Industry

Industrial Machinery | Pumps & Fluid Handling | Precision Casting

Project

Pump Casing (Volute) Development & Manufacturing

Manufacturing Process

Lost Foam Casting

Project Overview

A manufacturer in the industrial pump sector required precision-engineered pump casings with complex internal volute geometry, dimensional consistency, smooth internal surfaces, and reduced machining requirements.

Venttup supported the development and manufacturing of a 6x5x14 pump casing using the Lost Foam casting process.

The component was developed as a near-net-shape casting, enabling complex curved internal flow passages to be produced with minimal machining while maintaining dimensional consistency and functional accuracy.

The final component was designed for demanding centrifugal pump, slurry pump, and industrial process pump applications.

The Manufacturing Challenge

Pump casings with complex volute geometry can be difficult to manufacture using conventional casting methods.

Traditional sand casting may involve:

• Multiple core assemblies
• Parting lines
• Core alignment challenges
• Flash and excess material
• Additional fettling and finishing
• Greater machining requirements
• Potential dimensional variation between batches

For this project, the requirement was to manufacture a pump casing with intricate internal flow geometry while maintaining repeatability and minimizing unnecessary post-casting machining.

The manufacturing approach therefore needed to provide:

• Complex volute geometry in a single casting
• Smooth internal surfaces
• Close dimensional control
• Reliable flange geometry
• Consistent production across batches
• Reduced finishing and machining requirements

Venttup’s Solution

Venttup selected and coordinated a Lost Foam casting approach suited to the complexity of the pump casing.

Lost Foam casting uses a foam pattern that vaporizes during metal pouring. This allows the required geometry to be reproduced without the conventional parting lines and complex core assembly associated with traditional sand casting.

The process enabled the pump casing to be produced as a near-net-shape component with intricate internal passages.

Key Actions

1. Requirement & Drawing Review

The component requirements, dimensional specifications, geometry, flange configuration, and application requirements were reviewed before manufacturing.

The design was assessed for casting feasibility and the requirements for subsequent machining.

2. Lost Foam Pattern & Casting Development

A Lost Foam casting process was selected to reproduce the complex volute geometry.

The process was particularly suitable because it can create curved and intricate internal passages in a single casting operation.

3. Near-Net-Shape Manufacturing

The casting approach reduced the need for extensive machining and finishing.

Minimal draft requirements and the elimination of conventional parting lines helped achieve a closer-to-final component geometry.

4. Flange & Functional Machining

The suction and discharge flange faces were machined along with the required bore and bolt-hole configuration to support direct mounting and assembly requirements.

5. Quality & Dimensional Consistency

The manufacturing process was focused on maintaining close dimensional consistency and repeatability across production batches.

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Component Delivered

Pump Casing 6x5x14

Part Description: Casing, 6x5x14

Product Code / Processing #: 641101605

Part No.: 19123-01-30A

Casting Process: Lost Foam Casting

Material: Hard Iron

Configuration: Flanged pump casing with machined suction and discharge connections

The 6x5x14 designation represents the discharge × suction × impeller diameter configuration in inches.

The casing incorporates complex internal volute geometry designed to support efficient fluid flow through the pump.

Production Components Covered

The supplied production schedule included multiple pump casing configurations, demonstrating the ability to support different dimensional requirements.

Part No.	Processing #	Description	Material
19203-01-30A	641101753	Casing, 3x2x13	Hard Iron
19205-01-30A	641101902	Casing, 4x3x13	Hard Iron
19222-01-30A	641102058	Casing, 5x4x14	Hard Iron
19122-01-30A	641101456	Casing, 6x5x11	Hard Iron
19123-01-30A	641101605	Casing, 6x5x14	Hard Iron
19763-01-30A	641102157	Casing, 8x6x11	Hard Iron
19763-01-30A	641101308	Casing, 8x6x14	Hard Iron
20937-01-30A	641102322	Casing, 10x8x14	Hard Iron

This production range demonstrates the flexibility to manufacture pump casing configurations across different size requirements.

