which continued loading does not lead to fatigue
failure.
 In recent years, researchers (see, for example, the work of Bathias, Murakami,
and Stanzl-Tschegg) have found that failures can occur below the theoretical
fatigue limit at very high fatigue lives (109 to 1010 cycles). An ultrasonic
 6

resonance technique is used in these experiments with frequencies around 10–

20 KHz.
 High cycle fatigue strength (about 104 to 108 cycles) can be described by
stress-based parameters. A load controlled servo-hydraulic test rig is
commonly used in these tests, with frequencies of around 20–50 Hz. Other sorts
of machines like resonant magnetic machines can also be used, to achieve
frequencies up to 250 Hz.
 Low cycle fatigue (loading that typically causes failure in less than 104 cycles)
is associated with localized plastic behavior in metals; thus, a strain-based
parameter should be used for fatigue life prediction in metals. Testing is
conducted with constant strain amplitudes typically at 0.01–5 Hz

Fig1.3 Fracture of an aluminium crank arm. Dark area of striations: slow crack
growth. Bright granular area: sudden fracture.

1.3.2 Fatigue And Fracture Mechanics

The account above is purely empirical and, though it allows life

prediction and design assurance, life improvement or design optimization can be
enhanced using Fracture mechanics. It can be developed in four stages.

Stage I Crack nucleation;

Stage II crack-growth;
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Stage III crack-propagation; and

Stage IV Ultimate ductile failure.

1.3.3 FACTORS THAT AFFECT FATIGUE-LIFE:

 Cyclic stress state: Depending on the complexity of the geometry and the
loading, one or more properties of the stress state need to be considered,
such as stress amplitude, mean stress, biaxiality, in-phase or out-of-phase
shear stress, and load sequence.
 Geometry: Notches and variation in cross section throughout a part lead to
stress concentrations where fatigue cracks initiate.
 Surface quality: Surface roughness can cause microscopic stress
concentrations that lower the fatigue strength. Compressive residual
stresses can be introduced in the surface by e.g. shot peening to increase
fatigue life. Such techniques for producing surface stress are often referred
to as peening, whatever the mechanism used to produce the stress. Low
plasticity burnishing, laser peening, and ultrasonic impact treatment can
also produce this surface compressive stress and can increase the fatigue
life of the component. This improvement is normally observed only for
high-cycle fatigue.
 Material Type: Fatigue life, as well as the behavior during cyclic loading,
varies widely for different materials, e.g. composites and polymers differ
markedly from metals.
 Residual stresses: Welding, cutting, casting, grinding, and other
manufacturing processes involving heat or deformation can produce high
levels of tensile residual stress, which decreases the fatigue strength.
 Size and distribution of internal defects: Casting defects such as gas
porosity voids, non-metallic inclusions and shrinkage voids can
significantly reduce fatigue strength.
 Air or Vacuum: Certain materials like Metals are more prone to fatigue in
air than in a vacuum. Depending upon the level of humidity and
 8

temperature, the lifetime for metals such as aluminum or iron might be as

much as 5 to 10 times greater in a vacuum. This is mostly due to the effect
of the oxygen and water vapour in the air which will aggressively attack the
material and so encourage the propagation of cracks. Other environments
such as oil or seawater may reduce the fatigue life at an even greater rate.
 Direction of loading: For non-isotropic materials, fatigue strength depends
on the direction of the principal stress.
 Grain size: For most metals, smaller grains yield longer fatigue lives,
however, the presence of surface defects or scratches will have a greater
influence than in a coarse grained alloy.
 Environment: Environmental conditions can cause erosion, corrosion, or
gas-phase embrittlement, which all affect fatigue life. Corrosion fatigue is
a problem encountered in many aggressive environments.
 Temperature: Extreme high or low temperatures can decrease fatigue
strength.
 Crack Closure: Crack closure is a phenomenon in fatigue loading, during
which the crack will tend to remain in a closed position even though some
external tensile force is acting on the material. During this process the crack
will open only at a nominal stress above a particular crack opening stress.
This is due to several factors such as plastic deformation or phase
transformation during crack propagation, corrosion of crack surfaces,
presence of fluids in the crack, or roughness at cracked surfaces etc. this
will provide a longer fatigue life for the material than expected, by slowing
the crack growth rate.

