Challenge
Direct-current (DC) electromagnetic pumps drive liquid metals using Lorentz forces without mechanical impellers, making them ideal for high-temperature and corrosive fluid applications, such as Sodium Fast Reactors (SFR). However, conventional helical-type DC pumps require high input currents and complex manufacturing processes involving multiple brazed segments.
Fig. Conventional helical-type EM pump requires complex brazing process and specialized coatings
Approach: Design for Additive Manufacturing
Fig. Novel 3D-printable EM pump design with working principle
Multiple Lorentz Force Design
- Opposing magnet arrangement: Concentrated magnetic flux around flow paths
- Multiple force segments: Progressive pressure buildup from inlet to outlet
- Optimized current path: 67% of current concentrated in high-flux region
Design for Additive Manufacturing (DfAM)
- Build volume: 180 mm × 180 mm constraint for commercial 3D printers
- 45° ceiling angle: Eliminates need for support structures
- Semi-cylindrical channels: 5 mm diameter for optimal Lorentz force generation
- Monolithic fabrication: No brazed joints required
Results
Fig. MHD simulation results: magnetic flux density distribution (top) and pressure distribution (bottom)
| Parameter | Helical-type | 3D-Printable |
|---|---|---|
| Developed Pressure | 10.5 bar | 10.5 bar |
| Input Current | 684 A | 330 A (-52%) |
| Size (mm) | 123 × 195 × 405 | 166 × 195 × 106 |
- 52% lower simulated current demand than the helical-type pump at matched pressure and flow rate
- Compact concept designed for monolithic metal 3D printing
- The numerical model was checked against published helical-pump experimental data, with less than 12% difference; the new pump design was evaluated by simulation
- Under the simulated conditions, the maximum temperature near the magnets was 288°C, below the specified 350°C magnet limit
Fabrication and experimental testing of the proposed 3D-printable pump remain future work.
Publication
SCIE
- G. Lee, “Conceptual design of a 3D-Printable DC electromagnetic pump for additive manufacturing,” Nuclear Engineering and Technology, 58, 103916, 2026. DOI