VBN Components Enables Wear-resistant AM Integration in Large Slurry Pumps

VBN Components, in collaboration with a major pump manufacturer, has successfully demonstrated a new method for integrating additively manufactured (AM) cemented carbide into large-scale cast components. 

By casting directly on to Vibenite 480, the solution enables a step-change in wear resistance for slurry pumps or other casted equipment, without the need to manufacture full-size components additively.

The breakthrough is made possible by introducing a Vibenite Nucleation Net Zone (VNNZ) during the 3D printing process. This engineered interface allows high-chromium cast iron to bond effectively to the extremely wear-resistant Vibenite 480 during casting.

Wear testing in representative slurry pump environments showed that Vibenite 480 delivers exceptional performance, with erosive wear resistance approximately 10 times higher than high chromium cast iron and about 100 times higher than hardened steel plate, according to the company.

Without the VNNZ, molten cast iron tends to melt or intermix with the printed inserts, compromising both geometry and material performance. The VNNZ eliminates this issue, ensuring structural integrity and strong metallurgical bonding during casting.

The technology will now be verified in full-scale slurry pump housings. 

“This is an exciting development for our additive manufacturing technology,” said Dr. Ulrik Beste, CTO of VBN Components. “We are demonstrating how the superior wear resistance of Vibenite 480 can be integrated into large industrial components in a practical and scalable way — combining material performance with the design freedom of AM. It opens up significant new business opportunities.” 

Printing a nucleation net zone in Vibenite 480 is simple and it enables precise placement of the wear-resistant material inside the mold at the most critical positions, extending pump lifetime.

vbncomponents.com