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Off-the-shelf CFD software is available from firms such as AEA Technology Engineering Software, a Waterloo, Ont., firm that recently introduced an updated version of its CFX-TASCflow, which features a greatly enhanced cavitation model. Cavitation is the primary cause of pump failure, Jones points out. CFD software was more geared to hydraulic flows in pumps and inducers in turbomachinery when Alfa Laval embraced the technology. The payoff has been centrifugal pumps that create less sheer and can handle some pumping jobs previously reserved for positive usedlawnmowerparts displacement pumps.

Select hardfacing materials based on weld-deposit microstructure and the wear situation the part will encounter, with consideration given to thermal treatments applied to the material before and after hardfacing. Deposit chemistry can be crucial in attaining the desired corrosion resistance or wear properties, or for minimizing the risk of solidification cracking. Acceptable deposit chemistry is achieved through the initial choice of consumables, using wire analysis and flux composition, and by specifying the number of weld passes needed to reduce parent-metal dilution to within acceptable limits. With the submerged-arc process, the flux and electrode govern the characteristics of the applied hard facing. For example, those fluxes neutral to manganese and silicon are not necessarily neutral to carbon and chromium, elements that matter most in hardfacing.