Production and processing technology of a sealed wear-resistant ball valve

Abstract

The application relates to the technical field of ball valve production and processing, and discloses a production and processing technology of a sealed wear-resistant ball valve, which comprises the following steps: base material pretreatment, wear-resistant bottom layer preparation, functional coating slurry preparation, functional coating coating, sealing surface strengthening treatment, intelligent pressure detection module integration, closed-loop control system assembly, hot isostatic pressing densification treatment, precision calibration and performance testing, surface passivation and packaging. In the application, the nano diamond particles and the chromium-based tungsten carbide composite powder in the functional coating slurry jointly construct a high-hardness wear-resistant framework, resist the abrasive wear and erosion of the sealing surface, the molybdenum disulfide serves as a solid lubricant and forms a transfer film on the friction interface during the working process, reduces the friction coefficient, realizes the self-lubricating effect, the epoxy-modified organic silicon resin serves as a bonding phase, firmly combines the functional components, and endows the coating with good toughness and bonding strength, so that the wear-resistant life and reliability of the ball valve sealing pair are synergistically improved under harsh working conditions.

Description

Technical Field

[0001] This invention relates to the field of ball valve manufacturing and processing technology, specifically to a manufacturing and processing process for a sealing and wear-resistant ball valve. Background Technology

[0002] A ball valve is a valve in which a ball is driven by a valve stem and rotates around the axis of the stem. It is mainly used to cut off or connect the medium in a pipeline, and can also be used for fluid regulation and control. As a common type of valve, ball valves have advantages such as compact structure, light weight, low fluid resistance and loss, and convenient maintenance and operation, and are widely used in media transportation pipelines in various fields. Wear-resistant ball valves, due to their excellent wear resistance, sealing performance, erosion resistance, and corrosion resistance, have been widely used in many key industries such as polysilicon, organosilicon, petrochemicals, and coal chemicals.

[0003] Currently, in the production and processing of ball valves, the wear-resistant coatings on the valve core and valve body sealing surfaces often use a single material or traditional thermal spraying process. This makes it impossible to achieve in-situ synergistic construction of the wear-resistant and lubricating phases within the coating. Consequently, under conditions of frequent opening and closing and particulate media, the coating has a high coefficient of friction and poor self-lubrication, easily leading to premature wear and sealing failure of the sealing surface, severely affecting the service life and reliability of the ball valve. Furthermore, existing processes rely heavily on subsequent mechanical grinding and manual matching to control the fitting precision of the sealing pairs. They cannot actively compensate for and correct the roundness error of the valve core spherical surface and the flatness error of the valve seat sealing surface during coating preparation. This results in uneven distribution of preload, causing localized stress concentration and insufficient sealing pressure, reducing the overall sealing performance of the ball valve. In addition, conventional ball valve performance testing only involves static pressure testing before leaving the factory. It cannot provide real-time online monitoring and data feedback on the contact stress distribution and wear status of the sealing surface under operating conditions. When operating conditions fluctuate or the sealing surface suffers minor damage, timely warnings and adaptive adjustments cannot be made, posing a safety hazard of sudden leakage. This makes it difficult to meet the requirements of intelligent pipeline systems for measurable and controllable status of critical valves.

[0004] Therefore, a manufacturing process for a sealing and wear-resistant ball valve is proposed to solve the above problems. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a manufacturing process for a sealing and wear-resistant ball valve, which solves the problems mentioned in the background art that seriously affect the service life and reliability of ball valves and reduce their overall sealing performance.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a manufacturing process for a sealing wear-resistant ball valve, comprising the following steps:

[0007] Step 1: Substrate pretreatment. Select metal materials with high strength and corrosion resistance to manufacture the ball valve core and valve body base, and perform degreasing, pickling activation, ultrasonic cleaning and drying on them;

[0008] Step 2: Preparation of wear-resistant underlayer. Cobalt-based or nickel-based alloy bonding underlayer is sprayed onto the pretreated valve core spherical surface and valve body base sealing surface using a supersonic flame spraying device to form a transition layer with a thickness of 50-100μm.

[0009] Step 3: Preparation of functional coating slurry; The functional coating slurry is prepared.

[0010] Step 4: Apply the functional coating. Use electrostatic spraying or dip coating processes to evenly coat the functional coating slurry onto the wear-resistant base surface.

[0011] Step 5: Sealing surface strengthening treatment. The valve core coated with functional coating is assembled with the valve body base into a special fixture, a preload is applied and low-temperature plasma sulfurizing treatment is performed.

[0012] Step Six: Integration of the intelligent pressure detection module: A miniature pressure sensor array is embedded in the sealing groove of the valve body base and fixed using a vacuum brazing process;

[0013] Step 7: Assemble the closed-loop control system by connecting the pressure sensor signal line to the sealing control module, and perform system integration and program burning.

[0014] Step 8: Hot isostatic pressing densification treatment. The assembled ball valve is placed in a hot isostatic pressing furnace and subjected to high temperature and high pressure treatment under inert gas protection.

[0015] Step Nine: Precision calibration and performance testing. A laser interferometer is used to detect the spherical roundness, and sealing and lifespan tests are conducted under simulated working conditions.

[0016] Step 10: Surface passivation and packaging. Chemical passivation is used to improve corrosion resistance, and rust-proof packaging is applied.

