Quais materiais são utilizados para impulsores de bombas de polpa?

Os impulsores de bombas de polpa ATF estão disponíveis em ferro fundido branco alto cromo (27% Cr), borracha natural e poliuretano. O alto cromo é ideal para polpas abrasivas grossas, a borracha se destaca com partículas finas e polpas corrosivas, e o poliuretano oferece bom desempenho geral.

Como selecionar entre revestimentos de borracha e metal para bombas?

Os revestimentos metálicos (alto cromo) lidam melhor com partículas grossas e pontiagudas e altas temperaturas. Os revestimentos de borracha oferecem desempenho superior com partículas finas, polpas corrosivas e onde a redução de ruído é importante. As características da polpa determinam a escolha ideal.

O que causa desgaste prematuro em bombas de polpa?

As causas comuns incluem partículas superdimensionadas, operação de bombas fora do ponto de projeto, cavitação e folga inadequada do impulsor. Manter os parâmetros operacionais corretos e ajustar regularmente a folga prolonga significativamente a vida útil dos componentes.

Volutas de Bomba de Polpa

Especificações principais

Chrome Grades: A05 (Cr27), A07 (Cr27Mo), A61 Cr-Mo
Chrome Hardness: 550–700 BHN (grade-dependent)
Rubber Grades: R55 (55 Shore A), R26 (40 Shore A), R08 Neoprene
Construction: Single-piece or split (2-piece) designs
Pump Compatibility: Warman AH, Metso HM/HR, KSB GIW, ITT Goulds
Size Range: 1.5/1 through 20/18 (Warman frame equivalent)
Max Temperature: 70 C (rubber), 120 C (chrome)
Sealing: Machined mating faces, O-ring grooves to OEM spec

Key Features of ATF Volute Liners

High-Chrome White Iron

A05/A07 grade chrome iron (Cr27) with 600+ BHN hardness. Optimized microstructure with uniformly distributed carbides for consistent wear resistance throughout liner thickness.

Natural Rubber Lining

Vulcanized natural rubber bonded to steel backing shells. 40-55 Shore A durometer provides excellent fine particle erosion resistance with chemical compatibility for acidic slurries.

Precision Casting

Volute profiles cast to OEM tolerances ensuring proper flow passage geometry. Critical cutwater and tongue dimensions maintained for hydraulic efficiency.

Split Design Options

Two-piece split volute liners available for large pumps where single-piece removal is impractical. Matched halves with precision joint faces prevent leakage and wear concentration.

Integrated Wear Backs

Thick metal sections at high-wear areas including cutwater, discharge flange, and impeller clearance zones. Extended service life where erosion is most severe.

Machined Sealing Faces

All mating surfaces machined to ensure proper sealing against frame plates and suction covers. Prevents slurry leakage that accelerates external component wear.

Volutes

Volute Liners: Directing Flow in Centrifugal Slurry Pumps

The volute is the spiral-shaped casing that surrounds the impeller in centrifugal slurry pumps, and its liner is one of the most critical wear components in the pump wet-end assembly. As slurry exits the impeller periphery at velocities of 10–25 m/s, the volute collects this high-energy flow and converts kinetic energy into static pressure through its progressively expanding cross-section. Volute geometry—including the cutwater (tongue) angle, throat area, and discharge nozzle dimensions—directly affects pump efficiency, head development, and radial thrust on the shaft and bearings. In abrasive mining service, replaceable volute liners manufactured from A05 high-chrome white iron (Cr27, 600–650 BHN) or A07 Cr27Mo (650–700 BHN) protect the structural steel casing from erosion, while rubber-lined options (R55 at 55 Shore A, R26 at 40 Shore A) provide superior performance in fine-particle and corrosive slurry environments with operating temperatures below 70 degrees C.