1.4 SPECIGFICATION OF TESTING MATERIAL

1.4.1 INCONEL Alloy 740

INCONEL alloy 740H is a nickel-base, precipitation hard enable super

alloy that offers a unique combination of high strength and creep resistance at
elevated temperatures along with resistance to coal ash corrosion. The alloy was
 9

originally targeted for use as A-USC boiler tubes in the super heater sections of
these plants but was then adapted for application as a material for the steam
headers to which the boiler tubes are connected.

INCONEL alloy 740H (UNS N07740) is derivation of NIMONIC alloy

263. With its higher content of chromium (24.5%), alloy 740H offers a
significant improvement is resistance to high temperature corrosion mechanisms.
Alloy 740H is age hardened by the precipitation of a second phase, gamma prime
(γ’). By balancing the hardener content (niobium, aluminum and titanium), alloy
740H exhibits good thermal stability in addition to high strength.

1.4.2 INCONEL ALLOY 783

The newest of the high-performance super alloys invented by Special

Metals Corporation, INCONEL alloy 783 (UNS R30783/U.S. Patent 5,478,417),
is an oxidation-resistant, low expansion, nickel-cobalt-iron alloy with aluminum,
chromium, and niobium additions. The new alloy is of considerable interest to
aircraft gas turbine engine designers and materials engineers for containment and
clearance control components such as rings, casings, shrouds and seals for
compressors, turbines and exhaust systems. The three-phase age hard enable alloy
offers a range of improvements for these applications over alternative alloys in
current use.

1.4.3 WROUGHT ALUMINIUM ALLOY 2219

2219 aluminium alloy is an alloy in the wrought aluminium-copper

family. It can be heat treated to produce tempers with a higher strength but a lower
ductility. The aluminium-copper alloys have high strength, but are generally less
corrosion resistant and harder to weld than other types of aluminium alloys. To
compensate for the lower corrosion resistance, 2219 aluminium can be clad in a
commercially pure alloy such as 1050 or painted. This alloy is commonly formed
by both extrusion and forging but is not used casting.
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CHAPTER II

LITERATURE REVIEW

Fabrication of internal driven micro centrifugal force pump based

on synchronous micro motors with polymer magnet rotors by, Waldschik,
A Inst. for Microtechnol Tech. Univ. Braunschweig,. In this paper the fabrication
of a micro centrifugal force pump based on a synchronous motor is presented. The
pump unit as well as the electromagnetic drive unit is fully integrated and mainly
realized by means of micro fabrication technologies including UV-depth
lithography and electroplating. Furthermore, one specialty is the application of
polymer magnets which allow a miniaturization of the toothed rotor down to 2
mm. The presented pump reveals a promising basic concept for other micro rotary
pumps like spiral, impeller or gear pumps.

Failure analysis of a polymer centrifugal impeller By,Nikhil K.Kar a,

YinghuiHub, NareshJ.Kar a, RameshJ.K.in this paper Centrifugal pumps,
compressors, and blowers utilize various impeller designs that are an essential
component for bulk transport of fluids. Typically, a motor is used to spin a shaft
that is connected to a housed impeller, which draws fluid in along a rotating axis.
The fluid is accelerated and whirled radially and tangentially outward through the
impeller vanes, where it exits through a casing designed to decelerate the fluid
velocity and increase fluid pressure. Centrifugal pumps are susceptible to various
modes of impeller failure including but not limited to intergranular corrosion,
erosion, cavitation, material defects, as there are a number of documented case
studies in the literature.

