Bi-Metal Valve Body Casting With Fused Port Ring for Severe Service

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Solution Overview

Problem

Control valves in severe service conditions face issues like erosion, corrosion, and vibration due to stress risers from shrink fitting and unreliable mechanical stops, which lead to premature failure and reduced effectiveness under temperature changes.

Innovation Solution

A method of forming a valve body with a ring of dissimilar material fused into the valve port using a metal ring between the inlet and outlet sections, where the metal ring is heated during casting to fuse with the valve body material, eliminating the need for separate corrosion-resistant inserts and mechanical stops.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If shrink fitting is used to attach inserts to valve body, then corrosion resistance is improved, but stress risers are created leading to premature failure

Engineering Contradiction:

Improvecorrosion resistanceVSAvoidstress concentration

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent merges the insert and valve body into a single monolithic structure through additive manufacturing, eliminating the shrink fit interface that causes stress risers. The corrosion-resistant material is deposited directly onto the valve body substrate, creating a bonded structure without mechanical fastening or thermal contraction interfaces.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent uses composite materials by combining a base valve body material with a corrosion-resistant overlay material through additive manufacturing. This creates a bi-material structure where the corrosion-resistant layer is metallurgically bonded to the substrate, providing both structural integrity and corrosion protection without stress concentration.

Inventive Principle:

Principle #40Composite materials

2Manufacturing precision

If mechanical stops are used to secure inserts, then positioning is improved, but reliability decreases under severe service conditions

Engineering Contradiction:

Improveinsert positioningVSAvoidservice condition performance

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent merges the positioning function into the monolithic structure itself. The additive manufacturing process directly forms the final geometry with precise dimensional control, eliminating the need for separate mechanical stops or retention features. The structure is self-positioned through its integrated design.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If separate corrosion-resistant inserts are used, then corrosion protection is improved, but device complexity increases

Engineering Contradiction:

Improvecorrosion protectionVSAvoidnumber of components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges multiple components (valve body, inserts, retention features) into a single monolithic structure manufactured by additive manufacturing. This integration eliminates assembly steps, reduces the number of parts, and simplifies maintenance while maintaining corrosion protection through the corrosion-resistant material selection.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The additive manufacturing process provides multi-functionality by simultaneously achieving complex geometries, integrated corrosion-resistant coatings, and self-positioning features in a single manufacturing step. The process consolidates multiple manufacturing operations into one unified process.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Reliability

If corrosion-resistant material is applied throughout the valve body, then corrosion resistance is improved, but manufacturing cost increases

Engineering Contradiction:

Improvecorrosion resistanceVSAvoidmaterial cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent applies local quality by using additive manufacturing to deposit corrosion-resistant material only in specific zones where corrosion exposure occurs. The process allows selective application of expensive corrosion-resistant materials to critical areas while using cheaper base materials in non-critical regions, optimizing both performance and cost.

Inventive Principle:

Principle #3Local quality

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 approach enhances durability and reduces costs by targeting corrosion-resistant materials only where needed, providing a defect-free surface for improved sealing and eliminating the need for a separate seat ring, while maintaining reliability under severe service conditions.

Implementation Method 1

the metal ring is heated during casting to fuse with the valve body material

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

the metal ring is heated during casting to fuse with the valve body material

Methodology Applied

Scientific EffectFusion: Melting

Data Source

PatentUS11090713B2Bi-metal valve body casting and method of making same

Publication Date: 2021.08.17 FISHER CONTROLS INT LLC

AI summary

A valve body having a ring of dissimilar material and a method of forming the valve body are described. The valve body includes an inlet, an outlet and a ring of dissimilar material. The method includes forming a valve core, splitting the valve core, placing a metal ring of dissimilar material between two pieces of the valve core, casting a valve body around the valve core, and fusing the metal ring to the valve body.