With regard to water turbine runners, it is not necessary to go to 'one
piece' lost wax castings, although this is a nice solution for small
complex shapes. I started with sand cast (cast iron and later steel)
components that are welded together. On moderate heads the epoxy pain
was still in place on the runner after 10 years!
If you don't keep the silt out, it will destroy any runner in a very
short time. Carbon steel is fine for most installations and will
probably out live the owner. Stainless steel and bronze are nice but not
necessary for basic projects and it is much easier to weld. If people
also want to make the dreaded crossflow, I would suggest that runner is
cast in a similar way.
If enough people are interested, I will try and get funding to write it
all down (it is rather difficult to run a small business and provide a
free information service for NGOs, which is what I have being trying to
do)
I could produce a batch of cheap steel runners or help you get started
with foundry patterns. Anyway, let me know if I can help and what time
scale you are looking at.
Regards
Rupert
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