Layer Build of Titanium Alloy Components for Complex-Geometry

Rocket Engine Components By John Halchak, John Wooten, and Brian
McEnerney. Liquid rocket engine performance has historically been constrained
by the limitations of materials and processes used for component fabrication.
Traditional manufacturing processes, such as machining from forgings, are
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capable of producing reliable components; however, such processes are expensive

because of the materials needed, the complexity of designs and the low production
quantities typically associated with liquid rocket engines. In particular, titanium
alloy components, such as shrouded pump impellers with their complex flow
passages, are exceedingly expensive to machine. This high machining cost offers
considerable room for cost savings by alternative fabrication processes.
Recognizing these cost drivers, Pratt & Whitney Rocket dyne has been exploring
various additive manufacturing processes as a potential approach to lower costs
for low-volume production components. Since additive manufacturing does not
require tooling, it allows for complex shapes to be produced directly from CAD
files, and it has an economic order quantity of one. If components can be produced
with the quality and reproducibility of wrought materials, then additive
manufacturing offers the potential of significantly reducing the cost of the next
generation of liquid rocket engines. This paper provides the results of initial work
performed to fabricate demonstration titanium-6Al-4V alloy impellers from
powder metal by a layer-build additive manufacturing process. Evaluations of
process results, microstructural examination, and mechanical property testing are
presented.

Root Cause Analysis to Identify the Problem Causing Turbine

Failure. By Mithun Ekanathan,Binu C.Assistant Professor,Department of
Mechanical Engineering,Mar Athanasius College of Engineering,
Kothamangalam, Kerala, IndiaThe root cause analysis method consists of three
steps: target problem detection, root cause detection and corrective action
innovation. In this paper a root cause analysis method to identify a turbo-driven
pump failure case occurring in leading petrochemical companyis presented.The
turbo driven pumps are one of the primary equipment that pumps steam into the
boiler in order to generate the required amount of power to run the plant. The root
cause is identified using a ‘Symptom’ based approach of the Root Cause Analysis
 12

method where in the symptoms are first focused. Various industrial engineering
tools are used and finally a feasible and acceptable solutionis identified
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CHAPTER III

PROBLEM IDENTIFICATION

3.1 EXISTING SYSTEM

Fatigue failure of centrifugal impellers has occurred all over the world
in various services operated by different companies, users and machinery built by
several manufacturers. When considering fatigue, covered radial impellers are
perhaps one of the most reliable components for centrifugal pump.A number of
these failures have been due to poor design. However, it has been discovered that
many failures have been caused by preexisting notches or flaws in materials that
initiate cracks that grow and lead to fracture. This discovery has, in a sense, lead
to the field of study known as fracture mechanics. The field of fracture mechanics
is extremely broad. It includes applications in engineering, studies in applied
mechanics (including elasticity and plasticity), and materials science (including
fracture processes, fracture criteria, and crack propagation). The successful
application of fracture mechanics requires some understanding of the total field.
Thus, as implied above, fracture mechanics is a method of characterizing the
fracture behavior of sharply notched members and based on a stress analysis in the
vicinity of a notch or crack. Therefore, using fracture mechanics, allowable stress
levels and inspection requirements can be quantitatively established to design
against the occurrence of fractures in equipment’s and machinery. In addition,
fracture mechanics can be used to analyze the growth of small cracks to critical
size by fatigue loading and to evaluate the fitness-for-service, or life extension of
existing equipment.The traditional material use for impeller productions are Steel,
Plastic, Iron, Aluminium etc. These materials have average life span and
gooddamage resistance.
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3.2 PRESENT STUDY

In this project we are using the new material inconel alloy 740, inconel alloy 783,
wrought aluminum alloy 2219The impeller is analyzed under different loading
condition and its corresponding fatigue life is calculated using different results
obtained from the analysis.
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CHAPTER IV

