In industries such as petrochemical, offshore engineering, and sewage treatment, ball valves often face the challenges of complex working conditions such as acid-base corrosion, electrochemical corrosion, and erosion corrosion. The corrosion of valves not only affects their sealing performance and service life, but may even trigger safety accidents such as leaks. Therefore, it is of utmost importance to improve the corrosion resistance of ball valves.
Materials form the basis for determining the corrosion resistance of ball valves. For different complex working conditions, it is necessary to rationally select corrosion-resistant materials. In strong acid and alkali environments, Hastelloy can be selected. It exhibits excellent corrosion resistance to various oxidizing and non-oxidizing acids, alkalis, salt solutions, as well as wet chlorine gas under high temperature and high pressure. Titanium alloys perform outstandingly in the application of ball valves in the marine engineering field due to their good seawater corrosion resistance and crevice corrosion resistance. For working conditions with solid particles that are prone to erosion corrosion, ceramic materials can be used. They have high hardness and strong wear resistance, effectively resisting corrosion damage to valves caused by erosion. In addition, duplex stainless steel combines the advantages of austenitic stainless steel and ferritic stainless steel, featuring high strength and good pitting and crevice corrosion resistance, making it suitable for a variety of complex corrosion environments.
Surface treatment can form a protective film on the surface of ball valves, further enhancing their corrosion resistance. Electroless nickel-phosphorus alloy plating is one of the commonly used surface treatment technologies. Through chemical deposition, a uniform and dense nickel-phosphorus alloy layer is formed on the valve surface. This layer has good chemical stability and wear resistance, which can significantly improve the corrosion resistance of ball valves. Thermal spraying technologies, such as supersonic flame spraying of ceramic coatings and arc spraying of metal coatings, can quickly form a high-hardness and corrosion-resistant coating on the surface of ball valves, isolating the contact between the medium and the base material. There is also surface passivation treatment. Through chemical or electrochemical methods, an extremely thin passivation film is formed on the surface of ball valves, reducing the activity of the metal and improving its corrosion resistance.
A rational structural design can help reduce the occurrence of corrosion. Optimize the flow channel design of the ball valve to prevent the formation of vortices and dead corners of the medium inside the valve, thus reducing the scouring and local corrosion of the valve by the medium. Improve the sealing structure, use corrosion-resistant sealing materials, and optimize the design of the sealing surface to enhance the sealing performance and prevent corrosion problems caused by medium leakage. For parts prone to crevice corrosion, such as the connection between the valve body and the valve cover and the contact between the ball and the valveseat, reasonable clearances and drain holes can be designed to avoid medium accumulation and reduce the risk of crevice corrosion. In addition, design the structure of the ball valve to be detachable, which facilitates replacement and maintenance in case of local corrosion and extends the overall service life of the valve.
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