Hybrid Casting Boosts Slurry Pump Wear Resistance with Vibenite 480

Hybrid casting method VBN Components enables wear-resistant AM integration in large slurry pumps

2026-04-27 Source: VBN Components 1 min Reading Time

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Large slurry pump housings are too big to print economically, but their most exposed wear zones can still benefit from additive manufacturing. VBN Components has demonstrated a hybrid casting method that places Vibenite 480 precisely where wear resistance is needed most.

Printing a nucleation net zone in Vibenite® 480 is simple, yet it enables precise placement of the wear resistant material inside the mold at the most critical positions — significantly extending pump lifetime.(Source: VBN Components) — Printing a nucleation net zone in Vibenite® 480 is simple, yet it enables precise placement of the wear resistant material inside the mold at the most critical positions — significantly extending pump lifetime.
(Source: VBN Components)

In collaboration with a major pump manufacturer, VBN Components has successfully demonstrated a new method for integrating additively manufactured cemented carbide into large cast components. By casting directly onto Vibenite 480, the approach significantly improves wear resistance in slurry pumps and other cast equipment without requiring full-size components to be produced additively.

The development is based on the introduction of a Vibenite Nucleation Net Zone (VNNZ) during the 3D printing process. This engineered interface enables high-chromium cast iron to bond effectively with the extremely wear-resistant Vibenite 480 during casting.

According to the company, wear tests in representative slurry pump environments showed that Vibenite 480 delivers exceptional performance. Its erosive wear resistance was approximately ten times higher than that of high-chromium cast iron and around 100 times higher than hardened steel plate.

While these material properties are already well established, VBN Components notes that the size limitations of current metal additive manufacturing systems make it impractical to print meter-scale pump housings. The company has therefore developed a hybrid approach in which smaller, strategically designed AM components are positioned in the most exposed wear zones of a casting mould.

Without the VNNZ, molten cast iron can melt or intermix with the printed inserts, compromising both geometry and material performance. The VNNZ is designed to prevent this, preserving structural integrity while ensuring strong metallurgical bonding during casting.

Following successful trials, the technology will now be verified in full-scale slurry pump housings, focusing on the most critical wear areas. The approach is flexible and allows wear components of almost any geometry to be integrated, rather than being limited to flat plates.

By enabling precise placement of Vibenite 480 only where it is needed, this method provides a scalable and cost-efficient route to significantly extended component lifetime in demanding expensive applications.

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