| Stellite 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: High-Performance Metallurgical Overlays Engineered for "Wear"
Stellite alloy is a cobalt-based superalloy renowned for retaining extreme hardness and excellent resistance to various wear types at high temperatures. Our core expertise lies in perfectly overlaying it onto the valve ball substrate.
Grade Selection for Different Wear Mechanisms
We offer hardfacing services with various Stellite alloy grades to precisely match your operating conditions:
- STL6 Balls for ball valve: Exhibits outstanding resistance to metal-to-metal wear and mild impact, with high hardness and good corrosion resistance. Suitable for conditions involving friction, fretting, and moderate-temperature corrosion.
- STL12 Coated Ball: Offers enhanced impact toughness and thermal fatigue resistance while maintaining good corrosion resistance. A superior choice for handling high-temperature/pressure steam, solid particle erosion, and thermal cycling conditions.
Metallurgical Bonding Beyond "Coating"
Unlike electroplating or spraying, our Stellite Coated Balls are created by fusing the Stellite alloy with the substrate (typically stainless or heat-resistant steel) through high-temperature hardfacing processes like Plasma Transferred Arc (PTA) welding. This creates a transition layer with low dilution and extremely high bond strength, ensuring the overlay will not spall under severe thermal stress or mechanical shock.
Stable Barrier Against High-Temperature Oxidation
Stellite alloys retain their hardness and oxidation resistance at temperatures up to 1000°C. This makes our Alloy Coated Balls ideal for critical applications such as high-temperature vent valves, catalytic cracking units, and high-temperature steam systems, effectively preventing rapid failure due to high-temperature softening and oxidation.
Turnkey Finished Product Delivery
We provide not just the hardfacing service but the complete manufacturing process, including substrate machining, overlaying, stress relieving, precision machining, and final grinding/polishing. The delivered Stellite Balls are finished products meeting all dimensional and performance specifications, ready for immediate assembly.
Technical Focus: The Overlay Process for Achieving High-Strength Metallurgical Bonding
The quality of a Stellite overlay depends on precise control over heat input, dilution rate, and solidification.
Low Heat Input & Dilution Rate Control:
We employ high-energy-density plasma arc as the heat source, enabling rapid melting and solidification. This minimizes the heat-affected zone on the substrate and strictly controls the proportion of base material melting into the overlay (dilution rate), ensuring the overlay retains the optimal original properties of the Stellite alloy.
Multi-Layer Overlaying & Crack Prevention:
For thick overlay requirements, we employ specialized multi-layer hardfacing techniques. Through precise interpass temperature control and compositional design, we ensure perfect bonding between layers and effective relief of internal stresses, fundamentally preventing crack formation in the overlay.
Post-Overlay Heat Treatment & Machining:
Following overlaying, we perform stress relief annealing to stabilize the structure. Subsequently, using specialized grinding processes for high-hardness materials, we finish the ball to achieve exceptional spherical accuracy and surface finish, meeting the sealing requirements of high-precision valves.
Why Trust TongBall's Stellite Overlaid Valve Balls for Extreme Wear Service?
Overlay Process Experts, Not Just Welders:
We possess deep knowledge of the molten pool characteristics and phase transformation rules of different Stellite grades, enabling us to match process parameters with material properties and part geometry for optimal metallurgical bonding and coating performance.
Turnkey Solution Capability from Material Selection to Finished Product:
We can recommend the most suitable grade (STL6, STL12, etc.) based on your specific wear type (abrasive, erosive, fretting, high-temperature) and are responsible for the final precision manufacturing, ensuring the overlay performance is fully realized in the finished product.
Providing a Fundamental Solution for "No-Fail" Conditions:
When wear is the primary cause of valve failure, changing the base material or applying conventional surface treatments often addresses symptoms, not the root cause. Our Stellite Alloy Overlaid Valve Balls represent a fundamental reinforcement at the surface material level, designed to maximize the service life and reliability of critical valves.
When Wear and Heat Are the Primary Threats to Valve Life
If your valves are enduring relentless wear in slurry pipelines, coal chemical processes, high-temperature steam, or catalytic units, a high-performance surface based on metallurgical bonding may be the key to breaking through the lifespan bottleneck. TongBall's Stellite Alloy Overlaying Technology is dedicated to transforming top-tier wear-resistant alloys into the most durable working surfaces on your equipment.
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