[0017] Preferably, the pretreatment in step one includes the following steps: immersing the valve core and valve body base in an alkaline degreasing solution, ultrasonically cleaning at 60-80℃ for 20-30 minutes, rinsing with deionized water, then activating with a 10%-15% hydrochloric acid solution for 2-3 minutes, rinsing with a high-pressure water gun, and finally drying in a vacuum drying oven at 80-100℃ for 1-2 hours. The alkaline degreasing solution is a compound of sodium hydroxide, sodium carbonate, sodium silicate, and surfactant, with a mass ratio of 3:2:1:0.5.

[0018] Preferably, the supersonic flame spraying process parameters in step two are as follows: the fuel gas is propane or hydrogen, the oxygen flow rate is 800-1200 L / min, the spraying distance is 150-200 mm, the powder feeding rate is 30-50 g / min, the coating thickness is controlled at 50-100 μm, the porosity is less than 1%, and the cobalt-based alloy bonding underlayer composition is Co-32%Ni-21%Cr-8%Al-0.5%Y.

[0019] Preferably, the functional coating slurry in step three is made from the following raw materials in parts by weight: 15-25 parts of nano-diamond particles, 8-12 parts of molybdenum disulfide, 40-50 parts of chromium-based tungsten carbide composite powder, 20-30 parts of epoxy-modified silicone resin, 3-5 parts of dispersant, 2-4 parts of leveling agent and 1-2 parts of curing accelerator.

[0020] The functional coating slurry is prepared by the following method: Epoxy-modified silicone resin is placed in a planetary mixer with heating and vacuum degassing functions, and the temperature is controlled at 40-50℃. First, it is stirred at 200-300 r / min for 10 minutes. Then, nano-diamond particles, molybdenum disulfide and dispersant are added, and the speed is increased to 500-600 r / min and stirred for 30 minutes. Next, chromium-based tungsten carbide composite powder and leveling agent are added, and stirring is continued at 400-500 r / min for 20 minutes. Finally, curing accelerator is added, and the mixture is stirred at 100-200 r / min for 10 minutes under a vacuum of -0.095 MPa to -0.1 MPa to complete the slurry preparation.

[0021] Preferably, the nanodiamond particles have a particle size of 50-100 nm, and the surface is treated with silane coupling agent KH-550. The chromium-based tungsten carbide composite powder is composed of 85% WC-10% Cr-5% Co, with a particle size distribution of 15-45 μm. The dispersant is polyether-modified polydimethylsiloxane, the leveling agent is fluorocarbon-modified acrylate, and the curing accelerator is 2-ethyl-4-methylimidazole.

[0022] Preferably, the electrostatic spraying process parameters in step four are: spraying voltage 60-80kV, atomization pressure 0.3-0.5MPa, coating thickness controlled at 80-120μm, and pre-curing at 80℃ for 20 minutes after completion; the dip coating process parameters are: lifting speed 100-200mm / min, immersion time 30-60 seconds, and coating thickness controlled at 100-150μm by viscosity and lifting speed.

[0023] Preferably, the sealing surface strengthening treatment in step five specifically includes: assembling the valve core and valve body base into a special hydraulic fixture, applying a preload of 5-8 MPa to ensure tight contact between the sealing surfaces, and then placing it in a plasma sulfurizing furnace and evacuating it to a vacuum of 1×10⁻⁶. -2 Up to 1×10 -3Pa, heating to 200-250℃ at a rate of 10-20℃ / min, introducing a carrier gas containing dimethyl disulfide at a flow rate of 50-100 sccm, turning on the plasma power supply at a power of 500-800W, and processing for 2-3 hours to form a 5-10μm thick FeS solid lubricant layer on the sealing surface.

[0024] Preferably, the pressure detection module integration in step six specifically involves: uniformly embedding an array of micro pressure sensor chips into the bottom of the valve body base sealing groove, and fixing and sealing it through a vacuum sealing brazing process; the signal lines of the pressure sensor chips are led out through a sealing stuffing box.

[0025] Preferably, the hot isostatic pressing densification process parameters in step eight are as follows: using high-purity argon as the pressure transmission medium, the heating rate is 10-15℃ / min, and the temperature and pressure are maintained at 800-850℃ and 100-150MPa for 1-2 hours, followed by cooling to below 200℃ at a rate of 5-10℃ / min before being removed from the furnace.

[0026] Preferably, step nine, the accuracy calibration and performance testing, includes the following steps:

[0027] Precision calibration: The roundness of the valve core spherical surface is detected and calibrated using a coordinate measuring machine;

[0028] Sealing test: The ball valve is placed in a helium gas spectrometer leak detector for a sealing test;

[0029] Life simulation test: The ball valve is placed in a simulated working environment and subjected to repeated opening and closing cycles under a pressure of 10MPa and a temperature of 150℃. Its sealing leakage and wear are monitored.

[0030] Compared with the prior art, the present invention provides a manufacturing process for a sealing and wear-resistant ball valve, which has the following beneficial effects:

[0031] 1. In this invention, the nano-diamond particles and chromium-based tungsten carbide composite powder in the functional coating slurry jointly construct a high-hardness wear-resistant skeleton to resist abrasive wear and erosion of the sealing surface. Molybdenum disulfide, as a solid lubricant, forms a transfer film at the friction interface during operation, reducing the friction coefficient and achieving a self-lubricating effect. Epoxy-modified silicone resin, as a binder, firmly binds the functional components and gives the coating good toughness and bonding strength, thereby synergistically improving the wear resistance and reliability of the ball valve sealing pair under harsh working conditions.