METHODOLOGY

Study of existing analysis

Analysis of performane parameters and literarure riview

Development and selectiion of appropriate parameters

Analysis of current performane level including structural

strength of materials

Fabricate impeller using Inconnel alloy 740, Inconnel alloy

783 and Wrought aluminium alloy 2219 material

Comparison of performance and cost

Conclusion and future scope

Fig 4.1 Methodology of the project

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CHAPTER V

EXPERIMENTAL WORKS

Tool used

1. Design tool :CATIA

2. Meshing & Analyses tool: AnsyS

5.1 INTRODUCTION TO ANSYS

The ANSYS program has many finite element analysis capabilities,

ranging from a simple, linear, static analysis to a complex non – linear, transient
dynamic analysis.

A typical ANSYS analysis has three distinct steps:

 Building the model

 Applying loads and obtains the solution
 Review the results.
5.1.1 Building The Model

Building a finite element model requires a more of an ANSYS user’s

time than any other part of the analysis. First you specify the job name and analysis
title. Then, define the element types, real constants, and material properties, and
the model geometry.

5.1.2 Defining the Model

The analysis element library contains more than 100 different element
types. Each element type has a unique number and a prefix that identifies the
element category. Example: beam, pipe, plant, shell, solid.
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5.1.3 Defining The Element Real Constant

Element real constant are the properties that depend on the element
type, such as cross sectional properties of a beam element. For example real
constants for BEAM3 , the 2-d beam element, or area, moment of inertia(IZZ),
height , shear deflection constant (SHEAR Z), initial strain (ISTRN) different
elements of same type may have different real constant values.

5.1.4 Defining The Material Properties

Most elements types require material properties. Depending on the application,

material properties may be:

 Linear or non linear

 Isotropic, or an isotropic
 Constant temperature or temperature – dependant

As with element type and real constant, each set of material properties
has a material reference number. The table of material reference number verses
material property set ids called material property table. Within, one analysis you
may have multiple material properties set.

5.1.5 Material Property Test

Although you can define material properties separately for each element
analysis, the ANSYS program enables you to store a material property set in an
archival material library file, then retrieve the set and reuse it in multiple analysis.
The material library files also enable several ANSYS user to share common used
material property data.

5.2 INTRODUCTION TO CATIA

CATIA which stands for computer aided three dimensional interactive

applications is the most powerful and widely used CAD (computer aided design)
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software of its kind in the world. CATIA is owned/developed by Dassault system

of France and until 2010, was marketed worldwide by IBM.

The Following general methodologies and best practices can be followed

in the modeling of components in CATIA. The Below methodologies and Best
practices followed will help in capturing the design intent of the Feature that is to
be Modeled and will make the design robust and easy to navigate through.

 Specification tree structuring

 Renaming appropriate features & bodies in specification tree
 Handling input data & foreign bodies
 Dimensioning & constraining in sketches
 Parameters and relations.

5.2.1 Specification Tree Structuring

a) The SPECIFICATION TREE is the place where the histories of the features
modeled are captured. So it is highly important to have an organized tree
structure which gives ease for navigation of the features when any
modification takes place.
b) The SPECIFICATION TREE in a structured manner. The Machining Body
features are grouped under one body and base block features in another and
so on with appropriate feature operations.
c) It is also important in structuring the reference and construction element in
the tree in an orderly manner.
d) The points that would be often used (like the Global Origin Point 0, 0, 0,)
can be created under Points GEOMETRICAL SET and any reference
.planes defining legal limits can be created in the planes GEOMETRICAL
SET.
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5.2.2 Renaming Appropriate Features & Bodies In Specification Tree

a) The renaming of features within the design becomes mandatory as it will
be useful for the end users to by far identify things for modification.
b) For instance an end user who wants to identify the M5 holes on the model
the SPECIFICATION TREE helps easily in identifying the M5 holes in
the model there by making modifications easy.
c) Also renaming all the features every now and then as it is created will
easy things at the end.
d) “Base Block Sketch” and “Base Block” is which will be useful in
identifying them at a later stage.
e) Renaming the Bodies also helps in navigation.