Technical Specifications

Parameter	Specification
Component	Pump Casing / Volute
Primary Size	6x5x14
Product Code	641101605
Part Number	19123-01-30A
Processing Number	641101605
Casting Process	Lost Foam Casting
Material	Hard Iron
Geometry	Complex volute / curved internal passages
Surface	Smooth internal volute surface
Dimensional Requirement	Close tolerance / near-net-shape casting
Flange	Machined bolt-hole pattern flange
Machining	Suction/discharge flange faces and bore
Production Capability	Multiple casing sizes and configurations

Why Lost Foam Casting Was the Right Choice

The Lost Foam process provided several manufacturing advantages for this pump casing.

Complex Geometry in a Single Casting

The process allows intricate volute curves and internal flow passages to be produced without complicated conventional core assemblies.

Reduced Parting-Line Issues

The process eliminates conventional parting lines and reduces flash-related finishing requirements.

Minimal Machining

Near-net-shape production reduces the amount of material that needs to be removed during post-casting machining.

Improved Internal Surface Quality

A smoother internal volute surface helps reduce flow turbulence and supports improved hydraulic efficiency.

Better Dimensional Repeatability

The process supports consistent reproduction of the casing geometry across production batches.

Reduced Finishing Requirements

Reduced fettling and finishing requirements can improve manufacturing efficiency and lower downstream processing effort.

Applications

The manufactured pump casing is suitable for applications including:

• Centrifugal pumps
• Slurry pumps
• Industrial process pumps
• Fluid-handling equipment
• Industrial rotating equipment
• Pump systems requiring complex internal flow passages

Results & Value Delivered

Through the Lost Foam casting approach, the project achieved a manufacturing solution focused on complex geometry, dimensional consistency, surface quality, and reduced machining requirements.

✔ Complex Volute Geometry

Intricate curved internal passages were produced through a Lost Foam casting process.

✔ Near-Net-Shape Manufacturing

The casting process reduced the amount of machining required after casting.

✔ Smooth Internal Surface

The internal volute geometry was produced with a smooth surface finish to support efficient fluid movement.

✔ Dimensional Consistency

The manufacturing approach supported repeatable dimensions across production batches.

✔ Reduced Finishing Requirements

Eliminating conventional parting lines and reducing casting-related finishing requirements helped streamline post-casting processing.

✔ Multiple Size Configurations

The production schedule covered pump casing configurations ranging from 3x2x13 through 10x8x14, demonstrating flexibility across different pump casing requirements.

Venttup’s Manufacturing Value

This project demonstrates Venttup’s ability to support complex industrial component manufacturing through the right combination of engineering assessment, manufacturing process selection, casting coordination, machining, and quality control.

Rather than treating the requirement as a standard casting order, the project focused on selecting a process that matched the component’s geometry and functional requirements.

The result was a precision pump casing manufacturing solution designed around:

• Complex geometry
• Functional performance
• Dimensional consistency
• Production repeatability
• Reduced machining
• Efficient manufacturing

Venttup’s manufacturing-as-a-service approach enables industrial companies to access suitable manufacturing capabilities while reducing the complexity of managing multiple suppliers and production stages.

Conclusion

The development of the 6x5x14 pump casing using Lost Foam casting demonstrates how the right manufacturing process can simplify the production of complex industrial components.

By using Lost Foam technology, the project enabled the production of intricate volute geometry, smooth internal flow passages, near-net-shape components, and consistent dimensional performance while reducing conventional casting and finishing challenges.

The same manufacturing approach can be adapted to different pump casing sizes and configurations based on customer drawings, material requirements, and production volumes.

Need a complex casting manufactured to your drawing?

Share your component drawing with Venttup for manufacturing feasibility assessment, process recommendation, and production support.

Talk to Venttup about your next casting project.