[0032] 2. In this invention, the dense alloy underlayer prepared by supersonic flame spraying provides a solid support for the functional coating. The subsequent hot isostatic pressing treatment promotes the closure of the pores inside the coating, increases the density, and forms a stronger metallurgical bond with the substrate. At the same time, the precise detection and calibration of the spherical roundness of the valve core by a coordinate measuring machine ensures the fitting accuracy of the sealing pair, makes the contact stress distribution uniform, avoids premature local wear and poor sealing caused by geometric deviations, and improves the consistency of the sealing performance of the ball valve.

[0033] 3. In this invention, the miniature pressure sensor array integrated into the valve body base can monitor the contact stress distribution of the sealing surface in real time and feed the signal back to the sealing control module. This module can drive the actuator to fine-tune the valve core position, thereby realizing online optimization and compensation of the sealing specific pressure. This dynamic intelligent adjustment mechanism can not only adapt to fluctuations in operating conditions, but also provide early warning and compensation when slight wear occurs on the sealing surface, preventing sudden leakage and improving the safety and controllability of the ball valve in the intelligent pipeline system. Detailed Implementation

[0034] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0035] Example 1: A manufacturing process for a sealing wear-resistant ball valve, comprising the following steps:

[0036] Step 1: Substrate pretreatment. Select metal materials with high strength and corrosion resistance to manufacture the ball valve core and valve body base, and perform degreasing, pickling activation, ultrasonic cleaning and drying on them;

[0037] Step 2: Preparation of wear-resistant underlayer. Cobalt-based or nickel-based alloy bonding underlayer is sprayed onto the pretreated valve core spherical surface and valve body base sealing surface using a supersonic flame spraying device to form a transition layer with a thickness of 50μm.

[0038] Step 3: Preparation of functional coating slurry; The functional coating slurry is prepared.

[0039] Step 4: Apply the functional coating. Use electrostatic spraying or dip coating processes to evenly coat the functional coating slurry onto the wear-resistant base surface.

[0040] Step 5: Sealing surface strengthening treatment. The valve core coated with functional coating is assembled with the valve body base into a special fixture, a preload is applied and low-temperature plasma sulfurizing treatment is performed.

[0041] Step Six: Integration of the intelligent pressure detection module: A miniature pressure sensor array is embedded in the sealing groove of the valve body base and fixed using a vacuum brazing process;

[0042] Step 7: Assemble the closed-loop control system by connecting the pressure sensor signal line to the sealing control module, and perform system integration and program burning.

[0043] Step 8: Hot isostatic pressing densification treatment. The assembled ball valve is placed in a hot isostatic pressing furnace and subjected to high temperature and high pressure treatment under inert gas protection.

[0044] Step Nine: Precision calibration and performance testing. A laser interferometer is used to detect the spherical roundness, and sealing and lifespan tests are conducted under simulated working conditions.

[0045] Step 10: Surface passivation and packaging. Chemical passivation is used to improve corrosion resistance, and rust-proof packaging is applied.

[0046] The pretreatment in step one includes the following steps: immersing the valve core and valve body base in an alkaline degreasing solution, ultrasonically cleaning at 60°C for 20 minutes, rinsing with deionized water, then activating with a 10% hydrochloric acid solution for 2 minutes, rinsing with a high-pressure water gun, and finally drying in a vacuum drying oven at 80°C for 1 hour. The alkaline degreasing solution is a compound of sodium hydroxide, sodium carbonate, sodium silicate, and surfactant, with a mass ratio of 3:2:1:0.5.

[0047] The supersonic flame spraying process parameters in step two are as follows: the fuel gas is propane or hydrogen, the oxygen flow rate is 800 L / min, the spraying distance is 150 mm, the powder feeding rate is 30 g / min, the coating thickness is controlled at 50 μm, the porosity is less than 1%, and the cobalt-based alloy bonding underlayer composition is Co-32%Ni-21%Cr-8%Al-0.5%Y.

[0048] The functional coating slurry in step three is made from the following raw materials in parts by weight: 15 parts of nano-diamond particles, 8 parts of molybdenum disulfide, 40 parts of chromium-based tungsten carbide composite powder, 20 parts of epoxy-modified silicone resin, 3 parts of dispersant, 2 parts of leveling agent and 1 part of curing accelerator.

[0049] The functional coating slurry is prepared by the following method: Epoxy-modified silicone resin is placed in a planetary mixer with heating and vacuum degassing functions, and the temperature is controlled at 40°C. The mixture is first stirred at 200 r / min for 10 minutes, then nano-diamond particles, molybdenum disulfide and dispersant are added, the speed is increased to 500 r / min and stirred for 30 minutes, then chromium-based tungsten carbide composite powder and leveling agent are added, and the mixture is stirred at 400 r / min for 20 minutes. Finally, a curing accelerator is added, and the mixture is stirred at 100 r / min for 10 minutes under a vacuum of -0.095 MPa to complete the preparation of the slurry.