5.2.3 Handling Input Data And Foreign Bodies

a) Any external data that are to be handled in the model can be grouped under
a GEOMETRICAL SET called input data which can be used in the model
when situation demands.

b) Some foreign elements like planes, points, curves and surfaces that would
be used in the modeling process.

c) By grouping the foreign elements in a separate GEOMETRICAL SET it is

easy to identify them in the SPECIFICATION TREE.

5.2.4 Dimensioning And Constraining In Sketches

a) Planes should be intersected in the sketches and made as construction
elements and should be used as dimension reference for geometries, this
helps in identifying the dimension line clearly in a complex sketch.
b) Equivalent dimension should be used wherever possible to minimize
modification time in the sketches.
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c) Usage of sketch analysis command is mandatory at the end of every sketch

build which helps in diagnosing the sketch thereby identifying
abnormalities.
d) Robust design Intent can be Achieved with the Integration of Parameters
and Relations.
5.2.5 Parameters And Relations
a) The parameters functionality helps in building a robust design with ease of
relating object.
b) Parameters can be declared globally and related to radius value thereby
controlling the radius value outside the command.
c) The advantage of declaring parameters is to control and relate the values to
multiple values.
d) A parameter “corner radius” which is related to the fillet radius, thereby now
modifying the corner radius parameter the fillet radius can be modified. Also
there can be multiple values associated to the same parameter.

5.3 TESTING MATERIAL FOR IMPELLER

5.3.1 INCONEL Alloy 740

INCONEL alloy 740H is a nickel-base, precipitation hard enable super

alloy that offers a unique combination of high strength and creep resistance at
elevated temperatures along with resistance to coal ash corrosion. The alloy was
originally targeted for use as A-USC boiler tubes in the super heater sections of
these plants but was then adapted for application as a material for the steam headers
to which the boiler tubes are connected. A-USC boiler tubes are conventional sizes
[typically 1.5 to 3 inch (38 to 76 mm) outside diameter]. Main steam header pipe
sizes occupy a much larger size range, with outer diameter greater than 12 inches
(305 mm) and wall thickness likely exceeding 1.5 inches (38 mm). Seamless steam
reheat piping, at up to 30 inch (760 mm) outer diameter, is also a feasible product
line with INCONEL alloy 740.
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5.3.1.1 Chemical Composition

INCONEL alloy 740H (UNS N07740) is derivation of NIMONIC alloy
263. With its higher content of chromium (24.5%), alloy 740H offers a significant
improvement is resistance to high temperature corrosion mechanisms. Alloy 740H
is age hardened by the precipitation of a second phase, gamma prime (γ’). By
balancing the hardener content (niobium, aluminum and titanium), alloy 740H
exhibits good thermal stability in addition to high strength.

Table 5.1 chemical composition of Inconel alloy 740

Element Composition (%)

Nickel, Ni 48.27

Chromium, Cr 25

Cobalt, Co 20

Niobium, Nb 2

Titanium, Ti 1.8

Aluminium, Al 0.9

Iron, Fe 0.7

Silicon, Si 0.5

Molybdenum, Mo 0.5

Manganese, Mn 0.3

Carbon, C 0.03

5.3.1.2 Metallurgy & Microstructure

Alloy 740H exhibits an austenitic structure and is age hardened by the
precipitation of a gamma prime (γ’) Ni3 (Al,Ti,Nb) phase. During heat treatment,
niobium, aluminum, and titanium form the gamma prime precipitates required for
 22

strengthening. The microstructure of alloy 740H extruded pipe in the solution

annealed and aged condition is seen in Figure 1. Second phases observed in this
condition include primary carb-nitrides of the (Nb,Ti)(C,N) type, Cr23C6 type
carbides, and gamma prime. Additional exposure across the temperature range
anticipated for A-USC service serves simply to modify the relative amounts of
these same phases. Figure 5.1 shows an SEM image of the microstructure of
INCONEL alloy 740H after solution annealing followed by exposure for 5,000
hours at 1380°F (750°C).

