Wear-Resistant Nickel alloy forged gate valve

Wear-Resistant Nickel Alloy Forged Gate Valve is a specialty control valve that combines the corrosion resistance of nickel alloys, the high strength of forging, and the flow advantages of gate valves. It is specifically designed for severe operating conditions involving particulate-laden, highly corrosive, high-temperature, and high-pressure media. It is suitable for chemical, mining, and oil & gas transportation industries, providing reliable flow control and system isolation for corrosive media containing solids. The valve’s core advantages include wear and corrosion resistance, robust structure, and high flow efficiency, effectively addressing common industry challenges such as valve wear, corrosion-induced leakage, and high flow resistance.

Structural design focuses on wear resistance, corrosion resistance, and forged strength:

• The valve body is made from premium corrosion-resistant nickel alloys such as Monel (Monel 400/K-500), Hastelloy (C-276/C-22), or Inconel (625/825), formed by full forging. This process ensures high density, uniform microstructure, and eliminates porosity and sand inclusions. Mechanical strength is improved by over 30% compared to cast valves, enabling long-term resistance to corrosive media and particulate impact.

• The gate is forged from the same nickel alloy as the body, with a surface coated via supersonic flame spraying of WC-Co (tungsten carbide-cobalt) wear-resistant layer (thickness 0.8–1.2 mm, hardness ≥ HRC65, bond strength ≥ 70 MPa). The sealing surfaces are overlaid with Stellite 6, forming a “nickel alloy substrate + wear-resistant coating + hard seal” composite structure that enhances both wear resistance and corrosion protection.

• The sealing system uses a “metal hard seal + elastic compensation” design. Seats are made from nickel alloy base overlaid with hard alloy, combined with an Inconel spring preload mechanism that automatically compensates for wear and thermal deformation. Leakage meets ANSI B16.104 Class V standards.

• The stem is integrally forged from nickel alloy, nitrided, and uses dual packing of flexible graphite and PTFE to prevent leakage along the stem. Actuation options include manual, electric (explosion-proof), and gear-driven, suitable for different control needs.

Key technical parameters:

• Nominal sizes: DN25–DN400 (1"–16")

• Pressure ratings: PN10–PN420 (Class 150–2500 LB)

• Operating temperature: –196 °C to 550 °C (suitable for cryogenic particulate media at low temperatures, and high-temperature chemical processes)

• Wear resistance: ASTM G65, suitable for solid particles ≤ 5 mm

• Corrosion resistance: NACE MR0175/MR0103, suitable for pH 0–14 strong acids/bases, and Cl⁻/H₂S/CO₂-containing corrosive media

• Connections: Flanged (ASME B16.5, GB/T 9113), butt-welded; sealing surfaces support RF and RTJ types

Manufacturing and testing strictly follow API 6D, ASME B16.34, and API 598 standards. Each valve undergoes wear erosion tests, corrosion immersion tests, hydrostatic strength tests, and non-destructive inspections (UT/RT/MT) to ensure suitability for severe operating conditions.

Performance advantages:

1. Dual wear and corrosion resistance – nickel alloy body resists corrosion, wear coating and hard seal withstand particulate abrasion; service life is 4–6 times longer than standard gate valves.

2. High structural strength – fully forged construction provides excellent pressure and impact resistance, eliminating risks of deformation or leakage.

3. High flow efficiency – fully open gate valve design with flow coefficient ≤ 0.3 and low pressure drop, ideal for transporting particulate-laden media.

Applications: Suitable for chemical particulate-laden acid/base solutions, mining tailings, sand-containing oil & gas media, offshore seawater treatment, etc. Typical installations include chemical reactor inlets/outlets, mining pipelines, oilfield production pipelines, and acid/alkali storage tank outlets in particulate corrosive conditions. It is critical for ensuring stable operation under severe environmental conditions.