Method for manufacturing a valve body having one or more corrosion-resistant internal surfaces

Patent metadata

Field	Value
Publication number	US-11229947-B2
Application number	US-201916255467-A
Country	US
Kind code	B2
Filing date	Jan 23, 2019
Priority date	May 10, 2016
Publication date	Jan 25, 2022
Grant date	Jan 25, 2022

Abstract

A method of manufacturing a valve body having one or more corrosion-resistant internal surfaces. The method involves performing a casting process, which includes pouring a first material into a mold box, to produce a valve body casting made of the first material. During the casting process, a layer of a second material is formed on one or more internal surfaces of the valve body casting, the second material having a higher corrosion resistance than the first material, by: (1) applying, with an additive manufacturing technique, the second material to one or more external surfaces of a core, and (2) inserting the core into the mold box. A portion of the first material binds to the second material on the one or more external surfaces of the core while the first material is poured into the mold box.

First claim

The invention claimed is:

1. A valve body having a corrosion-resistant interior, comprising:
a body portion formed of a first material using a casting process; and
a layer of a second material formed on one or more internal surfaces of the body portion during the casting process, the second material having a higher corrosion resistance than the first material,
wherein the first material is carbon steel, and
wherein the second material is a carbon fiber reinforced material.

2. The valve body according to claim 1 , further comprising an inlet, an outlet, and a fluid passageway extending between the inlet and the outlet, wherein the fluid passageway is at least partially defined by the layer of the second material.

3. The valve body of claim 1 , wherein the carbon fiber reinforced material is formed on only one of the internal surfaces of the body portion.

4. The valve body of claim 1 , wherein the carbon fiber reinforced material is formed on more than one but less than all of the internal surfaces of the body portion.

5. The valve body of claim 1 , wherein the carbon fiber reinforced material is formed on all of the internal surfaces of the body portion.

6. A valve body having a corrosion-resistant interior, comprising:
a body portion formed of carbon steel using a casting process and defining a single inlet, a single outlet, and a fluid passageway extending between the single inlet and the single outlet; and
a layer of a carbon fiber reinforced material formed on one or more internal surfaces of the body portion during the casting process,
wherein the fluid passageway is at least partially defined by the layer of the carbon fiber reinforced material.

7. The valve body of claim 6 , wherein the carbon fiber reinforced material is formed on only one of the internal surfaces of the body portion.

8. The valve body of claim 6 , wherein the carbon fiber reinforced material is formed on more than one but less than all of the internal surfaces of the body portion.

9. The valve body of claim 6 , wherein the carbon fiber reinforced material is formed on all of the internal surfaces of the body portion.

10. A control valve, comprising:
a valve body having a corrosion-resistant interior, comprising:
a body portion formed of carbon steel using a casting process and defining an inlet, an outlet, and a fluid passageway extending between the inlet and the outlet; and
a layer of a carbon fiber reinforced material formed on one or more internal surfaces of the body portion during the casting process,
wherein the fluid passageway is at least partially defined by the layer of the carbon fiber reinforced material;

a valve trim assembly comprising a flow control member, a valve stem, and a valve seat; and
an actuator assembly configured to operably position the flow control member within the valve body.

11. The control valve of claim 10 , wherein the carbon fiber reinforced material is formed on only one of the internal surfaces of the body portion.

12. The control valve of claim 10 , wherein the carbon fiber reinforced material is formed on more than one but less than all of the internal surfaces of the body portion.

13. The control valve of claim 10 , wherein the carbon fiber reinforced material is formed on all of the internal surfaces of the body portion.

Assignees

• Fisher Controls Int Llc

Inventors

• Lai Tan K
• Siang Chong S

Classifications

• B22C9/10 Primary

  Cores; Manufacture or installation of cores {(breaker cores B22C9/084)} · CPC title

• Y02P10/25

  Process efficiency · CPC title

• B22F10/25

  Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS] · CPC title

• B22F10/28

  Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] · CPC title

• B22C3/00

  Selection of compositions for coating the surfaces of moulds, cores, or patterns · CPC title