Fig 5.1 micro structure of INCONEL alloy 740

5.3.1.3 Physical Properties

Table 5.2 physical properties of INCONEL Alloy 740
Density g/cm3 8.05

Density, lb/in3 0.291

Melting Range, °C 1288-1362
Melting Range, °F 350-2484

Electrical Resistivity, Ω-circ mil/ft 702.7

Electrical Resistivity, Ω –m 1.168
 23

5.3.1.4 Thermal properties

Table 5.3 thermal properties of INCONEL alloy 740
Properties Metric Imperical

Thermal expansion 12.38 µm/m0C 6.878 µin/in0F

coefficient
Thermal conductivity 10.2 W/m-K 70.8 BTU in/hr.ft2.0F

5.3.1.5 Mechanical propertieS

Table 5.4 Mechanical properties of INCONEL alloy 740
Properties Metric Imperical

Tensile strength 1209 MPa 175300 psi

Yield strength 818.4 MPa 118700 psi

Elastic modulus 221 GPa 32 ksi

Elongation at break 36.40 % 36.40%

Hardness, Rock 33.6 33.6

well C

5.3.2 INCONEL ALLOY 783:

The newest of the high-performance super alloys invented by Special

Metals Corporation, INCONEL® alloy 783 (UNS R30783/U.S. Patent 5,478,417),
is an oxidation-resistant, low expansion, nickel-cobalt-iron alloy with aluminum,
chromium, and niobium additions. The new alloy is of considerable interest to
aircraft gas turbine engine designers and materials engineers for containment and
clearance control components such as rings, casings, shrouds and seals for
compressors, turbines and exhaust systems. The three-phase age hard enable alloy
offers a range of improvements for these applications over alternative alloys in
current use.
 24

Table 5.5 chemical composition of INCONEL alloy 783

Element Composition (%)

Nickel , Ni 26-30

Iron, Fe 24-27

Aluminium, Al 5-6

Chromium, Cr 2.5-3.5

Niobium, Nb 2.5-3.5

Copper, Cu 0.50

Manganese, Mn 0.50

Silicon, Si 0.50

Titanium, Ti 0.10-0.40

Carbon, C 0.03

Boron, B 0.003-0.012

A coefficient of thermal expansion approximately 20% lower than that

of INCONEL alloy 718. Excellent resistance to oxidation, demonstrated in cyclic
tests, at temperatures up to and beyond 1300°F (704°C). Resistance to SAGBO
(stress accelerated grain boundary oxidation) comparable to that of INCONEL
alloy 718, and significantly better than that of INCOLOY alloy 909. A density of
0.282 lb/in3 (7.81 g/cm3), 5% less than INCONEL alloy 718 or INCOLOY® alloy
909, contributing to an important potential improvement in strength-to-weight
ratios.
Manufacturing/processing characteristics comparable to those of
INCONEL alloy 718, and less limiting than those of INCOLOY alloy 909. Special
Metals’ INCONEL alloy 783 is available as forging billet (AMS 5940), rod and
 25

bar for machining, extruded section, and wire rod. Sheet product is currently under
development.

5.3.2.1 Mechanical Properties

In the age-hardened condition, INCONEL alloy 783 has high

mechanical properties at room temperature and retains much of its strength at
temperatures to about 1300°F (704°C). All mechanical properties given here are
for the standard heat treatment: Solution anneal at 2050°F (1121°C)/1 hr, air cool,
plus “beta age” at 1550°F (845°C)/4 hr, air cool to room temperature, plus age
harden at 1325°F (718°C)/8 hr, furnace cool at 100°F (55°C)/ hr to 1150°F
(621°C)/8 hr, and air cool.
Table 5.6 mechanical properties of Inconel 783
Properties metric imperical