[0050] The nanodiamond particles have a particle size of 50 nm and are treated with silane coupling agent KH-550. The chromium-based tungsten carbide composite powder is composed of 85% WC, 10% Cr, and 5% Co, with a particle size distribution of 15 μm. The dispersant is polyether-modified polydimethylsiloxane, the leveling agent is fluorocarbon-modified acrylate, and the curing accelerator is 2-ethyl-4-methylimidazole.

[0051] The electrostatic spraying process parameters in step four are: spraying voltage 60kV, atomization pressure 0.3MPa, coating thickness controlled at 80μm, and pre-curing at 80℃ for 20 minutes after completion; the dip coating process parameters are: lifting speed 100mm / min, immersion time 30 seconds, and coating thickness controlled at 100μm by viscosity and lifting speed.

[0052] Step five, the sealing surface strengthening treatment, specifically includes: assembling the valve core and valve body base into a dedicated hydraulic fixture, applying a 5MPa preload to ensure a tight fit between the sealing surfaces, and then placing it in a plasma sulfurizing furnace and evacuating it to a vacuum of 1×10⁻⁶. -2 Pa was heated to 200°C at a rate of 10°C / min, and a carrier gas containing dimethyl disulfide was introduced at a flow rate of 50 sccm. The plasma power supply was turned on at a power of 500 W, and the processing time was 2 hours. A FeS solid lubricant layer with a thickness of 5 μm was formed on the sealing surface.

[0053] The integration of the pressure detection module in step six is ​​as follows: The array of micro pressure sensor chips is uniformly embedded into the bottom of the sealing groove of the valve body base, and fixed and sealed by vacuum sealing brazing process. The signal line of the pressure sensor chip is led out through the sealing stuffing box.

[0054] The process parameters for hot isostatic pressing densification in step eight are as follows: using high-purity argon as the pressure transmission medium, the heating rate is 10℃ / min, and the temperature and pressure are maintained at 800℃ and 100MPa for 1 hour, followed by cooling to below 200℃ at a rate of 5℃ / min before being removed from the furnace.

[0055] Step nine, accuracy calibration and performance testing, includes the following steps:

[0056] Precision calibration: The roundness of the valve core spherical surface is detected and calibrated using a coordinate measuring machine;

[0057] Sealing test: The ball valve is placed in a helium gas spectrometer leak detector for a sealing test;

[0058] Life simulation test: The ball valve is placed in a simulated working environment and subjected to repeated opening and closing cycles under a pressure of 10MPa and a temperature of 150℃. Its sealing leakage and wear are monitored.

[0059] Example 2: A manufacturing process for a sealing and wear-resistant ball valve, comprising the following steps:

[0060] Step 1: Substrate pretreatment. Select metal materials with high strength and corrosion resistance to manufacture the ball valve core and valve body base, and perform degreasing, pickling activation, ultrasonic cleaning and drying on them;

[0061] Step 2: Preparation of wear-resistant underlayer. Cobalt-based or nickel-based alloy bonding underlayer is sprayed onto the pretreated valve core spherical surface and valve body base sealing surface using a supersonic flame spraying device to form a transition layer with a thickness of 70μm.

[0062] Step 3: Preparation of functional coating slurry; The functional coating slurry is prepared.

[0063] Step 4: Apply the functional coating. Use electrostatic spraying or dip coating processes to evenly coat the functional coating slurry onto the wear-resistant base surface.

[0064] Step 5: Sealing surface strengthening treatment. The valve core coated with functional coating is assembled with the valve body base into a special fixture, a preload is applied and low-temperature plasma sulfurizing treatment is performed.

[0065] Step Six: Integration of the intelligent pressure detection module: A miniature pressure sensor array is embedded in the sealing groove of the valve body base and fixed using a vacuum brazing process;

[0066] Step 7: Assemble the closed-loop control system by connecting the pressure sensor signal line to the sealing control module, and perform system integration and program burning.

[0067] Step 8: Hot isostatic pressing densification treatment. The assembled ball valve is placed in a hot isostatic pressing furnace and subjected to high temperature and high pressure treatment under inert gas protection.

[0068] Step Nine: Precision calibration and performance testing. A laser interferometer is used to detect the spherical roundness, and sealing and lifespan tests are conducted under simulated working conditions.

[0069] Step 10: Surface passivation and packaging. Chemical passivation is used to improve corrosion resistance, and rust-proof packaging is applied.

[0070] The pretreatment in step one includes the following steps: immersing the valve core and valve body base in an alkaline degreasing solution, ultrasonically cleaning at 70°C for 25 minutes, rinsing with deionized water, then activating with a 12% hydrochloric acid solution for 2 minutes, rinsing with a high-pressure water gun, and finally drying in a vacuum drying oven at 90°C for 1.5 hours. The alkaline degreasing solution is a compound of sodium hydroxide, sodium carbonate, sodium silicate, and surfactant, with a mass ratio of 3:2:1:0.5.

[0071] The supersonic flame spraying process parameters in step two are as follows: the fuel gas is propane or hydrogen, the oxygen flow rate is 1000L / min, the spraying distance is 180mm, the powder feeding rate is 40g / min, the coating thickness is controlled at 70μm, the porosity is less than 1%, and the cobalt-based alloy bonding underlayer composition is Co-32%Ni-21%Cr-8%Al-0.5%Y.

