| Alumina-Titania Coated Valve Balls | ||
| Size Range | 1/2" to 56" (Custom sizes available) | |
| Pressure Rating | PN10-PN420 (Class150-2500) | |
| Body Material | A105, A350 LF2, A182 F304, A182 F316, A182 F321, A182 F51, A182 F53, A182 F55, A182 F60, A182 F44, A564 630 (17-4PH) INCONEL625, INCONEL718, INCONEL825, Monel 400, Monel 500 etc |
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| Core Process/Coating | ENP,HCR,STL6, STL12, STL20,Cr3C2, WC-Co, WC-Cr3C2-Ni, TiC-NiMo, SiC, CrC,ZrO2, Al2O3, Cr2O3, ZnO, TiO, Al2O3-TiO2,STL1, STL6, STL12,Ni60, Ni55, Ni45 etc. | |
| Operating Temperature Range | ≤1200°C | |
| Parameter Category | Core Technical Parameters | Standards for Determining Advanced Technological Level |
| Machining ball accuracy | ≤ 0.025 mm | ≤ 0.005 mm (Ultra-High Precision) |
| Processing ball Roundness | ≤ 0.025 mm | ≤ 0.011 mm (Micron-Level ) |
| Balls concentricity | ≤ 0.025 mm | ≤ 0.005 mm (Ultra-High Precision) |
| Other supplements | ≤ 0.4 μm | ≤ 0.1 μm (Mirror-Level) |
| Parameter Category | Core Technical Parameters | Criteria for High-End Technical Level |
| Coating Thickness Control | Thickness Uniformity | Thickness deviation at any spherical position ≤±8% (stricter than the general ±10% standard) |
| Thickness Tolerance Range | 100 - 300 μm (common range for wear-resistant layers); special ranges can be noted. No missed spraying for ultra-thin coatings (<10μm) | |
| Coating Adhesion Performance | Surface Hardness | HV 1300+ |
| Bond StrengthBond Strength | ≥80 MPa | |
| Interface PorosityInterface Porosity | <0.5% | |
| Coating Surface Quality | Surface Roughness (Ra) | ≤0.2 µm |
| Spraying Accuracy (Positioning & Coverage) | Spraying Positioning Accuracy | ±0.1mm |
Core Products: Optimized for Wear Service with Higher Toughness Demands
AT13 Formulation: The Epitome of Classic Balance
Our widely used AT13 thermal spray coating ball refers to the alumina-titania composite material containing 13% titania. This classic formulation greatly optimizes the coating's comprehensive performance:
Significantly Enhanced Toughness & Thermal Shock Resistance: The introduction of TiO₂ effectively inhibits the propagation of micro-cracks within the coating, granting it higher fracture toughness and making it more capable of withstanding thermal shock and minor mechanical impact.
Improved Coating Bond Strength: This composite system forms a coating interface that bonds more strongly to the metal substrate, typically achieving 20%-50% higher bond strength than pure alumina coatings, fundamentally enhancing the coating's service reliability.
Maintained Excellent Wear Resistance: While sacrificing a small amount of absolute hardness, its wear resistance still far exceeds that of most metal alloys. It is particularly adept at resisting low-stress abrasive wear and erosive wear.
Conquering Adhesive and Fretting Wear Conditions
Thanks to its denser, smoother surface characteristics, the Alumina titania coated ball shows a significantly reduced tendency for the adhesion of certain sticky or fouling-prone media. Simultaneously, its excellent resistance to fretting wear makes it an ideal choice for valve applications subject to vibration or frequent minor cycling, effectively avoiding the issue of particle spallation common in brittle coatings.
Providing the Complete Core for Thermal Spray Wear-Resistant Ball Valves
We are committed to supplying proven, performance-matched core components for Plasma sprayed ceramic ball valves. Our Al₂O₃-TiO₂ Coated valve Ball can be paired with corresponding ceramic-coated seats, providing a consistent and reliable wear solution for the valve's entire friction pair, ensuring the overall performance and longevity of the valve in severe wear environments.
Wide Applicability Across Industrial Wear Sectors
From mining slurry pumping and fly ash handling in thermal power plants to slurry and powder conveyance in the chemical industry, our Wear resistant thermal spray ball has gained widespread recognition for its outstanding cost-effectiveness and reliability in numerous industrial scenarios involving medium-to-low stress scouring, corrosive wear, and fretting wear.
Technical Focus: Microstructure Control of Composite Ceramics via Plasma Spray
The superiority of the composite coating stems from our precise control over the powder melting, phase transformation, and deposition behavior during the spray process.
Powder Pre-Treatment & Feedstock Optimization:
We use specially agglomerated and sintered composite ceramic powders, ensuring uniform distribution of Al₂O₃ and TiO₂ within individual powder particles. This guarantees that both phases melt and deposit in a coordinated manner within the plasma plume, forming a uniform composite microstructure.
Process Parameter Matching to Regulate Phase Composition:
By precisely regulating the energy and atmosphere of the plasma, we control the degree of TiO₂ reduction during spraying, ensuring it exists in the coating in ideal non-stoichiometric titanium oxide forms (e.g., Ti₃O₅), which are key to enhancing coating toughness and bond strength.
Post-Coating Treatment to Optimize Surface State:
After spraying, we treat the coating surface through controlled mechanical polishing. This process not only achieves the smoothness required for sealing but can also form a dense "tribologically adapted" layer on the surface, further reducing the coefficient of friction and enhancing resistance to adhesive wear.
Why is TongBall's Alumina-Titania Coating Solution Trustworthy?
Deconstruction Experts for Complex Wear Conditions:
We excel at analyzing the multiple factors in wear mechanisms (scouring, fretting, adhesion) and providing targeted solutions like the Alumina-Titania Composite Coating, rather than simply recommending the hardest or most corrosion-resistant material.
Deep-Rooted Practitioners of Composite Ceramic Coating Processes:
We possess in-depth research and extensive practical experience in spraying the classic Al₂O₃-TiO₂ system, enabling stable reproduction of its excellent toughness and bonding characteristics, ensuring batch-to-batch consistency in product performance.
Focus on the Overall Wear Performance of the Valve System:
We provide not just individual wear-resistant balls but focus on the long-term stable operation of the friction pair system they form with the seats. Our coating solutions aim to achieve minimized and synchronized wear rates for the entire system.
When the Wear Environment Presents Implicit Demands for Component Toughness
If your valve faces challenges of vibration, thermal cycling, or mild media adhesion in addition to wear, then a surface that balances hardness and toughness may be a wiser, more durable choice. TongBall's Alumina-Titania Composite Coating Technology, with its exceptional engineering balance, provides a proven and reliable answer to this widely prevalent industrial wear challenge.
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