Key Questions to Ask When Ordering Carbide Valve Ball

If you’re a project manager or site foreman – here’s an important question you should find out if you don’t already know.  What generation of abrasive metering valve do you have on your blast pots?

If you are looking for more details, kindly visit YIYUAN.

It may surprise you that your metering valve is one of the most significant indicators of your efficiency and profit.   This is one of the most important (yet neglected) considerations on the majority of jobsites we visit.  It’s so important in fact – that if you’re a project manager looking to turn ONE DIAL to improve your team’s performance – we suggest investigating your abrasive metering valve.  It’s to your financial advantage to understand the metering valve you’re using and why it’s most likely costing you hundreds of dollars a day in inefficiencies.

First… here’s a general layout of the abrasive metering valves currently in use. These are listed from least efficient to most efficient across the broad range of blasting applications.

So, what makes one metering valve any better than another?  ONE metric.   Which valve saves you the most money? And this metric should be evaluated on the following 4 criteria:

1. Wasted Abrasive
2. Clean-up Costs
3. Productivity/Downtime
4. Needed Repairs/Replacement Parts

We’ve explained these costs in a previous Primed Insight if you’d like to learn more.  But suffice it to say, thousands of dollars can be lost each day simply by saving $200 on the purchase of a cheap metering valve. This is something every project manager should pay attention to.

A popular misunderstanding is all these valves represent different methods of metering. That is not correct. Each column is actually a generational improvement on the previous valves.

Think of the above valves through this perspective:

Engineering and materials have improved with each product upgrade.

• The metering has gotten more precise – conserving abrasive
• Breakdowns and repairs have drastically reduced with each generation

Now, as we’re presented things, it may seem that the silver bullet to everyone’s problems is simply to buy this most current valve – The Axxiom Schmidt TeraValve.

And it probably is our top recommendation.  It not only improves efficiency across the broadest range of industrial applications, but surprisingly, it also costs less than its predecessor – The Thompson 2 Valve.

However, for high flow jobs that use multiple #10 nozzles or in blast room situations using a robot, the Thompson 2 is actually our top recommendation.

Now in case you think we’re just trying to sell you a more expensive valve – here’s an insight within an insight…

Because we’re a business like you, profit and loss is something we must also manage.  That’s why we have installed over 200 Tera Valves on our vast rental fleet. You can imagine that renting blast pots comes with quite a bit of maintenance and repair when they’re returned. We discovered that simply by installing Tera Valves on our rental pots, those maintenance costs dropped 75%.

THAT’S why we recommend TeraValves.  They’re a superior product.

And in case you’re interested – this link leads to a Tera Valve retrofit kit so you can upgrade your current pot to the latest and greatest generation of metering valves.

If you have questions as to which valve is best for your pot and applications – just reach out and ask. That’s our job!

We’re discussing the iconic combo valve from Axiom manufacturing today. This is a deadman valve which controls the air into, and the air out-of, your blast pot. It’s how your deadman works on a pressure release blast pot. That is a blast pot where the pressure is released out of the pot every time we stop blasting, versus a pressure hold where the pressure is kept in the blast pot when we stop blasting.

At the core of a pressure-release blast pot is this deadman valve called the combo valve and the reason is was the first valve in the industry to combine both the inlet which you see on this side and the outlet which you see on the other side into one valve.

There’s three key criteria in choosing a dead man valve for a blast pot. The first is safety. I’d like to go through the key safety requirements for the combo valve.

The first is that the air from the blast pot is exhausted through a piece of blast hose.

This is a failsafe aspect to this valve because it has a large spring it automatically when you lose pressure or something goes wrong this opens up and lets the air of the blast pot out.

The second thing is, because it has such a large piston and spring, it’s very fast active. That is very important because if there’s an incident takes place I need to make sure the blast pot shuts down as soon as possible.

The second key purchasing criteria for a Deadman control valve is productivity. The way to maximize productivity is to minimize pressure drop, and the way we do that with the combo valve is that as the air comes in to the bottom of the valve… travels up and through and heads on to blast, it passes through the valve itself.