[0072] The functional coating slurry in step three is made from the following raw materials in parts by weight: 20 parts of nano-diamond particles, 10 parts of molybdenum disulfide, 45 parts of chromium-based tungsten carbide composite powder, 25 parts of epoxy-modified silicone resin, 4 parts of dispersant, 3 parts of leveling agent and 1.5 parts of curing accelerator.

[0073] The functional coating slurry was prepared by the following method: Epoxy-modified silicone resin was placed in a planetary mixer with heating and vacuum degassing functions, and the temperature was controlled at 45°C. The mixture was first stirred at 250 r / min for 10 minutes, then nano-diamond particles, molybdenum disulfide and dispersant were added, and the speed was increased to 550 r / min and stirred for 30 minutes. Chromium-based tungsten carbide composite powder and leveling agent were then added, and the mixture was stirred at 450 r / min for 20 minutes. Finally, a curing accelerator was added, and the mixture was stirred at 150 r / min for 10 minutes under a vacuum of -0.098 MPa to complete the preparation of the slurry.

[0074] The nanodiamond particles have a particle size of 70 nm and are treated with silane coupling agent KH-550. The chromium-based tungsten carbide composite powder is composed of 85% WC-10% Cr-5% Co with a particle size distribution of 30 μm. The dispersant is polyether-modified polydimethylsiloxane, the leveling agent is fluorocarbon-modified acrylate, and the curing accelerator is 2-ethyl-4-methylimidazole.

[0075] The electrostatic spraying process parameters in step four are: spraying voltage 70kV, atomization pressure 0.4MPa, coating thickness controlled at 100μm, and pre-curing at 80℃ for 20 minutes after completion; the dip coating process parameters are: lifting speed 150mm / min, immersion time 45 seconds, and coating thickness controlled at 120μm by viscosity and lifting speed.

[0076] Step five, the sealing surface strengthening treatment, specifically includes: assembling the valve core and valve body base into a dedicated hydraulic fixture, applying a 6MPa preload to ensure a tight fit between the sealing surfaces, and then placing it in a plasma sulfurizing furnace and evacuating it to a vacuum of 1×10⁻⁶. -2 Pa was heated to 220°C at a rate of 15°C / min, and a carrier gas containing dimethyl disulfide was introduced at a flow rate of 70 sccm. The plasma power supply was turned on at a power of 650 W, and the treatment time was 2.5 hours, forming a 7 μm thick FeS solid lubricant layer on the sealing surface.

[0077] The integration of the pressure detection module in step six is ​​as follows: The array of micro pressure sensor chips is uniformly embedded into the bottom of the sealing groove of the valve body base, and fixed and sealed by vacuum sealing brazing process. The signal line of the pressure sensor chip is led out through the sealing stuffing box.

[0078] The hot isostatic pressing densification process parameters in step eight are as follows: using high-purity argon as the pressure transmission medium, the heating rate is 12℃ / min, and the temperature and pressure are maintained at 820℃ and 130MPa for 1.5 hours, followed by cooling to below 200℃ at a rate of 7℃ / min before being removed from the furnace.

[0079] Step nine, accuracy calibration and performance testing, includes the following steps:

[0080] Precision calibration: The roundness of the valve core spherical surface is detected and calibrated using a coordinate measuring machine;

[0081] Sealing test: The ball valve is placed in a helium gas spectrometer leak detector for a sealing test;

[0082] Life simulation test: The ball valve is placed in a simulated working environment and subjected to repeated opening and closing cycles under a pressure of 10MPa and a temperature of 150℃. Its sealing leakage and wear are monitored.

[0083] Example 3: A manufacturing process for a sealing wear-resistant ball valve, comprising the following steps:

[0084] Step 1: Substrate pretreatment. Select metal materials with high strength and corrosion resistance to manufacture the ball valve core and valve body base, and perform degreasing, pickling activation, ultrasonic cleaning and drying on them;

[0085] Step 2: Preparation of wear-resistant underlayer. Cobalt-based or nickel-based alloy bonding underlayer is sprayed onto the pretreated valve core spherical surface and valve body base sealing surface using a supersonic flame spraying device to form a transition layer with a thickness of 100μm.

[0086] Step 3: Preparation of functional coating slurry; The functional coating slurry is prepared.

[0087] Step 4: Apply the functional coating. Use electrostatic spraying or dip coating processes to evenly coat the functional coating slurry onto the wear-resistant base surface.

[0088] Step 5: Sealing surface strengthening treatment. The valve core coated with functional coating is assembled with the valve body base into a special fixture, a preload is applied and low-temperature plasma sulfurizing treatment is performed.

[0089] Step Six: Integration of the intelligent pressure detection module: A miniature pressure sensor array is embedded in the sealing groove of the valve body base and fixed using a vacuum brazing process;

[0090] Step 7: Assemble the closed-loop control system by connecting the pressure sensor signal line to the sealing control module, and perform system integration and program burning.

[0091] Step 8: Hot isostatic pressing densification treatment. The assembled ball valve is placed in a hot isostatic pressing furnace and subjected to high temperature and high pressure treatment under inert gas protection.

[0092] Step Nine: Precision calibration and performance testing. A laser interferometer is used to detect the spherical roundness, and sealing and lifespan tests are conducted under simulated working conditions.

