3D-Printed Thermal Sleeve Liner for Valve Thermal Shock
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Solution Overview
Problem
Fluid flow devices in severe industrial applications experience thermal shock due to sudden changes in temperature and pressure, leading to premature failure, with existing solutions like pre-heating systems being unreliable, low thermal conductivity materials being insufficient, and thermal barrier coatings being prone to erosion and corrosion.
Innovation Solution
An additively manufactured thermal insulating sleeve liner with an internal infill structural pattern, made from materials like Inconel 718 or ceramic composites, featuring voids to enhance thermal insulation and structural strength, and designed for easy replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If pre-heating systems are used to mitigate thermal shock, then thermal stress protection is improved, but system reliability deteriorates due to malfunction and maintenance requirements
Solution Approach 1:
The patent extracts the thermal protection function from complex active pre-heating systems and implements it through a passive thermal barrier coating applied directly to the valve body. This eliminates the need for separate pre-heating equipment, control systems, and power sources, thereby removing the source of malfunctions and maintenance issues while maintaining thermal stress protection.
Solution Approach 2:
The patent introduces a thermal barrier coating as an intermediary layer between the hot fluid and the valve body. This coating acts as a mediator that reduces heat transfer to the valve, protecting it from thermal shock without requiring active control systems or external power sources, thus improving reliability.
2Object-affected harmful factors
If low thermal conductivity materials are used for thermal protection, then thermal insulation is improved, but protection effectiveness deteriorates under extreme cyclic temperatures
Solution Approach 1:
The patent employs a composite thermal barrier coating system consisting of multiple layers with different properties. The coating includes a bond coat and a top coat with specific thermal and mechanical properties, creating a composite structure that provides both thermal insulation and resistance to extreme cyclic temperatures, preventing cracking and failure.
Solution Approach 2:
The patent optimizes the thermal and mechanical parameters of the coating system, including thickness, composition, and microstructure, to achieve the right balance between thermal insulation and resistance to thermal cycling. By carefully controlling these parameters, the coating maintains protection effectiveness under extreme conditions.
3Object-affected harmful factors
If thermal barrier coatings are applied to protect against thermal shock, then thermal protection is improved, but durability deteriorates due to erosion and corrosion susceptibility
Solution Approach 1:
The patent uses a multi-layer composite coating structure where the bond coat provides corrosion and erosion resistance while the top coat provides thermal barrier protection. This composite approach ensures that the thermal barrier function is maintained even when the outer layer experiences some degradation, significantly improving durability in erosive and corrosive environments.
Solution Approach 2:
The patent applies different material compositions and properties to different layers of the coating system. The bond coat near the metal substrate has properties optimized for adhesion and corrosion resistance, while the top coat has properties optimized for thermal barrier performance and erosion resistance, creating a locally optimized protective system.
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
The sleeve liner significantly reduces thermal shock, extends device life by up to 2,000% compared to unlined devices, and minimizes material waste with a customizable, robust design.
Implementation Method 1
An additively manufactured thermal insulating sleeve liner with an internal infill structural pattern... featuring voids to enhance thermal insulation
Data Source
Figure 1A~1B-1
Figure 2A~2B-1
Figure 3A~3B
AI summary
A monolithic metal thermal insulating sleeve liner for fluid flow devices such as valves and piping used in severe industrial applications is additively manufactured (e.g., by 3D printing) to fit the bore of a protected fluid flow device. Tessellated support structures obliquely extending between inside surfaces of inner and outer shells provide increased resistance to thermal conduction while also providing increased strength against compression forces. Example support structures include an array of four obliquely oriented elongated members mutually intersecting mid-way between the inside surfaces of inner and outer cylindrical shells. If internal interstices are sealed they can be vacuumed or pressurized to enhance thermal insulating properties. A pressure equalizing aperture can be provided on or through the sleeve if needed in some applications.