Composite Valve Body With Wear-Resistant Inner Core
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Solution Overview
Problem
Existing fluid valves in process control systems face challenges with material degradation and wear due to exposure to process fluids, especially in applications with particulate or entrained solids, leading to increased costs and limitations in size and geometry for erosion-resistant materials.
Innovation Solution
A valve body design featuring a wear-resistant inner core made of materials like nickel-based or cobalt-based alloys, combined with a high-strength outer shell of carbon steel, where the inner core is manufactured using additive processes like 3D metal printing and the outer shell is cast around it, providing enhanced corrosion and erosion resistance while meeting pressure and temperature ratings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If erosion-resistant materials are used for the entire valve body, then wear resistance is improved, but material cost and manufacturing complexity increase
Solution Approach 1:
The patent applies different material properties to different parts of the valve body. The inner core that contacts process fluid is made of erosion-resistant material (nickel-based or cobalt-based alloy), while the outer shell is made of cost-effective carbon steel. This local differentiation provides wear resistance where needed without the complexity and cost of using erosion-resistant material throughout the entire valve body.
Solution Approach 2:
The patent creates a composite structure by combining two different materials - a metal core made of nickel-based or cobalt-based alloy and an outer shell made of carbon steel. The metal core is manufactured using additive manufacturing processes, then the outer shell is cast around it, creating a composite valve body that leverages the advantages of both materials.
2Duration of action of stationary object
If wear-resistant materials are used, then lifespan is improved, but material cost increases
Solution Approach 1:
The patent applies erosion-resistant material only to the inner core that is exposed to process fluid and subject to wear, rather than using it throughout the entire valve body. This localized application extends valve lifespan where needed while significantly reducing material costs compared to using erosion-resistant material for the complete valve assembly.
Solution Approach 2:
The composite structure combines expensive erosion-resistant material (nickel-based or cobalt-based alloy) with cost-effective carbon steel. The metal core provides wear resistance to extend lifespan, while the carbon steel outer shell reduces overall material cost, achieving an economical balance between durability and cost.
3Reliability
If cladding is applied to valve bodies, then erosion resistance is improved, but applicability is limited to larger sizes
Solution Approach 1:
The patent creates a metal core with uniform erosion-resistant material distribution throughout the entire inner surface area, including regions that would be difficult or impossible to clad on smaller valves. The additive manufacturing process allows the metal core to be formed with consistent material properties regardless of valve size, making this solution applicable to small, medium, and large valve configurations.
Solution Approach 2:
The composite structure with a metal core manufactured via additive manufacturing provides erosion resistance independent of valve size. Unlike cladding which requires minimum thickness and access for application, the metal core approach works for valves of any size, including small bore valves where cladding equipment cannot access the internal surfaces.
4Reliability
If complex geometries are manufactured with wear-resistant materials, then performance is improved, but manufacturing difficulty increases
Solution Approach 1:
The patent manufactures the metal core with complex internal geometries and flow paths using additive manufacturing processes, which can create intricate structures that would be difficult or impossible to achieve with traditional casting or machining. The outer shell is then cast around the metal core using conventional casting techniques, combining the geometric flexibility of additive manufacturing with the cost-effectiveness of traditional methods.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enables the creation of valve bodies with complex geometries that are cost-effective, resistant to wear, and compliant with industry standards, even in smaller sizes where cladding is not feasible, thus extending the lifespan and reducing material costs.
Implementation Method 1
the outer shell is cast around it, providing enhanced corrosion and erosion resistance while meeting pressure and temperature ratings
Implementation Method 2
The outer shell is bonded to the metal core
Data Source
AI summary
Example valve bodies having resistant inner cores are disclosed herein. An example valve body comprises a metal core including a fluid inlet, a fluid outlet, and a fluid passageway extending between the fluid inlet and the fluid outlet, and an exterior shell overmolded with the metal core, the exterior shell bonded to the metal core, the exterior shell to provide a pressure-boundary of the valve body.