[0093] Step 10: Surface passivation and packaging. Chemical passivation is used to improve corrosion resistance, and rust-proof packaging is applied.

[0094] The pretreatment in step one includes the following steps: immersing the valve core and valve body base in an alkaline degreasing solution, ultrasonically cleaning at 80°C for 30 minutes, rinsing with deionized water, then activating with a 15% hydrochloric acid solution for 3 minutes, rinsing with a high-pressure water gun, and finally drying in a vacuum drying oven at 100°C for 2 hours. The alkaline degreasing solution is a compound of sodium hydroxide, sodium carbonate, sodium silicate, and surfactant, with a mass ratio of 3:2:1:0.5.

[0095] The supersonic flame spraying process parameters in step two are as follows: the fuel gas is propane or hydrogen, the oxygen flow rate is 1200 L / min, the spraying distance is 200 mm, the powder feeding rate is 50 g / min, the coating thickness is controlled at 100 μm, the porosity is less than 1%, and the cobalt-based alloy bonding underlayer composition is Co-32%Ni-21%Cr-8%Al-0.5%Y.

[0096] The functional coating slurry in step three is made from the following raw materials in parts by weight: 25 parts of nano-diamond particles, 12 parts of molybdenum disulfide, 50 parts of chromium-based tungsten carbide composite powder, 30 parts of epoxy-modified silicone resin, 5 parts of dispersant, 4 parts of leveling agent and 2 parts of curing accelerator.

[0097] The functional coating slurry is prepared by the following method: Epoxy-modified silicone resin is placed in a planetary mixer with heating and vacuum degassing functions, and the temperature is controlled at 50°C. First, it is stirred at 300 r / min for 10 minutes. Then, nano-diamond particles, molybdenum disulfide and dispersant are added, and the speed is increased to 600 r / min and stirred for 30 minutes. Next, chromium-based tungsten carbide composite powder and leveling agent are added, and stirring is continued at 500 r / min for 20 minutes. Finally, curing accelerator is added, and the mixture is stirred at 200 r / min for 10 minutes under a vacuum of -0.1 MPa to complete the preparation of the slurry.

[0098] The nanodiamond particles have a particle size of 100 nm and are treated with silane coupling agent KH-550. The chromium-based tungsten carbide composite powder is composed of 85% WC, 10% Cr, and 5% Co, with a particle size distribution of 45 μm. The dispersant is polyether-modified polydimethylsiloxane, the leveling agent is fluorocarbon-modified acrylate, and the curing accelerator is 2-ethyl-4-methylimidazole.

[0099] The electrostatic spraying process parameters in step four are: spraying voltage 80kV, atomization pressure 0.5MPa, coating thickness controlled at 120μm, and pre-curing at 80℃ for 20 minutes after completion; the dip coating process parameters are: lifting speed 200mm / min, immersion time 60 seconds, and coating thickness controlled at 150μm by viscosity and lifting speed.

[0100] Step five, the sealing surface strengthening treatment, specifically includes: assembling the valve core and valve body base into a special hydraulic fixture, applying an 8MPa preload to ensure a tight fit between the sealing surfaces, and then placing it in a plasma sulfurizing furnace and evacuating it to a vacuum of 1×10⁻⁶. -3 Pa was heated to 250°C at a rate of 20°C / min, and a carrier gas containing dimethyl disulfide was introduced at a flow rate of 100 sccm. The plasma power supply was turned on at a power of 800 W, and the treatment time was 3 hours, forming a 10 μm thick FeS solid lubricant layer on the sealing surface.

[0101] The integration of the pressure detection module in step six is ​​as follows: The array of micro pressure sensor chips is uniformly embedded into the bottom of the sealing groove of the valve body base, and fixed and sealed by vacuum sealing brazing process. The signal line of the pressure sensor chip is led out through the sealing stuffing box.

[0102] The hot isostatic pressing densification process parameters in step eight are as follows: using high-purity argon as the pressure transmission medium, the heating rate is 15℃ / min, and the temperature and pressure are maintained at 850℃ and 150MPa for 2 hours, followed by cooling to below 200℃ at a rate of 10℃ / min before being removed from the furnace.

[0103] Step nine, accuracy calibration and performance testing, includes the following steps:

[0104] Precision calibration: The roundness of the valve core spherical surface is detected and calibrated using a coordinate measuring machine;

[0105] Sealing test: The ball valve is placed in a helium gas spectrometer leak detector for a sealing test;

[0106] Life simulation test: The ball valve is placed in a simulated working environment and subjected to repeated opening and closing cycles under a pressure of 10MPa and a temperature of 150℃. Its sealing leakage and wear are monitored.

[0107] The performance of the sealing wear-resistant ball valves prepared in Examples 1-3 and Comparative Examples 1-4 was tested. The test items and test methods are as follows:

[0108] For the sealing performance test, at a rated pressure of 1.6 MPa, the ball valve was half-opened and helium gas was introduced into the valve chamber using a helium gas spectrometer leak detector. The helium gas spectrometer leak rate at the sealing joint was then detected.

[0109] Wear resistance life test: On a dedicated life test bench, under the conditions of medium pressure of 10MPa and temperature of 150℃, the cycle is repeatedly opened and closed at a frequency of 6 times per minute. The number of cycles when the specified leakage amount is reached is monitored and recorded.

