Development of innovative valve components for operation in extreme environments
In industries with severe processes, such as offshore platforms or chemical plants where corrosive mixtures of gas, saltwater, fuels, and suspended solids are present, flow control valves must operate safely and reliably under conditions that far exceed standard market specifications.
Extreme environments characterized by highly corrosive conditions, marine exposure, sudden pressure fluctuations, and temperatures below -10°C represent a critical challenge for the reliability of flow control systems.
In this context, quarter-turn mechanical actuators are key components for operational safety, as they multiply and transmit the valve closing torque. A failure in the actuator could lead to serious and costly operational incidents.
Given the lack of standard commercial solutions capable of operating under these extreme conditions, AZTERLAN and Meshind are supporting Talleres Larrinaga, a manufacturer of valve components, in the development of a new range of actuators specifically designed for corrosive and cryogenic environments, with high reliability and durability requirements.
A new product range with enhanced resistance to corrosion and cryogenic temperatures
Main objective: to develop actuators capable of operating in environments where the following conditions coexist:
- Aggressive corrosive media (saltwater, acids, alkalis, and abrasive substances).
- Low temperatures representative of extreme climates.
A strategy based on the combination of advanced design, laser cladding techniques, and rigorous testing on critical components (cover, housing, shaft, and gear), along with prototype development, has been implemented.
Activities performed:
- Manufacturing of custom NiTi metallic powder with high sphericity characteristics for surface modification.
- Production of components through controlled cladding using INCONEL 625 superalloy powder, optimizing geometries and minimizing corrosion-prone areas.
- Prior simulations of mold filling and solidification for complex parts.
- Redesign of preforms and CAD adjustments to incorporate efficient cladding strategies in functionally critical areas.
- Characterization and validation tests:
- Characterization of material and metallic powder: microstructural analysis (SEM) and chemical composition of NiTi and INCO 625 powders.
- Salt spray testing according to ASTM B117 and UNE EN ISO 9227 standards on developed prototypes.
- Electrochemical testing in synthetic seawater: polarization curves to evaluate corrosion thermodynamics and kinetics of coated surfaces.
Valve actuator components (shaft and gear) with NiTi coating for operation in highly corrosive environments.
- 9 new actuator models developed and prototyped.
- Integration of laser cladding manufacturing processes improving corrosion resistance and low-temperature performance.
- Definition of innovative design criteria based on corrosion-resistant superalloy cladding.
The final results indicate substantial improvements in:
- Operational reliability in aggressive environments.
- Durability of critical components.
- Product competitiveness compared to standard and low-cost solutions.