Mining and mineral processing pumps employ replaceable volute liners as the primary strategy for managing wet-end wear costs, since the volute experiences continuous erosive attack from slurry flowing at high velocity through a complex three-dimensional passage. ATF manufactures aftermarket volute liners in high-chrome white iron, chrome-moly alloys, natural rubber, and neoprene to match OEM specifications for all major pump brands including Warman/Weir, Metso, KSB GIW, and ITT Goulds. All volute profiles are reverse-engineered from OEM parts using 3D laser scanning, with critical dimensions—cutwater clearance, throat area, discharge bore, and sealing face geometry—verified by CMM inspection to ensure hydraulic performance matches original pump curves. Both single-piece and split (two-piece) designs are available, with split liners offered for large pumps (typically 10/8 frame and above) where single-piece removal is impractical. Proper liner fit eliminates internal leakage paths that would reduce efficiency and create localised erosion hot spots.

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Slurry pump volute liner in high-chrome and rubber manufactured by ATF

Volute liners and casings in A05 high-chrome white iron and rubber-lined configurations for mining slurry service

OEM Compatibility

ATF manufactures aftermarket volute liners and casings for all major slurry pump brands. Liners are reverse-engineered from OEM parts using 3D scanning to ensure exact dimensional fit and hydraulic performance.

Warman / Weir Minerals

AH Series (all sizes 1.5/1 through 20/18)
AHP High Pressure Series
L Series Light Duty
M Series Medium Duty
HH Series Heavy Duty

Metso (Sala/Thomas/Orion)

HM Series Horizontal
HR Series
HS Series
MD Mill Discharge
VASA Vertical

KSB GIW

LSA Series
LCC-M
LCC-H
LCV Vertical
MDX Mill Duty
TBC Tailings

ITT Goulds

XHD Extra Heavy Duty
SRL Rubber Lined
5500 Series
CV 3196

Flowserve

Durco Slurry Series
IDP Slurry Pumps

Schurco Slurry

S Series
H Series High Head
SC Series

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Volute Liner Material Options

Volute liner material selection follows similar criteria to impellers but with additional consideration for the lower velocity environment. The volute sees lower impact angles and velocities than the impeller, often making it suitable for different material grades.

Volute Liners and Casings for Slurry Pumps — Comparação de materiais mostrando classificações de dureza, aplicações e características de desempenho
Material	Dureza	Aplicação	Notas
A05 High-Chrome (Cr27)	600-650 BHN	Standard grade for coarse slurries, mill discharge, cyclone feed	Most common choice for mining applications
A07 High-Chrome (Cr27Mo)	650-700 BHN	Corrosive-abrasive slurries, acidic mineral processing	Molybdenum improves corrosion resistance in low pH
A61 Chrome-Moly	550-600 BHN	Moderate abrasion with corrosion, phosphate applications	Better toughness than A05, lower hardness
R55 Natural Rubber	55 Shore A	Fine slurries <150 microns, flotation circuits, tailings	Bonded to steel shell, max temperature 70C
R26 Natural Rubber	40 Shore A	Ultra-fine slurries, thickener underflow	Softest rubber grade for maximum fine particle resistance
R08 Neoprene	65 Shore A	Oil-contaminated slurries, hydrocarbon exposure	Superior oil resistance, moderate abrasion performance

A05 High-Chrome (Cr27)

Dureza:600-650 BHN

Aplicação:Standard grade for coarse slurries, mill discharge, cyclone feed

Notas:Most common choice for mining applications

A07 High-Chrome (Cr27Mo)

Dureza:650-700 BHN

Aplicação:Corrosive-abrasive slurries, acidic mineral processing

Notas:Molybdenum improves corrosion resistance in low pH

A61 Chrome-Moly

Dureza:550-600 BHN

Aplicação:Moderate abrasion with corrosion, phosphate applications

Notas:Better toughness than A05, lower hardness

R55 Natural Rubber

Dureza:55 Shore A

Aplicação:Fine slurries <150 microns, flotation circuits, tailings

Notas:Bonded to steel shell, max temperature 70C

R26 Natural Rubber

Dureza:40 Shore A

Aplicação:Ultra-fine slurries, thickener underflow

Notas:Softest rubber grade for maximum fine particle resistance

R08 Neoprene

Dureza:65 Shore A

Aplicação:Oil-contaminated slurries, hydrocarbon exposure

Notas:Superior oil resistance, moderate abrasion performance

Note: Volute and cover liners are typically matched as sets. Contact ATF for complete wet-end quotations.