[0110] The intelligent monitoring function was verified by applying stepped pressure to a ball valve with integrated sensors on a pressure test bench and using a signal acquisition system to record the pressure value and linearity of the sensor output signal to verify its monitoring accuracy.

[0111] Strength performance testing was conducted using a hydraulic pressure test bench, which applied a hydrostatic pressure of 4 times the nominal pressure to the closed ball valve cavity and maintained the pressure for a specified time.

[0112] The test data of the sealing wear-resistant ball valves prepared in Examples 1-3 and Comparative Examples 1-4 are recorded in the table below:

[0113] Testing items Maximum sealing pressure (MPa) Wear life (10,000 cycles) coefficient of friction Compressive strength (MPa) Example 1 42.5±0.3 15.2±0.5 0.08±0.01 285 Example 2 41.8±0.4 14.8±0.6 0.09±0.01 279 Example 3 43.2±0.3 15.6±0.4 0.07±0.01 291 Comparative Example 1 35.2±0.5 8.3±0.7 0.15±0.02 245 Comparative Example 2 36.8±0.4 9.1±0.6 0.14±0.02 251 Comparative Example 3 38.5±0.4 10.2±0.5 0.12±0.02 263 Comparative Example 4 34.7±0.6 7.9±0.8 0.16±0.02 240 ;

[0114] By comparing and analyzing the data in the table, it can be seen that the sealing and wear-resistant ball valves prepared using the processes in Examples 1-3 exhibit significantly superior performance compared to the ball valves prepared using the processes in Comparative Examples 1-4. This indicates that the nanodiamond particles and chromium-based tungsten carbide composite powder in the functional coating slurry jointly construct a high-hardness wear-resistant skeleton, resisting abrasive wear and erosion of the sealing surface. Molybdenum disulfide, as a solid lubricant, forms a transfer film at the friction interface during operation, reducing the friction coefficient and achieving a self-lubricating effect. Epoxy-modified silicone resin, as a binder phase, firmly bonds the various functional components and imparts good toughness and bonding strength to the coating, thereby synergistically improving the wear resistance and reliability of the ball valve sealing pair under harsh working conditions. A dense alloy underlayer, prepared by supersonic flame spraying, provides a solid support for the functional coating. Subsequent hot isostatic pressing (HIP) treatment promotes the closure of pores and increases density within the coating, forming a stronger metallurgical bond with the substrate. Simultaneously, precise detection and calibration of the valve core's spherical roundness using a coordinate measuring machine ensures the fitting accuracy of the sealing pair, resulting in uniform contact stress distribution. This prevents premature localized wear and sealing defects caused by geometric deviations, improving the consistency of the ball valve's sealing performance. A miniature pressure sensor array integrated into the valve body base monitors the contact stress distribution on the sealing surface in real time and feeds the signal back to the sealing control module. This module drives the actuator to fine-tune the valve core position, thereby achieving online optimization and compensation of the sealing specific pressure. This dynamic intelligent adjustment mechanism not only adapts to fluctuations in operating conditions but also provides early warning and compensation when slight wear occurs on the sealing surface, preventing sudden leaks and enhancing the safety and controllability of the ball valve in intelligent pipeline systems.

[0115] By comparing and analyzing the relevant data in the table, it can be seen that the sealing and wear-resistant ball valve produced by the process of this invention not only has excellent wear resistance, sealing performance, and long service life, but also possesses intelligent monitoring and adaptive adjustment capabilities. This demonstrates that the manufacturing process of the sealing and wear-resistant ball valve provided by this invention has outstanding overall performance.

[0116] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes the element.

[0117] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A manufacturing process for a sealing wear-resistant ball valve, characterized in that: Includes the following steps: Step 1: Substrate pretreatment. Select metal materials with high strength and corrosion resistance to manufacture the ball valve core and valve body base, and perform degreasing, ultrasonic cleaning, acid pickling activation and drying. Step 2: Preparation of wear-resistant underlayer. A cobalt-based or nickel-based alloy bonding underlayer is sprayed onto the pretreated valve core spherical surface and valve body base sealing surface using a supersonic flame spraying device to form a transition layer with a thickness of 50-100μm. The supersonic flame spraying process parameters are as follows: the fuel gas is propane or hydrogen, the oxygen flow rate is 800-1200L / min, the spraying distance is 150-200mm, the powder feeding rate is 30-50g / min, the coating thickness is controlled at 50-100μm, and the porosity is less than 1%. The composition of the cobalt-based alloy bonding underlayer is Co-32%Ni-21%Cr-8%Al-0.5%Y. Step 3: Preparation of functional coating slurry. The functional coating slurry is prepared from the following raw materials in parts by weight: 15-25 parts of nano-diamond particles, 8-12 parts of molybdenum disulfide, 40-50 parts of chromium-based tungsten carbide composite powder, 20-30 parts of epoxy-modified silicone resin, 3-5 parts of dispersant, 2-4 parts of leveling agent, and 1-2 parts of curing accelerator. The functional coating slurry is prepared by the following method: Epoxy-modified silicone resin is placed in a planetary mixer with heating and vacuum degassing functions, and the temperature is controlled at 40-50℃. First, it is stirred at 200-300 r / min for 10 minutes. Then, nano-diamond particles, molybdenum disulfide and dispersant are added, and the speed is increased to 500-600 r / min and stirred for 30 minutes. Next, chromium-based tungsten carbide composite powder and leveling agent are added, and stirring is continued at 400-500 r / min for 20 minutes. Finally, curing accelerator is added, and the mixture is stirred at 100-200 r / min for 10 minutes under a vacuum of -0.095 MPa to -0.1 MPa to complete the preparation of the slurry. Step 4: Apply the functional coating. Use electrostatic spraying or dip coating processes to evenly coat the functional coating slurry onto the wear-resistant base surface. Step 5: Sealing surface strengthening treatment. The valve core coated with functional coating is assembled with the valve body base into a special fixture, a preload is applied and low-temperature plasma sulfurizing treatment is performed. Step Six: Integration of the intelligent pressure detection module: A miniature pressure sensor array is embedded in the sealing groove of the valve body base and fixed using a vacuum sealing brazing process; Step 7: Assemble the closed-loop control system by connecting the pressure sensor signal line to the sealing control module, and perform system integration and program burning. Step 8: Hot isostatic pressing densification treatment. The assembled ball valve is placed in a hot isostatic pressing furnace and subjected to high temperature and high pressure treatment under inert gas protection. Step 9: Precision calibration and performance testing. A coordinate measuring machine is used to check the roundness of the sphere, and sealing and life tests are conducted under simulated working conditions. Step 10: Surface passivation and packaging. Chemical passivation is used to improve corrosion resistance, and rust-proof packaging is applied.

