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As part of any water pump development for engine cooling system, the interaction between materials with different coefficient of thermal expansion is unexceptional. Though in very specific applications where the coolant temperature is over 115°C several factors and variables can cause movement between parts because of the interference and coefficient of thermal expansion interaction combined with engine vibration and external loads. These factors were listed and evaluated considering several variables being validated physically and by simulation resulting on an optimized method to enhance this kind of fixation.

This paper relates de development of an automotive water pump with a new production concept. During these past years, automotive components had lots of modifications on its design, function and manufacturing process. Water pumps are not include in this context, once no relevant changes were verified on design of these parts on last 30 years. By looking this scenario and the observing progress reached by engineering plastics, we decided to implement a new concept of water pump where its structural element (housing), were produced with a thermoplastic material, replacing the traditional aluminum. Note that this is not a material change because utilization of thermoplastic open possibilities of new manufacturing concepts that help to improve performance and reduce production costs. This paper relates the development process, from idea until production.