Tensile strength 1194 MPa 171 ksi

Yield strength 779 MPa 113 ksi

Elastic modulus 177.3 GPa 25.72 ksi

Elongation at break 24% 24%

Poisons ratio 0.31 0.31

Table 5.8 Thermal properties

Properties metric imperical

Thermal expansion 10.08 µm/m0C 5.60 µin/in0F

coefficient
Thermal conductivity 10.1 W/m-K 71 BTU in/hr.ft2.0F
 26

5.3.3 WROUGHT ALUMINUM ALLOY 2219

2219 aluminium alloy is an alloy in the wrought aluminium-copper

family. It can be heat treated to produce tempers with a higher strength but a lower
ductility. The aluminium-copper alloys have high strength, but are generally less
corrosion resistant and harder to weld than other types of aluminium alloys. To
compensate for the lower corrosion resistance, 2219 aluminium can be clad in a
commercially pure alloy such as 1050 or painted. This alloy is commonly formed
by both extrusion and forging but is not used casting

Table 5.9 Chemical composition of wrought aluminium 2219

Element Composition (%)

Aluminium 91.5 to 93.8

Copper 5.8 to 6.8

Iron 0.3

Magnesium 0.02

Manganese 0.2 to 0.4

Silicon 0.2

Titanium 0.02 to 0.10

Vanadium 0.05 to 0.15

Zinc 0.1
Zirconium 0.10 to 0.25

Residuals 0.15
 27

Table 5.10 Properties of wrought aluminium alloy 2219

Property Value in metric Value in US unit

unit
Density 2.84 kg/m³ 177 lb/ft³
*10³
Modulus of elasticity 73 GPa 10600 Ksi
Thermal expansion (20 ºC) 22.3*10- ºCˉ¹ 12.4*10- in/(in* ºF)
6 6

Specific heat capacity 864 J/(kg*K) 0.207 BTU/(lb*ºF)

Thermal conductivity 171 W/(m*K) 1190 BTU*in/(hr*ft²*ºF)
Electric resistivity 3.99*10- Ohm*m 3.99*10- Ohm*cm
8 6

Tensile strength (annealed) 172 MPa 25000 Psi

Yield strength (annealed) 76 MPa 11000 Psi
Elongation (annealed) 18 % 18 %
Shear strength (annealed) 106 MPa 15400 Psi
Hardness (annealed) 46 HB 46 HB
Tensile strength (T851) 455 MPa 66000 Psi
Yield strength (T851) 352 MPa 51000 Psi
Elongation (T851) 10 % 10 %
Shear strength (T851) 285 MPa 41300 Psi
Fatigue strength (T851) 103 MPa 15000 Psi
Hardness (T851) 130 HB 130 HB
Annealing temperature 413 ºC 775 ºF
Solution temperature 535 ºC 995 ºF
Aging temperature 163-191 ºC 325-375 ºF

5.4 CENTRIFUGAL PUMP IMPELLER VANE PROFILE

The concept of impeller design and the application of inverse design for
the vane profile construction are discussed in this chapter. The vane profile plays
a vital role to develop the streamlined flow. In conventional design, the designer
uses vane arc method to develop the profile. Due to this approach, the eddy and
 28

flow reversal may occur in the flow path. The main focus on inverse design concept
is explained here in detail for the vane profile construction. Subsequently, the
different vane profile geometry is constructed based on this approach. The design
of the centrifugal pump impeller is not a universally standardized one. Every firm
depends on its designer’s experience, expertise and technical intuition to design a
good impeller. The fact that the impeller flow physics has not been understood
fully has led the designers to fall back on tried and tested old design methodologies.

5.4.1 Design Methodology

The impeller dimensions are designed based on the head and discharge.
The following are the steps involved in designing a centrifugal impeller
• From the head (H) and discharge (Q), the kinematic specific
speed (nSQ) is calculated,
• From the head and discharge, the shaft power (Psh) required is calculated.

