The study aimed to evaluate the tensile strength of additively manufactured (AMed) IN 625 using sub-sized test pieces and compare them to standard specimens. Cylindrical round coupons of varying diameters were manufactured along the Z-axis using the laser powder bed fusion technique and subjected to heat treatment. The simulation of the alloy solidification predicted the formation of several intermetallics and carbides under equilibrium conditions (slow cooling), apart from the γ phase (FCC). Sub-sized tensile specimens with different gauge diameters were machined from the coupons and tensile tested at ambient temperature. The results showed that sub-sized specimens exhibited lower tensile and yield strengths compared to standard specimens, but still higher than the minimum requirements of the relevant ASTM standard for AMed IN 625. The lower strength was attributed to the “size effect” of the test specimens. Fracture surfaces of the sub-sized test specimens exhibit a mixed character, combining cleavage and microvoid coalescence, with improved ductility compared to standard test pieces. The study highlights the importance of adapting characterization methods to the particularities of manufactured parts, including reduced thicknesses that make sampling standard-size specimens impractical. It concludes that sub-sized specimens are valuable for quality control and verifying compliance with requirements of AMed IN 625 tensile properties.

This study presents a numerical approach to the design and optimization of centrifugal impellers used in the pumps of active thermal control systems of spacecraft. Although launch costs have shrunk in the last decade, the performance requirements, such as efficiency and reliability, have increased, as such systems are required to work up to 15 years, depending on the mission. To that effect, our paper deals with the first step in this pump design, namely the hydraulic optimization of the impeller. Constructively, this type of impeller allows for certain balancing systems and labyrinth seals to be applied in a more effective way, as well as allowing for additive manufacturing methods to be used—however, details regarding these aspects are beyond the scope of the current paper. By combining empirical formulas, computational fluid dynamics (CFD) analysis, and artificial neural networks (ANNs), the research focuses on achieving high efficiency and fast manufacturing. A series of geometries have been sized and validated using steady-state RANS (Reynolds Averaged Navier-Stokes) simulations, leading to the identification of the most efficient configuration. Subsequent optimization using an ANN resulted in a refined impeller design with notable improvements in hydraulic performance: a 3.55% increase in efficiency and a 7.9% increase in head. Key parameters influencing impeller performance, including blade number, incidence, and backsweep angles, are identified. This approach offers a comprehensive method to address the evolving requirements of space missions and contributes to the advancement of centrifugal pump technology in the space domain.

The current paper addresses the challenges in manufacturing a critical component of a centrifugal pump for space active thermal control systems of satellites, namely, the closed centrifugal impeller. Compared to the classical technologies, there is an obvious advantage of additive manufacturing of closed impellers, due to the possibility of creating complex geometries, which boost the hydraulic performances of the part and, implicitly, of the pump. In this regard, the authors performed a comparative analysis between a closed impeller obtained by classical machining and three manufactured by additive technology (selective laser melting) by means of dimensional inspection, non-destructive testing, and experimental evaluation. The study performed here showed that the additively manufactured closed impellers exhibited similar hydraulic performances to the classical one, without the need for performing post-processing of internal surfaces. Also, in terms of dimensional and geometrical stability, the additively manufactured closed impellers were within the imposed tolerances, demonstrating the feasibility of obtaining such complex parts by using additive manufacturing. Subsequently, the allocated time for manufacturing decreased by 75% for the closed impellers manufactured by additive technologies, and the need for using four technological processes was decreased to only two, printing and post-processing.

This paper presents a case study comparing CFD predictions with experimental measurements for micropumps, with the goal of evaluating the accuracy and limitations of CFD methods in complex microscale geometries. A fast design and evaluation methodology was developed, integrating linear design, 3D fully viscous CFD-based optimization, and rapid prototyping and testing. The main problem at this scale and configuration of pumps is the combination of Reynolds and Taylor numbers. Their impact on labyrinth performance prediction and therefore volumetric efficiency dominates the losses at this scale. Multiple CFD simulations were conducted using various turbulence models and solver settings, and results were compared against experimental data. The labyrinth region was simulated both independently and as part of the full pump assembly, with RANS and LES used for the former and RANS for the latter. Precision 3D-printed rotors and volutes were tested, and performance maps were obtained. Significant discrepancies between CFD and experiments were observed, which were reconciled using two empirical scaling coefficients for pressure and mass flow. These collapsed the CFD predictions onto the experimental data across all available speedlines. While the generalizability of these coefficients remains uncertain, the concept of using corrected scales, rather than other methods, seems to capture the macroscopic discrepancies between CFD and experiments.