Optimizing Efficiency by Increasing Speed and Reducing Noise in Marine Pumps Using Metal-Based Additive Manufacturing

Project background

The key innovative elements are the development and optimization of both a centrifugal pump and a positive-displacement pump equipped with a centrifugal pump stage. Passive-adaptive noise-reduction measures are integrated into these two test beds using additive manufacturing. These consist of elements for structural acoustic component damping as well as speed-adaptive Helmholtz resonators specifically arranged within the positive displacement pump housing. 

With these measures—which are designed and tested significantly more efficiently through the synergistic combination of a forward-looking, holistic simulation methodology for the integrated analysis of fluid, body, and airborne sound phenomena with the additive manufacturing technologies of the Laser-Powder-bed fusion process, significantly lower noise emissions can be achieved despite increased rotational speed.

Project background

The key innovative elements are the development and optimization of both a centrifugal pump and a positive-displacement pump equipped with a centrifugal pump stage. Passive-adaptive noise-reduction measures are integrated into these two test beds using additive manufacturing. These consist of elements for structural acoustic component damping as well as speed-adaptive Helmholtz resonators specifically arranged within the positive displacement pump housing. 

With these measures—which are designed and tested much more efficiently through the synergistic combination of a forward-looking, holistic simulation methodology for the integrated analysis of fluid, body, and airborne sound phenomena with the additive manufacturing technologies of the Laser-Powder-bed fusion process, can be designed and tested much more efficiently; as a result, significantly lower noise emissions can be achieved despite increased rotational speeds.

Project objective

The consortium’s project objectives include improving efficiency, reducing the sound power level, and increasing the operating speed of positive-displacement pumps—depending on the size, for example, from 2,500 rpm to 4,000 rpm. 

The subproject at Rosenheim Technical University of Applied Sciences aims to systematically integrate additive manufacturing (AM) as an enabler technology for low-noise, high-performance pumps, to incorporate AM expertise at the right stage in the research and development process, and thereby to harness previously untapped potential in pump design. In addition, there is a particular focus on developing methods for the efficient design, concept validation, and component testing of additively manufactured pump components in the maritime sector. 

Project objective

The consortium's project objectives include improving efficiency, reducing the sound power level, and increasing the operating speed of positive-displacement pumps—depending on the size, for example, from 2,500 rpm to 4,000 rpm. 

The subproject at Rosenheim Technical University of Applied Sciences aims to strategically integrate additive manufacturing (AM) as an enabler technology for low-noise, high-performance pumps, to incorporate AM expertise at the right stage in the research and development process, and thereby harness previously untapped potential in pump design. In addition, there is a particular focus on developing methods for the efficient design, concept validation, and component testing of additively manufactured pump components in the maritime sector. 

Project procedure

1. Project Year:

• Definition of approval requirements for additively manufactured pump components.
• Design and implementation of a test bench for static component testing.
• AM-specific design, technical and economic evaluation of concepts for positive-displacement pumps.

2. Project Year

• AM-specific design, technical and economic concept evaluation for positive displacement pumps.
• Identification & optimization of standard pump design geometries with regard to AM
• Additive manufacturing of pump components with integrated particle dampers.
• Identification of design potential & AM-specific functional principles for sound attenuation.

3. Project year:

• AM-specific design, technical and economic concept evaluation for positive displacement pumps.
• Production and quality assurance of 316L components
• Development and validation of a design methodology

Project procedure

1. Project Year:

• Definition of approval requirements for additively manufactured pump components.
• Design and implementation of a test bench for static component testing.
• AM-specific design, technical and economic evaluation of concepts for positive displacement pumps.

2. Project Year

• AM-specific design, technical and economic evaluation of concepts for positive displacement pumps.
• Identification & optimization of standard pump design geometries with regard to AM
• Additive manufacturing of pump components with integrated particle dampers.
• Identification of design potential & AM-specific functional principles for sound attenuation.

3. Project year:

• AM-specific design, technical and economic concept evaluation for positive displacement pumps.
• Production and quality assurance of 316L components
• Development and validation of a design methodology

Innovation

The project results will make substantial contributions to improving efficiency, reducing noise, optimizing weight, and promoting the sustainable use of materials and resources in maritime hydraulic and fluid systems, which will lead to significant direct and indirect environmental and economic efficiency gains. 

This is a comprehensive contribution to maritime hydraulic drives and fluid systems, which will become more environmentally friendly, sustainable, and resource-efficient in both manufacturing and operation. 

Innovation

The project results will make substantial contributions to improving efficiency, reducing noise, optimizing weight, and ensuring the sustainable use of materials and resources in maritime hydraulic and fluid systems, which will directly and indirectly lead to significant environmental and economic efficiency gains. 

This is a comprehensive contribution to maritime hydraulic drives and fluid systems, which will become more environmentally friendly, sustainable, and resource-efficient in both manufacturing and operation.