Many valves have a restricted convoluted air passageway through the valve. Not the combo valve. It has a single plug that blocks the air and when it activates it pulls right out of the way and allows full and free airflow.

The third important criteria is how easy the valve is to maintain. How easy it is to use.

I’d like to point out two key benefits:
The first is the most common wearing part – is this hose. No need to rebuild the valve it’s simply a matter of refitting it just like you refit a blast hose. So that’s a very significant time saver.
Then if something goes wrong with the valve itself, it has what we call a unitized piston assembly – you see one here in my hand. It allows you to very simply undo four bolts, change-out the entire working center of the valve, put the four bolts back in, and be up and operating again in less than 10 minutes.

No need to pull the valve off the pot, no need to get out thread tape, no need to touch the piping. It’s a massive benefit to operators in the field.

Two things to remember: combo valve must be used with the Schmidt Deadman handle. They are designed to work together, and the use of non-standard or other brand Deadman handles is a safety hazard. And the last point is make sure you use genuine parts. It’s a safety requirement on every job site that genuine parts are used.

Knowledge of valve ball

Part I material

Commonly used valve material classification

1. Valve bearing parts materials:
   

1.1. Pressure member definition: a part containing a flow that is released into the atmosphere upon failure

1.2. Categories:

1. Carbon steel (casting, e.g. WCB; Forgings such as: A105)
2. Stainless steel (casting: ZG022Cr18Ni10; Forging: 022Cr18Ni10)
3. Steel for high temperature (425-800℃) valves (ZG15CrMo1V, F11, F22…)
4. Low temperature (-29~-196 ℃) valve steel (LCB,LCC,LC1,LF2,LF3…..)
5. Inner parts: refer to the inner parts of different types of valves such as sealing surface, valve stem, bushing and internal small parts

2.1.1 Soft sealing materials (soft materials and hard materials) are shown in the table below

NoNameCodeApplicable TemperatureApplicable Medium1Natural rubberNR≤85 ℃salt, hydrochloric acid, water, wet chlorine…2NeopreneCR≤85 ℃Animal and vegetable oil, inorganic lubricating oil….3butyl rubberIIR≤100 ℃anti-corrosion, anti-wear, most of the inorganic acid….4nitrile rubberNBR≤85 ℃Water, oil, waste liquid, etc5ethylene propylene rubberEPDM ≤120 ℃brine,40% boron water, 5-15% nitric acid and NaCl6Chlorosulfonated polyethylene synthetic rubberCSM ≤100 ℃good acid resistance7Silicon rubberSI≤200 ℃high temperature resistance, low temperature, good electrical insulation, etc8Fluoride rubberFPM≤200 ℃dielectric corrosion resistance is better than other rubber9PolytetrafluoroethylenePTFE TFE≤150 ℃,good cold resistance;The usual chemical solution10perfluoropropyleneFEP F46≤150 ℃Chemical, light and weather resistance at high temperature11Meltable POLYtetrafluoethylenePFA FS-≤180 ℃Various concentrations of sulfuric acid, hydrofluoric acid, aqua aqua, strong alkali….12Para polystyrene≤300 ℃basically with teflon13Nylon ≤80 ℃alkali resistance, ammonia

2.1.2 Hard materials for sealing surface: there are many kinds, which can be roughly divided into: copper alloy, Babbitt alloy, alloy steel, stainless steel, Hartnett alloy, Monel, hard alloy, ceramics, WC, nickel-based alloy…

2.1.3 Surface treatment as sealing surface material

Surface treatment: hard chromium plating, chemical nickel phosphorus, surface nitriding and so on.

2.2 Stem materials:

Common stem materials:

Copper alloy: generally used in water, seawater, oxygen, etc.QA19-2,QA19-4,HMn58-2

Alloy steel: generally used for high temperature and high pressure valves.40 cr, 38 crmoal, ASTM .

