Valve Industry Manufacturing Solutions
Valves are widely used in petrochemical, energy, electricity, water treatment, food and medicine industries, and their sealing performance, wear resistance, corrosion resistance and long-term reliability directly affect the safety and cost of the system.
Common Customer Challenges
- Inadequate stability of sealing surface geometry and roughness, leakage and sealing life fluctuations
- Difficult to control cracks, dilution rate and bond strength of hard surface layer (cladding/hardening)
- Improper selection of materials and coatings in corrosion-resistant media (acid/alkali/seawater/high temperature steam) scenarios
- The processing deformation of the valve body/valve bonnet and the deep cavity hole system, the coaxiality and positional degree are extremely different
- Deburring and cleanliness do not close the loop, residual particles in the valve cavity cause seal failure
- Assembly preload and seat-spool pairing not datatable, poor repeatability
Valve Industry Manufacturing Process
Raw Materials And Incoming Materials Inspection
- Verify alloy grade (CI/SS/Duplex/Hastelloy), casting integrity and dimensions; sample chemistry and hardness.
- Optical spectrometer, universal testing machine, CMM, ultrasonic flaw detector, hardness tester, metallographic microscope.
Casting/Forging Prep And Roughing
- Remove risers/flash, shot‑blast, and rough‑turn/mill datums on body, bonnet and seat rings.
- Swing frame grinder amchine, shot blaster, CNC lathe, milling machine, machining center.
Benchmarking And Critical Machining
- Establish reference faces and finish critical bores (stem/seat/guide) with on‑machine probing compensation.
- Horizontal boring milling machine, jig borer, machining center, on‑machine probe, precision fixturing.
Seat Hardfacing / Surface Hardening
- Apply laser cladding or induction/laser hardening on seat/sealing areas to specified thickness and hardness.
- Laser cladding machine, induction/laser hardening machine, pyrometer, hardness tester.
Precision Grinding / Lapping Of Sealing Faces
- Grind and lap sealing faces (seat/plug/ball/disc) to flatness and roughness targets for low leakage.
- Surface grinder machine, spherical/OD grinder, lapping machine, flatness gauge, surface roughness tester.
Stem / Shaft Finishing
- Finish stem journals, threads and key areas to runout, roundness and Ra targets.
- CNC lathe, OD grinder, thread grinder, polishing machine, CMM.
Deburring, Cleaning And Drying
- Perform robotic/electrochemical deburring, multi‑stage ultrasonic cleaning and vacuum drying to cleanliness targets.
- Robot deburring cell, ECM deburring unit, ultrasonic washer, high‑pressure sprayer, vacuum dryer, cleanliness tester.
Assembly And Setting
- Assemble seats/seals/stem/packing, set preload and torque, and verify alignment and contact patterns.
- Assembly benches/fixtures, torque wrench, feeler gauges, blueing kit, dial indicators.
Pressure / Leak And Functional Testing
- Run hydrostatic/shell/seat leakage tests per standard, then functional cycling and torque/NVH checks.
- Hydrostatic/leak test bench, pressure transducers, flowmeter, torque tester, NVH meter, data logger.
Final Inspection, Marking And Packaging
- Perform CMM/visual checks, laser mark IDs and traceability, apply anti‑corrosion protection and VCI packing.
- CMM, laser marking machine, barcode printer/scanner, VCI/vacuum packaging system.
Data Traceability And Quality Control
- Capture machining/cladding/heat‑treat/test data in MES/SPC for full traceability and rapid containment.
MES, data acquisition system, SPC software, QMS with barcode/RFID.
Our Solution
Valve Body/Bonnet (Castings/Forging)
- Process Points: Turning / Milling / Boring / Drilling + On-machine probe compensation + Low clamping force for fixtures
- Key Points: Reference reconstruction, thin-wall deformation control, hole system coaxiality/position degree; seal surface reserved amount and subsequent surface shape control
Seat (hard/sealing surface)
- Program Points: Laser cladding/hardening → Fine grinding/grinding/mixing
- Key Process: Laser cladding/hardening, control dilution rate and layer thickness; sealing surface grinds until low leakage
Spool/Ball/Plate
- Program Points: Five-axis/turning and milling composite → Fine grinding/super refined → Matching
- Key Process: Spherical/taper/flat shape accuracy and roughness; paired contact spots and seal lines
Stem (shaft type)
- Program Points: External precision grinding → Surface reinforcement/plating → Polishing
- Key Process: Journal coaxiality, roundness and roughness; wear/corrosion resistant surface treatment
Spring/Filling/Sealing Assembly
- Program Points: Standard part selection → Cleanliness treatment → Controlled assembly
- Key Process: Assembly preload torque and pore control; temperature and chemical stability
