Nov.07.2024
The manufacturing of valves typically involves two main processes: casting and forging. Fleyenda Flow will provide an in-depth analysis of the differences between cast valves and forged valves.
1. Cast Valves
Process Overview
Cast valves are produced by heating metal to a molten state, such as carbon steel with a casting temperature of around 1450°C. The molten metal is then poured into a specific mold. Once the metal cools and solidifies, the desired valve structure is formed. After solidification, the casting is removed from the mold and finished. Cast valves can be made into complex shapes and intricate designs, which are difficult to achieve with forged valves. This design flexibility allows for various configurations and sizes.
Applications of Cast Valves
Cast valves are typically used in medium- and low-pressure applications, as well as low-temperature environments. For example, wastewater treatment plants and water supply systems often use cast valves because these operations typically do not involve extreme conditions. Cast valves are also common in general industrial applications, including oil and gas distribution, chemical processing for non-critical applications, and other processes that do not involve highly corrosive or abrasive fluids.
General Industrial Use: Due to their relatively simple manufacturing process and lower cost, cast valves are suitable for general industrial applications.
Medium Pressure Systems: Cast steel valves are used in systems with operating temperatures not exceeding 425°C for medium to small diameters.
Lower Pressure Pipeline Systems: Cast iron valves, with higher carbon content making them brittle, are not suitable for high-pressure or high-temperature environments. They are primarily used in lower pressure and ambient temperature pipeline systems.
Special Environments: In certain specialized industrial environments, such as high-temperature, high-pressure, or corrosive conditions, cast valves have their uses. For example, cast titanium alloy valves are widely used in marine, aerospace, and chemical industries due to their excellent corrosion resistance, high-temperature, and low-temperature properties.
However, cast valves are less effective at preventing leakage compared to forged valves, especially fully forged valves, which perform better in applications where leak prevention is critical. Therefore, forged valves are more commonly used in high-leakage-risk environments.
2. Forged Valves
Process Overview
Forged valves are made by applying high pressure to solid metal materials in a heated state, shaping them into the required form. During the forging process, the grain structure of the material is refined to enhance the mechanical properties of the component. The grains are stretched and then softened, giving the steel a uniform structure and improved mechanical performance. Forged valves typically have fewer internal defects (such as porosity), making them suitable for high-pressure and high-temperature applications.
Applications of Forged Valves
Forged valves excel in systems involving extreme temperatures and pressures. From oil and gas production and petrochemical refining to power generation and steam systems, these applications typically require forged valves for their durability and strength.
3. Choosing Between Cast and Forged Valves
When choosing between cast and forged valves, you need to consider the specific application. Cast valves are better suited for applications that require complex shapes but lower strength, such as general industrial equipment. On the other hand, forged valves are more appropriate for high-pressure, high-temperature environments that demand superior mechanical performance, such as the oil, gas, or nuclear industries.
Conclusion
Both cast and forged valves have their unique advantages, and the key is to understand the specific application requirements. Fleyenda Flow, as a professional valve manufacturer, offers a wide range of high-quality cast and forged valves to meet various needs. Whatever industrial challenges you face, we are here to provide the best valve solutions.
