Forging Medium and High-pressure Valves

Forging Medium and High-pressure Valves

Jun 03, 2024


Medium and high-pressure forged valves are indispensable and important equipment in modern industry. The main function of these forged valves is to control the flow of the media. They are widely used in many industries such as petroleum, chemical, electric power, and metallurgy industries.
 
Advantages of forged medium and high-pressure valves
Compared with cast valves, forged medium and high-pressure valves have the following significant advantages:
Superior mechanical properties: The forging process makes the metal’s internal structure more compact and the grains finer, providing higher strength, better toughness, and wear resistance.
Excellent corrosion resistance: By selecting high-quality materials and reasonable heat treatment processes, forged valves can work stably for a long time in corrosive environment.
Compact structure: The forging process makes valves have a more compact structure and lighter weight, making them easier to install and maintain.
Good reliability: Forged valves have better stability and reliability under high pressures and high temperatures, effectively preventing leakages and failures.
 
Forging process
Forging is a processing method that applies external force to metals to cause plastic deformation, resulting in workpieces with specific mechanical properties, shapes, and sizes. The manufacturing process directly impacts the performance and service life of the valve. The forging process of medium and high-pressure valves mainly includes material selection, heating, die forging, heat treatment, and finishing.

Medium and high-pressure valves usually use high-quality carbon steel, stainless steel, or alloy steel as raw materials. These materials have excellent mechanical properties and can work stably for a long time under high pressures. High-strength materials ensure that the valve does not easily deform or break when subjected to high-pressure fluid impact. Stainless steel and certain alloy steels have good corrosion resistance and can be used in corrosive environments. After proper treatment, these materials can adapt to various complex working conditions such as high temperatures, high pressures, and corrosive environments. 

Heat the metal to an appropriate temperature to soften it and facilitate subsequent forging and forming. The metal’s temperature must be uniform across the entire cross section to avoid defects caused by uneven heating during the forging process. The heating temperature must be strictly controlled within an appropriate range. Too high a temperature will cause the material’s grain size to become coarse, affecting the mechanical properties; too low a temperature will increase the difficulty of forging and easily cause cracks. Usually, an induction heating furnace or a gas heating furnace is used. These devices can heat the metal quickly and evenly, improving production efficiency. The corresponding forging die is designed according to the shape and size of the valve. The design and manufacture of the die directly affect the precision and quality of the forged parts. Through the die’s constraint and external force, the heated metal gradually takes shape. Sufficient pressure must be applied during the forging process to ensure that the metal flows and fills the die cavity. For complex shapes or large valves, it may be necessary to forge in sections and then combine them. This method can improve forging efficiency and product quality. Heat treatment is performed on the forged valve to improve its mechanical properties and internal structure. This includes quenching, tempering, normalizing, and annealing. The forged parts are heated to an appropriate temperature and then cooled rapidly to achieve better hardness and strength. The quenched forged parts are usually brittle and need to be tempered to eliminate internal stress and improve toughness. Some valves need to be normalized or annealed after forging to improve their material structure and overall mechanical properties.

The valve blanks that have been forged and heat-treated need to be finished, including turning, drilling, grinding, and other processes to ensure the dimensional accuracy and surface quality of the valve. Use a lathe to process the valve to achieve the size and shape required by the design. Drill the necessary channels and mounting holes on the valve body for subsequent assembly and use. Grind the sealing surface and other key parts of the valve to improve the surface finish and dimensional accuracy.
 
Conclusion
Forged medium and high-pressure valves play an irreplaceable and crucial role in modern industrial production. By continuously improving manufacturing processes, optimizing material selection, and strengthening quality control, the performance and reliability of forged medium and high-pressure valves can be further enhanced to meet the needs of various industries. In the future, with advancements in science and technology and the continuous expansion of application fields, forged medium and high-pressure valves will demonstrate their unique advantages and value in a wider range of fields.

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Launched in 1988, Topper Forged Valve Company is engaged in manufacturing forged steel valves. Our products cover Forged Steel Ball Valve, Gate Valve, Check Valve, Globe Valve, According to API, BS, DIN, JIS GB Standards.
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