Understanding the Differences in Manufacturing Processes
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There are distinct differences between casted and forged valves, and each type carries its own set of advantages and challenges.
Casted valves, as the name suggests, undergo a process called casting, where molten metal is poured into a valve mold and solidified. Once the molten metal cools and takes the shape of the casted valve, it is removed from the mold and goes through a finishing method. Castings or casted valves can be manufactured in complex shapes and intricate designs that can be challenging to achieve with forged valves. The design flexibility with castings can accommodate various combinations of configurations and sizes. Additionally, the cost-effectiveness of manufacturing a casted valve is generally greater, especially when producing larger quantities of valves.
Forged valves undergo a manufacturing process where metal is heated and shaped using compression. Forging sub jects&#; material to high pressure to create the valve shape and its grain structure is aligned to improve the mechanical properties of the component. The valve&#;s structural integrity comes from the grain structure; this allows for resistance to fatigue and stress. Forged valves typically result in fewer internal defects like porosity. These components are known for their strength, which is what makes them suitable for high-pressure and high-temperature applications.
When comparing the integrity of the two manufacturing processes, each has its own advantages and disadvantages. Casted valves tend to have lower strength and durability in comparison to forged valves. This is especially apparent in complex applications. Castings can also run a higher risk of having internal defects, as opposed to forged valves, which can impact the mechanical properties and the structural integrity of the valve. Forged valves, on the other hand, obtain limited complexity. These valves are most effective when the design and shape are simple. Forging can be higher in cost; it is generally more expensive to manufacture the forged valve.
The choice between casted and forged valves therefore typically depends on the specific requirements of the application and the trade-offs between cost, performance, and design complexity.
As a common industrial product in life, valves are widely used in various industries, such as chemical, shipbuilding, construction, papermaking, and so on. So how to choose the right valve during use.
(1) Selection of gate valve
In general, gate valve should be selected. In addition to steam, oil and other media, gate valves are also suitable for media containing granular solids and high viscosity, and are suitable for venting and low vacuum system valves. For media with solid particles, the gate valve body should be equipped with one or two purge holes. For low-temperature medium, low-temperature special gate valve should be selected.
(2) Globe valve selection:
Globe valve is suitable for pipelines with low requirements for fluid resistance, that is, pipelines or devices with little consideration for pressure loss, as well as high-temperature and high-pressure mediums, and is suitable for steam and other medium pipelines with DN<200mm; Small valves can choose globe valves, such as needle valves, instrument valves, sampling valves, pressure gauge valves, etc.; The globe valve has flow adjustment or pressure regulation, but the requirements for adjustment accuracy are not high, and the diameter of the pipeline is relatively small, so it is advisable to choose the globe valve or throttle valve; For highly toxic media, it is advisable to choose a bellows sealed globe valve; However, the globe valve should not be used for media with high viscosity and media containing particles that are easy to precipitate, nor should it be used as a venting valve and a valve for low vacuum systems.
(3) Ball valve selection:
Ball valves are suitable for low-temperature, high-pressure, high-viscosity media. Most ball valves can be used in media with suspended solids, but also in powdery and granular media, depending on the material requirements of the seal; The full-channel ball valve is not suitable for flow regulation, but is suitable for occasions that require rapid opening and closing, which is convenient for emergency shut-off in an accident; Ball valves are usually recommended in pipelines with strict sealing performance, abrasion, necking channels, rapid opening and closing action, high pressure cut-off (large pressure difference), low noise, gasification, small operating torque, and low fluid resistance.
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Ball valves are suitable for light structure, low pressure shut-off, corrosive media; The ball valve is also the most ideal valve for low-temperature and cryogenic medium, and the low-temperature ball valve with valve cover should be selected for the pipeline system and device of low-temperature medium; When the floating ball valve is selected, the seat material should bear the load of the ball and the working medium, the large-diameter ball valve needs a large force during operation, and the DN&#;200mm ball valve should be used in the form of worm gear transmission; Fixed ball valve is suitable for larger diameter and high pressure occasions; In addition, the ball valve used for the process of highly toxic materials and combustible medium pipelines should have a fireproof and anti-static structure.
(4) Butterfly valve selection instructions
Butterfly valves are suitable for large diameters (such as DN>600mm) and short structural length requirements, as well as the need for flow adjustment and fast opening and closing requirements. Itgenerally used for water, oil and compressed air with a temperature of &#;80°C and a pressure &#;of 1.0MPa; Because the pressure loss of butterfly valve is relatively large compared with gate valve and ball valve, butterfly valve is suitable for pipeline systems with low pressure loss requirements.
(5) Check valve selection:
Check valve is generally suitable for clean media, and should not be used for media containing solid particles and large viscosity. When DN&#; 40mm, it is advisable to use a lifting check valve (only allowed to be installed on the horizontal pipeline); When DN=50~400mm, it is advisable to use swing check valve (it can be installed on both horizontal and vertical pipelines, if installed on vertical pipelines, the flow direction of the medium should be from bottom to top); When DN&#;450mm, it is suitable to use wafer check valve; When DN=100~400mm, wafer check valve can also be selected; The swing check valve can be used in high pressure, reach to 42MPa, it can be applied to any working medium and any working temperature range according to the material of the housing and seal. The medium is water, steam, gas, corrosive medium, oil, medicine, etc. working temperature is between -196~800°C.?
Here's a table summarizing the key points:
Additional factors to consider:
By understanding these factors and the strengths of each valve type, you'll be well-equipped to choose the right valve for your specific needs. If you have further details about your application (fluids, pressures, etc.), I can provide a more tailored recommendation by sending
Remember, the best valve considers both upfront cost and future maintenance needs!
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