Stainless steel: generally used for corrosive medium, high and low temperature valves; Martensite and austenite main F6a,420,F304,F321,F316……

Heat resistant steel: generally used for high temperature valves F11(25CrMoV),F22(25Cr2Mo1V),

Precipitation hardened stainless steel: generally used in corrosive media and high pressure valves 17-4pH, 17-7pH

Low temperature steel: generally used for valves less than -29℃

3. Sealing materials

3.1 Sealing material can be divided into: gasket and packing according to functions.

3.2 Gaskets: Ensure the sealing of connections between relevant parts in contact with the medium.

3.3 Packing: ensure the sealing of the shaft with relative movement.

4. Bolting materials
   

4.1 The bolting material mainly refers to the bolts, nuts and other parts used to connect the valve parts.

4.2 Common bolt materials:

GB: 25, 40Cr, 42CrMo, 06Cr17Ni12Mo2

ASTM: ASTM A307 B, B7, B7M A193 B16, B8, B8M ASTM A320 L7

4.3 Common nut materials:

GB: 5, 8, 35CrMo, 06Cr18Ni10

ASTM: A194 2H, 2HM, 8, 8M, 8C, 4, 16

Part II of the material is formed

Valve parts Forming classification:

The main forming methods of valve parts are: forging, casting, etc. This part mainly describes forging

1. Forging classification: mainly divided into free forging and die forging
2. 1 Free exercise

Free forging is to place the heated metal billet between the top and bottom of the forging equipment to exert impact

A process in which a blank is directly plastic deformed by force or pressure, thereby obtaining the required forgings.

1.1.1 Classification: manual free forging, hammer free forging, hydraulic press free forging

1.1.2 Advantages: strong applicability, great flexibility, short cycle and the only method for large forgings

1.1.3 Disadvantages: low precision, large machining allowance, low efficiency and high labor intensity

Want more information on Carbide Valve Ball? Feel free to contact us.

1. 2 die forging
   

Die forging is called model forging. It is formed by placing the heated blank in a die fixed to the die forging equipment.

1.2.1 Die forging equipment: In industrial production, hammer up die forging is mostly used

1.2.1.1 Steam-air hammer, tonnage ranging from 5KN to 300KN (0.5 ~ 30 t)

1.2.1.2 Hot die forging press commonly used for die forging on pressure machine, with tonnage ranging from KN to KN.

1. 3 Forging ratio

Forging ratio: The ratio of the cross-sectional area of the metal billet before and after forging. The calculation method of forging ratio is different for different forging process.

1. When drawing, the forging ratio is y=F0/F1 or Y =L1/L0

F0,L0 — the cross-sectional area and length of the ingot or billet before drawing;

F1,L0 — the cross-sectional area and length of the ingot or billet after drawing.

2. Forging ratio during upsetting, also called upsetting ratio or compression ratio, whose value is y=F1/F0 or y=H0/H1

F0, H0 — the cross-sectional area and height of the ingot or billet before upsetting;

F1, H1 – Cross sectional area and height of steel ingot or billet after upsetting.

1 .4 Forging temperature

1.4.1 Initial forging temperature: The initial forging temperature shall be understood as the maximum allowable heating temperature of steel or alloy in the furnace.

1.4.2 Final forging temperature: the steel shall remain sufficiently plastic before the end of forging, and the forgings shall obtain recrystallization structure after forging.

1.4.3 Forging temperature of common materials (℃, for reference only):

Material markInitial forging temperatureFinish forging temperatureMaterial markInitial forging temperatureFinish forging temperatureMaterial markInitial forging temperatureFinish forging temperatureAFFLFF304LF/2CrFFF316L…..-4PH…..

Part III heat treatment

Heat treatment system of commonly used materials:

Carbon steel material: A105

1.1 Heat treatment system: normalizing and air cooling.

1.2 Metallographic structure general structure: pearlite + ferrite structure

Carbon steel material: LF2

2.1 Heat treatment system: quenching + tempering (tempering) (water cooling + air cooling).

2.2 General structure of metallographic structure: Sostenite structure

3:, low alloy steel

3.1 Heat treatment system: quenching + tempering (oil cooling + air cooling).

3.2 General structure of metallographic structure: Soxhlet structure

Martensitic stainless steel: F6a

4.1 Heat treatment system: quenching + tempering (or two tempering) (oil or air cooling + air cooling).

4.2 General structure of metallographic structure: Sostenitic structure

4.3 Description: F6a is divided into four grades, which are controlled by tempering temperature to ensure that the grade is reached

The mechanical properties of the corresponding grade are required.

