The products of fuel pumps are manufactured by combining precision engineering, superior material selection, and the latest manufacturing processes to ensure reliability and effectiveness. For example, the impeller, which serves as the ingenious movement mechanism in the transfer of fuel through the pump, is normally manufactured from a variety of materials such as stainless steel or high-strength polymers. Most importantly, stainless steel is used because it has high resistance against corrosion and wear, hence prolonging the life cycle of the fuel pump, especially those high-flow pumps able to deliver more than 255 liters per hour.
Injection molding of polymer components, such as impellers and casings, is one way in which manufacturers are able to achieve great precision with regard to size and shape. Material is melted and injected into the mold, then cooled, forming a solid structure. Parts constructed of polymer have additional advantages of reduced weight and resistance to corrosion, factors highly relevant to fuel pumps operating in moist conditions or using ethanol-based fuels.
It is quite common that the motor casing and shaft are fabricated by machining and die-casting, respectively. The machining ensures small, moving parts in the fuel pump are accurately dimensioned, thus offering higher efficiency by reducing energy loss. Die-casting forces molten metal under high pressure into molds/forms, forming robust pieces that can withstand the internal pressure, usually 40-60 psi in most fuel delivery applications.
Seals and gaskets/seals that prevent leaks in fuel applications are fabricated from fuel-resistant materials such as nitrile rubbers or fluorocarbon elastomers. The selected materials are based on their resistance to chemicals; test results indicate that a high-quality elastomer seal exposed to fuel is able to survive upwards of 10 years or more in continuous service. Manufacturing of these products often employs a process called compression molding, where the elastomer is subjected to heat and pressure in order to mold the part, which fits tightly and durably for each seal in the fuel pump.
How are the parts in fuel pumps manufactured? Each component is fabricated to exactitude by various methods, including injection molding, machining, die-casting, and compression molding, which helps to support high performance, durability, and dependability under a wide variety of operating conditions.