Cladded valve seat, assembly, and methods for cladding such seat
11473686 · 2022-10-18
Assignee
Inventors
Cpc classification
F04B53/1087
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16K1/42
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16K25/005
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B1/0461
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16K15/063
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B1/053
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B53/006
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
C23C24/103
CHEMISTRY; METALLURGY
F04B9/045
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F16K25/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
C23C24/10
CHEMISTRY; METALLURGY
F04B53/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B53/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16K1/42
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
This disclosure provides a valve seat having cladded surfaces of high hardness in order to improve the service life of valve seats. The cladded surfaces may include various materials of favorable mechanical properties for mitigating failure mechanisms known for common valve seats (e.g., having a common base metal throughout). In one example, the cladded surfaces are created using an additive manufacturing process, such as laser metal deposition. The cladded surfaces offer advantages including metallurgical bonding, localized low heat input at the laser focus (thus enabling accurate control of temperature and mitigating undesirable heat treatment effects), ductility in middle layers for increasing impact resistance, variable cladding thickness (optionally exceeding 1 mm), increased hardness by material and fusing temperature selections, corrosion resistance, modification of mechanical properties of the same selected material, and allowing for sensor embedment.
Claims
1. A valve seat comprising: a base supporting an engagement surface for receiving a valve, wherein the engagement surface includes a metal strike surface configured to engage with a metal surface of the valve and a contact surface configured to sealingly engage with a non-metal surface of the valve; a valve guide surface forming an inner surface in the base; and an external surface of the base for press fitting into a fluid cylinder; wherein the metal strike surface and the contact surface are cladded with a layer of fused metal disposed over and overlaying the entire engagement surface; and wherein the external surface of the base exposes a base metal having a hardness less than a hardness of the layer of fused metal of the metal strike surface.
2. The valve seat of claim 1, wherein the layer of fused metal of the metal strike surface of the engagement surface has a hardness no less than 62 HRc.
3. The valve seat of claim 1, wherein the layer of fused metal of the metal strike surface of the engagement surface comprises laser melted particles fused on top of the base metal of the base.
4. The valve seat of claim 1, wherein the layer of fused metal of the metal strike surface of the engagement surface embeds a sensor.
5. The valve seat of claim 1, wherein the hardness of the layer of fused metal of the metal strike surface of the engagement surface is variable through the selection of fused metal or fusing temperature.
6. The valve seat of claim 1, wherein the layer of fused metal of the metal strike surface of the engagement surface is machined or polished to provide a specific surface texture.
7. The valve seat of claim 1, wherein the layer of fused metal of the metal strike surface of the engagement surface is a cobalt-chromium alloy having carbon, tungsten, or molybdenum.
8. The valve seat of claim 1, wherein the layer of fused metal of the metal strike surface of the engagement surface extends through the base and forms the valve guide surface.
9. A valve assembly comprising: a fluid passage; a valve seat sealingly affixed to the fluid passage, the valve seat having an engagement surface and a base; and a valve body sealingly engageable with the engagement surface of the valve seat at a metal strike surface of the engagement surface and a contact surface of the engagement surface, wherein the engagement surface comprises a first layer of cladded metal fused on the base of the valve seat and overlaying the entire engagement surface, the first layer of cladded metal being more wear resistant than a base metal of the base, and wherein an external surface of the base exposes the base metal.
10. The valve assembly of claim 9, wherein the valve seat further comprises a valve guide surface forming an inner surface in the base; and the external surface of the base is configured for press fitting into a fluid cylinder.
11. The valve assembly of claim 10, wherein the external surface further includes a groove for receiving a sealing member, wherein the base metal has a hardness less than a hardness of the first layer of cladded metal of the metal strike surface of the engagement surface.
12. The valve assembly of claim 11, wherein the base metal is more ductile than the first layer of cladded metal.
13. The valve assembly of claim 12, wherein the base metal absorbs vibration and provides reinforcement to the first layer of cladded metal.
14. The valve assembly of claim 13, wherein the engagement surface further comprises a second layer of cladded metal different from the first layer of cladded metal, wherein the second layer of cladded metal is more wear resistant than the first layer of cladded metal.
15. The valve assembly of claim 14, wherein the second layer of cladded metal comprises tungsten not less than twenty percent by weight.