2. The manufacturing process of a sealing wear-resistant ball valve according to claim 1, characterized in that: The pretreatment in step one includes the following steps: immersing the valve core and valve body base in an alkaline degreasing solution, ultrasonically cleaning at 60-80℃ for 20-30 minutes, rinsing with deionized water, then acid-washing and activating in a 10%-15% hydrochloric acid solution for 2-3 minutes, rinsing with a high-pressure water gun, and finally placing in a vacuum drying oven to dry at 80-100℃ for 1-2 hours. The alkaline degreasing solution is a compound of sodium hydroxide, sodium carbonate, sodium silicate, and surfactant in a mass ratio of 3:2:1:0.

5.

3. The manufacturing process of a sealing wear-resistant ball valve according to claim 1, characterized in that: The nanodiamond particles have a particle size of 50-100 nm and are treated with silane coupling agent KH-550. The chromium-based tungsten carbide composite powder is composed of 85% WC-10% Cr-5% Co and has a particle size distribution of 15-45 μm. The dispersant is polyether-modified polydimethylsiloxane, the leveling agent is fluorocarbon-modified acrylate, and the curing accelerator is 2-ethyl-4-methylimidazole.

4. The manufacturing process of a sealing wear-resistant ball valve according to claim 1, characterized in that: The electrostatic spraying process parameters in step four are: spraying voltage 60-80kV, atomization pressure 0.3-0.5MPa, coating thickness controlled at 80-120μm, and pre-curing at 80℃ for 20 minutes after completion; the dip coating process parameters are: lifting speed 100-200mm / min, immersion time 30-60 seconds, and coating thickness controlled at 100-150μm by viscosity and lifting speed.

5. The manufacturing process of a sealing wear-resistant ball valve according to claim 1, characterized in that: The sealing surface strengthening treatment in step five specifically includes: assembling the valve core and valve body base into a special hydraulic fixture, applying a preload of 5-8 MPa to ensure tight contact between the sealing surfaces, and then placing it in a plasma sulfurizing furnace and evacuating it to a vacuum of 1×10⁻⁶. -2 Pa to 1×10 -3 Pa, heating to 200-250℃ at a rate of 10-20℃ / min, introducing a carrier gas containing dimethyl disulfide at a flow rate of 50-100 sccm, turning on the plasma power supply at a power of 500-800W, and processing for 2-3 hours to form a 5-10μm thick FeS solid lubricant layer on the sealing surface.

6. The manufacturing process of a sealing wear-resistant ball valve according to claim 1, characterized in that: The integration of the pressure detection module in step six specifically involves: uniformly embedding an array of micro pressure sensor chips into the bottom of the valve body base sealing groove, and fixing and sealing it through a vacuum sealing brazing process; the signal lines of the pressure sensor chips are led out through a sealing packing gland.

7. The manufacturing process of a sealing wear-resistant ball valve according to claim 1, characterized in that: The hot isostatic pressing densification process parameters in step eight are as follows: using high-purity argon as the pressure transmission medium, the heating rate is 10-15℃ / min, and the temperature and pressure are maintained at 800-850℃ and 100-150MPa for 1-2 hours, followed by cooling to below 200℃ at a rate of 5-10℃ / min before being removed from the furnace.

8. The manufacturing process of a sealing wear-resistant ball valve according to claim 1, characterized in that: Step nine, the accuracy calibration and performance testing, includes the following steps: Precision calibration: The roundness of the valve core spherical surface is detected and calibrated using a coordinate measuring machine; Sealing test: The ball valve is placed in a helium gas spectrometer leak detector for a sealing test; Life simulation test: The ball valve is placed in a simulated working environment and subjected to repeated opening and closing cycles under a pressure of 10MPa and a temperature of 150℃. Its sealing leakage and wear are monitored.