Austenitic stainless steel material: 5 F316 F316L/F304 / F304L/F321….

5.1 Heat treatment system: solid solution treatment (water cooling).

5.2 General structure of metallographic structure: austenite structure

6 Duplex stainless steel: F51/F53/F55….

6.1 Heat treatment system: solid solution treatment (water cooling).

6.2 General structure of metallographic Structure: Austenite + ferrite structure (about half)

Part IV electroplating

Common electroplating types:

Common surface coating types: electroplated hard chrome, electroless plating

1. Electroplated hard chrome:

1.1 General thickness of electroplated hard chromium: about 0.025mm

1.2 Characteristics of hard chromium electroplating: The thicker the coating, the less uniform the surface coating; The general hardness is 750~800HV;No current reaction and almost no coating in the depression; Such as the hole in the body of the ball and the junction of two end faces and end plane.

1.3 Relationship between heat treatment temperature and hardness: During heat treatment at 200 ° C, hardness begins to decline. Before 400 ° C, the hardness drops very little. During heat treatment at 600 ° C, the hardness drops by 50% and 70% at 980 ° C.Therefore, under 400 ℃ heat treatment, basically maintain the original hardness.

2. Electroless nickel-phosphorus plating (ASTM B733) :
3. 1 Classification by coating alloy type:

Class I: P no requirement

Class II: Lower phosphorus (1~3%)

Class III: Low phosphorus (2~4%P) : Plating hardness 620-750HK

Class IV: medium phosphorus (5-9% P) : widely used in wear resistance and corrosion resistance occasions

V: high phosphorus (> 10%) : excellent salt spray and acid resistance on various occasions. Coatings with phosphorus content greater than 11.2% are considered magnetic.

2.2 Classification according to thickness usage conditions:

SC0 0.1 m — Minimum conditions SC1 5 m — Conditions for light load

SC2 13 m — Moderate conditions SC3 25 m — moderate conditions

SC4 75 m — Severe conditions of use

2. 3 Classification according to post-plating heat treatment:

Class 1 — Deposited, no heat treatment

Class 2 — Minimum hardness of 850HK produced by heat treatment at 260~400 ℃

Class 3 — Heat treatment at 180~200 ℃ for 2~4 hours to improve the coating adhesion of steel and prepare for the elimination of hydrogen embrittlement.

Class 4 — Increase the adhesion (binding force) of aluminum alloy and carburized steel by heat treatment for more than 1 hour at 120~130 ℃.

Class 5 — Improve the adhesion of coating of aluminum, non-aging hardening aluminum alloy, copper and copper alloy at 140~150 ℃ for more than 1 hour.

Note: The hardness requirement of ball heat treatment is generally recommended for customers to choose between 500~650HV or 600~850HV or 850HV above.

2. 4 Component analysis:
   

Or analytical methods: The phosphorus content composition can be determined by atomic absorption, radiation or X-ray fluorescence spectrophotometry

2. 5 Thickness detection:

Methods: Mechanical measuring method, microscope method, magnetic induction instrument method, backscatterer method, micrometer method, weighing, plating,

Weighing method, electric quantity measurement method, X – ray spectrometric method.

2. 6 Adhesion test: Adhesion test methods: bending test, impact test, hot punching test, etc
3. 7 Hardness test:

Hardness testing with micro Vickers hardness or micro Nuop hardness tester.

2. 8 Porosity detection:

Rust agent test: 25g potassium ferricyanide +15g sodium chloride +1 l distilled water solution test

2.8.2 Boiling water test for iron base: refer to B733 for details

2.8.3 Test of aerated water in iron base: refer to B733 for details

The company is the world’s best Other Valve Related Components supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.