• Before finding the hub diameter, the shaft diameter (dsh) is found using the
formula

τ- Torsional Stress, (KP/cm2) (5.3)

 29

Fig 5.2 Pump Impeller

• The hub diameter (dh) is calculated from the empirical relation

given below.
dh = (1.3 ~1.4) dsh
• The inlet velocity (u1) is estimated using,
u1 = 0.95 × cm1, where cm1 =

where Kcm1 is the velocity coefficient.

• From the inlet velocity and the new discharge (Q°) calculated after accounting
for volumetric efficiency, the inlet cross section area (A0) is calculated
A0 = Q°/ u1
• From the area, the inlet diameter (d1) is calculated.

• Blade inlet angle is calculated as

• Breadth of the impeller (B1) at the inlet is

 30

• Blade outlet angle (_2) is assumed to lie within the limits of 15° to 35°, usually
of the order of 25°.

• The outlet peripheral velocity (u2) can be calculated as follows

Where Ku2 is the experimental velocity coefficient.

• The outlet diameter (d2) and the breadth of the impeller at the outlet are

5.4.2 Construction Of Vane Profile

Having now found the dimensions of impeller like the hub diameter,
inlet diameter, breadth of the impeller at the inlet and the outlet, outside diameter
and the vane angles, the vane profile or the curve has to be generated. The vane
profiles can be of different types and the designer has the discretion to choose the
type of curve to be drawn. The vane profile for the impeller of the pump considered
as model in this work is a multiple curvature profile with four different radii of
curvature with four different centers as shown in fig
The following are the steps involved in tracing the vane profile:
• The inlet and the outlet circles are drawn.
• Two axes of reference, one vertical and one horizontal, are drawn.
• In order to trace the profile with four radii of curvature, four more circles, that is,
point 1 to 6, are drawn at equal intervals on the axis. The curve is drawn through
A, B, C, D and E based on
The positions G, H, I, J and K.
 31

• From the point where inlet circle meets the horizontal axis, a line at an angle of
inlet vane angle (16°) is drawn to the length of the radius of curvature of the first
arc (47 mm).
• An arc is drawn with the end point of this line as the centre and with the
corresponding radius, till the arc meets the next circle.
• From the point where the arc meets the next circle, a line is drawn to the length
equal to the next radius of curvature and passing through the previous centre.
• An arc is drawn with the end point of this line as the centre and with the
corresponding radius till the arc meets the next circle.
• This procedure is followed till the four arcs are drawn. The curve drawn along
with the dimensions found above, form the basis with which the impeller can be
made.

Fig
5.3 Impeller Vane Profile Or Curve
 32

5.5 PUMP IMPELLER DIMENSIONS

Inlet Diameter (d1) = 75 mm

Outer Diameter (d2) = 160 mm
Curvature Radius = 47 mm, 62.5 mm, 81 mm and 98.5 mm
Number of vanes (z) = 6 (4 mm thick)
Breadth of Impeller (B) = 20.5 to 8 mm (converging from inlet to outlet)
Inlet vane angle (_1) = 16 degrees
Exit vane angle (_2) = 23.5 degrees
 33

CHAPTER VI

CONCLUSION AND FUTURE WORKS

In this project the new materials selected for the impeller fabrication as
INCONEL alloy 740 , INCONEL alloy789 and wrought Aluminium 2219. The
geometry of impeller and is modeled using ANSYS.
The 3D modelling of the impeller is shown below

Fig 6.1 Different Views Of Impeller

 34

Fig 6.2 Three Dimensional View of Impeller

6.1 FUTURE WORKS

Table 7.1 Future work

MONTH NOV DEC JAN FEB MAR
ACTIVITY
×
Material selection

Material Purchase ×

Fabrication × ×

Fatigue life analysis × ×

The materials are selected and ordered for doing the work. The impeller will be
fabricated using the selected material. Then its fatigue life will be tested analysed.
 35

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