16. The valve assembly of claim 9, wherein the entirety of the external surface of the base exposes the base metal.
17. A method for manufacturing a valve seat having a wear resistant contact surface to sealingly engage a valve, the method comprising: providing a seat base of a base metal; depositing a first layer of powder of a first blend of metal onto the seat base; melting the first layer of powder locally as the first layer of powder is deposited onto and overlaying at least a portion of the seat base; machining the melted first layer of powder of the first blend of metal to conform to contour and texture requirements for the contact surface; depositing a second layer of powder of a second blend of metal onto the first layer of powder, the second blend of metal different from the first blend of metal; and melting the second layer of powder locally as the second layer of powder is deposited onto the first layer of powder.
18. The method of claim 17, wherein the second blend of metal includes the first blend of metal and tungsten carbide.
19. The method of claim 17, wherein providing the seat base of the base metal comprises preheating the seat base of the base metal to about 400 to 450 degrees Celsius.
20. The method of claim 17, wherein machining the melted first layer of powder of the first blend of metal comprises preserving a thickness of about 0.075 to 0.156 inches of the melted first layer of powder of the first blend of metal.
21. The method of claim 16, further comprising machining the melted second layer of powder of the second blend of metal to conform to contour and texture requirements for the contact surface.
22. A method for manufacturing a valve seat having an engagement surface, the method comprising: depositing, onto a seat base of a base metal, a first layer of powder of a first blend of metal; melting the first layer of powder locally as the first layer of powder is deposited onto the seat base to form a fused metal layer overlaying the entire engagement surface of the seat base while leaving the base metal of an external surface of the seat base exposed; and conforming the engagement surface to contour and texture requirements, wherein the engagement surface includes a metal strike surface configured to engage with a metal surface of the valve and a contact surface configured to sealingly engage with a non-metal surface of the valve.
23. The method of claim 22, further wherein conforming the engagement surface to contour and texture requirements includes performing at least one of (a) adjusting a deposition resolution as the first layer of powder of the first metal blend is deposited onto the seat base or (b) machining the fused metal layer.
24. The method of claim 22, wherein leaving the base metal of the external surface of the seat base exposed comprises leaving the entirety of the base metal of the external surface of the seat base exposed.
Description
DESCRIPTION OF THE FIGURES
(1) The accompanying drawings facilitate an understanding of the various embodiments.
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(9) Like numerals refer to like elements.
DETAILED DESCRIPTION
(10) This disclosure presents a valve assembly having composite layers of fused metals deposited onto a base metal. Such fused metal deposition may be referred to as “cladding.” In some embodiments, the composite layers of fused metals are deposited using laser metal deposition (hereinafter “laser cladding”), an additive manufacturing process enabling different metal powders to be added onto a base valve seat to achieve specific material composition and mechanical characteristics (e.g., ductility, hardness, toughness, etc.). In other embodiments, cladding may be achieved using other techniques, such as welding. According to some embodiments, a combination of metallic materials, including carbides, are deposited on the ware and impact sensitive areas aiming to increase service life of the valve seat and/or the valve body. A specific combination of different metal elements forming different cladding layers achieves a durable contact surface that exceeds the performance of a single element surface.
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(12) Referring first to
(13) In the embodiment illustrated in
(14) As illustrated in
(15) In the embodiment illustrated in
(16) Briefly, in the embodiment illustrated in
(17) In the embodiment illustrated in
(18) With continued reference to
(19) In the embodiment illustrated in
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(21) The proportion of the contact surface 310 and the strike surface 320 corresponds to specific designs of the discharge valve 30. In some embodiments, the contact surface 310 may be manufactured the same as the strike surface 320 for machining efficiency or other considerations. In other embodiments, the contact surface 310 may be distinct from the strike surface 320 for cost considerations. In the examples shown in
(22) The inner wall portion 102 of the valve seat 18 may also be treated with laser cladding. The hardness requirement of this inner wall portion 102 is less than that of the strike surface 320 because it experiences primarily sliding forces. For example, in some embodiments, the inner wall portion 102 has a hardness greater than 62 HRC for good performance of the valve seat 18. Due to manufacturing considerations, such as surface quality and machining efficiency, the inner wall portion 102 may have the same laser cladding treatment as the engagement surface, as provided in the example embodiment of
(23) The valve seat 18 further includes an external surface 340 for press fitting into a fluid cylinder in the fluid end housing 20. The external surface 340 has a hardness level of at least 58 HRC. In some embodiments, the base metal of the valve seat 18 has a hardness level satisfying the requirement of the external surface 340. In other embodiments, the hardness may be achieved using various heat treatment methods to increase the surface hardness of the base metal of the valve seat 18. The external surface 340 includes at least one groove 350 for placement of a sealing member for sealing the valve seat 18 against the fluid cylinder in the fluid end housing 20. For example, the groove 350 is configured to receive an O ring made of a flexible material. The groove 350 may be left untreated to have the mechanical properties of the base metal of the valve seat 18.