Perguntas frequentes

Volutes Perguntas frequentes

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How do volute liners wear and when should they be replaced?

Volute liners typically wear fastest at three critical zones: the cutwater (tongue) where the volute throat transitions to the discharge nozzle, the discharge nozzle area where flow velocity is highest, and the impeller periphery clearance zone where tip leakage creates turbulent erosion. Wear patterns follow slurry flow paths, with the highest erosion occurring where particle velocity and impact angle combine to maximise material removal. In high-chrome liners (A05/A07), wear manifests as progressive thinning of the liner wall with eventual carbide washout creating a roughened surface. In rubber liners (R55/R26), wear appears as localised thinning or chunking at impact zones. Replace volute liners when wall thickness reaches minimum safe limits—typically 50–60% of the original dimension—to prevent catastrophic breakthrough and casing damage. Efficiency loss exceeding 7–10% at constant speed and flow also justifies replacement, as the increased power consumption often exceeds the cost of a new liner within weeks. Any external leakage through the liner indicates immediate replacement is required.

Why do some pumps use split volute liners?

Split (two-piece) volute liners are used on larger pumps—typically 10/8 Warman frame equivalent and above—where single-piece liners become impractical due to weight (often exceeding 500 kg for large chrome liners), physical dimensions that prevent access through pump house openings, and handling safety concerns. The split design allows each half to be removed and installed individually, significantly reducing the crane capacity required and enabling liner replacement without disassembling the full pump casing or disconnecting major piping. Matched halves are manufactured and marked as sets, with precision-machined joint faces and locating features that ensure correct alignment when assembled. It is critical to install matched halves together—mixing halves from different sets risks misalignment at the joint, creating turbulence, localised erosion, and potential slurry leakage. ATF manufactures split volute liners with joint face flatness verified to prevent gaps that could initiate wear or leakage.

Should volute and impeller materials match?

Volute and impeller materials do not need to match, and in many mining applications, using different materials for each component delivers lower total cost of ownership. The volute experiences different wear conditions than the impeller: lower slurry velocities (because the volute decelerates flow), lower and more oblique impact angles, and less turbulence-induced erosion. These conditions often make the volute more suitable for rubber (R55 at 55 Shore A) even when the impeller requires high-chrome (A05 at 600–650 BHN) due to its higher tip speeds and more aggressive erosion environment. A common and effective mixed configuration pairs an A05 chrome impeller with R55 rubber volute and frame plate liners—the chrome resists the high-velocity gouging at the impeller while rubber handles the lower-velocity fine-particle erosion in the volute. ATF engineers evaluate the specific velocity, particle size, and chemical conditions at each wet-end position to recommend the optimal material combination.

What causes localized volute wear?

Localised volute wear almost always indicates a flow-related problem rather than a material deficiency. The most common cause is operating the pump far from its Best Efficiency Point (BEP): at low flows (below 80% BEP), internal recirculation creates high-velocity eddies that concentrate erosion at the cutwater and impeller clearance zones, while at high flows (above 110% BEP), flow separation on the pressure side of the cutwater accelerates wear at the tongue. Air entrainment from vortexing in the sump creates a two-phase flow with localised high-velocity impacts. Oversized particles (tramp oversize above the pump design limit) impact at steep angles near the cutwater and discharge nozzle, causing gouging that high-chrome resists better than rubber. Insufficient cutwater clearance to the impeller—whether from manufacturing tolerance or impeller growth from deposits—creates a high-velocity jet that erodes the cutwater lip. ATF recommends maintaining pump operation within 80–110% of BEP flow and addressing sump design to eliminate vortexing.

Conteúdo técnico revisado pela equipe de engenharia da ATF | Especificações metalúrgicas verificadas conforme normas ASTM/ISO

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Volutas de Bomba de Polpa | ATF