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(25) In
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(27) The intermediate layer 515 provides a bonding medium between the top layer 525 and the base material 505 and increases the overall toughness of the fused metal layer 410 or 420. The top layer 525 can be made with fused metal powers of about 70% first metal alloy and about 30% tungsten carbide. In other embodiments, the top layer 525 may include fused metal powers of about 40% first metal alloy and about 60% tungsten carbide. Other proportions by weight of different metal powders or blends may vary. For example, the percentage of tungsten carbide may vary between 30% and 60% (or a different range for achieving specific or tailored hardness and wear-resistance), while the first metal alloy makes up the remaining percentage. Such tailored top layer 525 of different metals may provide high hardness as well as strong wear resistance. In the current embodiments, the average hardness of the top layer 525 is at least 72 HRC.
(28) As shown in
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(31) After the valve seat 18 has been secured, at step 715, the base metal of the valve seat 18 may be preheated to a high temperature, such as about 400 to 450 degrees Celsius. In some embodiments, the preheating of the base metal of the valve seat 18 depends on the metal powder blends used in cladding. For example, some metal powder blends may require the base metal to be at similar temperatures during deposition to avoid undesired shrinkage or even cracking upon cooling and/or any undesired stress associated with the temperature differences. In some embodiments, the preheating may be applied locally or throughout the valve seat 18. In yet some other embodiments, the preheating step 715 may include multiple stages for heat treating different locations of the valve seat 18.
(32) At step 720, metal powders corresponding to the desired material composition is deposited onto the base material of the valve seat 18. The delivery of the metal powders may be achieved via gravity or airflow or other delivery methods (such as statics or magnetic forces). During the delivery of the metal powders, at step 730, a focused laser beam is applied to the traveling powders in order to melt the solid powders into liquid state. The liquid state metal powders are then fused onto the base metal of the valve seat 18 and onto each other, forming a molten layer of metal, which soon cools down and solidifies.
(33) During the deposition of the metal powders and fusing operation at steps 720 and 730, the valve seat 18 is rotated to feed the fused metal layer onto desired locations in specified orientations at step 740. For example, the fused metal layer may be deposited along the radial direction of the valve seat. Finally at step 750, layers of fused metal are deposited in sequences to form complete coverage layer. In some embodiments, multi-level or multiple layers may be deposited and fused on top one another by repeating the steps 720 through 740, such as the example shown in
(34) Furthermore, while in certain embodiments, valve assemblies have been described herein to operate in conjunction with reciprocating pumps in the presence of highly abrasive fluids, such as fracturing fluids, it is to be understood that many other applications for said valve assemblies lie within the scope of the invention. For example, the valve assemblies can be used in pumps pumping drilling fluid directly into the well bore, mining slurry through a pipeline, in pumps that are used to plump fluid with fluid particulars, or in applications other than pumps.
(35) In the foregoing description of certain embodiments, specific terminology has been resorted to for the sake of clarity. However, the disclosure is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes other technical equivalents which operate in a similar manner to accomplish a similar technical purpose.
(36) In the specification and claims, the word “comprising” is to be understood in its “open” sense, that is, in the sense of “including”, and thus not limited to its “closed” sense, that is the sense of “consisting only of”. A corresponding meaning is to be attributed to the corresponding words “comprise”, “comprised” and “comprises” where they appear.
(37) In addition, the foregoing describes only some embodiments of the invention(s), and alterations, modifications, additions and/or changes can be made thereto without departing from the scope and spirit of the disclosed embodiments, the embodiments being illustrative and not restrictive.
(38) Furthermore, invention(s) have described in connection with what are presently considered to be the most practical and preferred embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the invention(s), as defined solely by the appended claims. Also, the various embodiments described above may be implemented in conjunction with other embodiments, e.g., aspects of one embodiment may be combined with aspects of another embodiment to realize yet other embodiments. Further, each independent feature or component of any given assembly may constitute an additional embodiment.