HARD COATINGS USED IN VALVES

CONTENT Page
1 Introduction 1
2 Selection of trim coatings 2
2.1 Chemical coatings 2
2.1.1 Hard Chromium 2
2.1.2 ENP (Electroless Nickel Plating) 3
2.2 Thermal coatings 3-4
2.2.1 Flame Spraying and Fusing 4-5
2.2.1.1 Flame spray and fusing coating Nickel based 5
2.2.1.2 Flame spray and fusing coating Tungsten carbide based 5
2.2.1.3 Flame spray and fusing coating Cobalt based 6
2.2.2 High Velocity Oxygen Fuel (HVOF) 7
2.2.2.1 HVOF coating chromium carbide based 8
2.2.2.2 HVOF coating tungsten carbide based 8
2.2.3 Atmospheric Plasma Spraying (APS) 9-10

1. Introduction

Valves used in severe services, as example in oilfield or mining applications are subjected to hostile
operating conditions. They must be corrossion resistante, be able to withstand high pressures, high
temperatures, and resist erosive and abrasive wear. The critical parts of the valve that are most
vulnerable to these conditions are the trim, seats and stem. Especially the trim and the seats are
exposed to the condiciones at all times and must maintain a tight seal when opened or closed.

The coatings widely used for valves include chemical and thermical coatings, all of which provide a
hard surface with much better resistance to abrasion compared to uncoated parts.

Metal seated ball valves achieve sealing by metal to metal contact between the trim and the seat.
When “soft” metals (like stainless steel) of similar hardness slide against each other under even
moderate pressure, the surfaces are scratched. Microscopic protrusions on the seating surfaces catch
on each other, resulting in surface friction, heat buildup and plastic deformation. Typically the damage
gets worse as the valve cycles until it becomes inoperable due to seizure. If no coatings are applied to
the trim, galling will be visible almost as soon as the valve is cycled on the test bench.

Once installed in service, the various effects of difficult media would increase wear rate exponentially.
Properly selected coatings reduce the friction between the trim and the seats allowing for smooth
sliding operation over many numerous cycles, minimizing damage and wear due to galling, abrasion,
erosion, particle impact, cavitation and thermal swings. Reducing friction in the trim lowers the valve’s
operating torque which has several advantages.

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 2. Selection of trim coatings

Valve body, trim and seats materials are selected based on factors such as pressure, temperature and
chemical compatibility. These criteria must also be considered when choosing trim coatings. Improper
selection can cause almost instant failure of the valve upon startup. It is also important to note that
properly selected trim coatings cannot make up for unsuitable base materials. Most coatings are
porous to some degree and do not isolate the base material against the effects of corrosive media.
Base material and coating must both be selected to meet the demands of the application and are
compatible to the form of application.

2.1 Chemical coatings

Chemically applied coatings, e.g. electrolitically have generally a high corrossion resistance, but a lower
mechanical resistance than thermical coatings. The most used are:
• Hard chromium
• ENP (Electroless Nickel Plating)

2.1.1 Hard Chromium

Hard Chromium is the standard coating and is suited to a wide range of applications in liquids and
gases at moderate temperatures and pressures. Corrosion resistance of HCr is generally comparable
with stainless steels. HCr do not resist strong acids like hydrochloric acid (HCl), hydrofluoric acid (HF)
or sulfuric acid (H2SO4), and it should not be used with seawater, wet chlorine or other media with
high chloride content.

Characteristics

Suitable base materials Stainless steels, nickel base alloys

Composition Chrome
Thickness < 50 µm
Maximum temperature 350°C
Hardness 70 HRC
Chemical resistance pH > 1

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2.1.2 ENP (Electroless Nickel Plating)

Electroless Nickel Plating (ENP) is the deposit of a nickel-alloy coating by chemical reduction – without
the electric current that’s used in electroplating processes.
The majority of ENP for engineering purposes is a nickel phosphorus deposit containing up to 14%
phosphorus.

The higher the phosphorus content the greater the corrosion resistance, however the compromise on
increased phosphorus content is a decrease in hardness.

ENP is being widely applied in valve ball production with its advantages such as simple processing, low-
cost, uniform thickness and large-area plating of the stem, trim and seats. Many clients will specify
A105/ENP because they believe it to be a more cost-effective option than a full stainless-steel trim.
The surface hardness of the ENP is quite high, the strength of the substrate is often the limiting factor,
especially in the instance where line scale, sand or similar is caught between the trim and the seat.
Once the ENP coating is compromised a failure will not be long in coming.

Characteristics

Suitable base materials carbon steel

Composition Nickel (Ni) + 10,5 to 13 % phosphorous (P)
Thickness < 75 µm
Maximum temperature 350°C
Hardness 70 HRC
Chemical resistance pH > 4,5

2.2 Thermal coatings

“Thermal spraying” or “thermal coating” is the collective term for a variety of methods, all of which
essentially involve metal, ceramic or composite materials being melted using a flame, electric arc,
laser beam etc. and bonded to a surface using expansion or discharge pressure (air or gas pressure).

Some methods make use of high velocities (kinetic energy): The coating material thus “splatters” on
impact with the roughened surface and mechanically digs into it. Other methods use extremely high
thermal energy and need a separate fusion process after molten particles or droplets have been
sprayed onto the surface. In such cases, fusion creates a metallurgical bond between the sprayed
droplets and the base material. The coating material has a variety of forms such as wire, granulate or
powder. All methods use some form thermal energy and a spraying system to expose the initial
material to a high temperature and thus set it in motion (releasing kinetic energy). Laser-based
methods use pure thermal energy to complete the welding process.

Different parameters such as temperature, velocity and particle/droplet size must be applied
depending on the method used. This fact alone clearly shows that each method is subject to its own
physical laws, and that each one can, as a result, produce widely differing characteristic or physical
properties such as hardness, concentration, adhesion and other coating properties.

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 The symbiosis between method, base material and the design of the parts to be coated is extremely
important to these methods. This symbiosis is responsible for the often excellent and, indeed, unique
properties of the finished product.

Subsequent treatment is the real art to manufacturing prefinished metal sealing systems. Such
treatment is imperative if – depending on the various factors of influence and operating conditions –
sealing systems that are impervious to gases and are to be produced in compliance with the required
leakage rate.
The most common technologies used for applications in valves are:
• Flame Spraying and Fusing
• HVOF (High Velocity Oxygen Fuel)
• APS (Atmospheric Plasma Spraying)

2.2.1 Flame Spraying and Fusing

Consists in the melting of the coating material by the combustion of fuel gas and oxygen and
accelerating of the particles by expansion of the flue gas.
A subsequent fusing of the coating at temperatures of 1000-1100°C in a vacuum oven eliminates
porosity and gives an excellent adherence due to metallurgical bond (diffusion)
Base materials are limited to self-fluxing alloys Stainless steel, Ni- or Co-based alloys

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Advantages
• A wide variety of spraying materials
• The coating system is impervious to gases and liquids
• Non-porous coating layers
• Strong wear-resistance when subject to linear, concentrated and distributed stresses
• Powerful adhesive strength
• Metallurgical bond to the base material
• Coating lends itself to subsequent treatment (turning, milling, grinding and lapping)
• Strong resistance to corrosion by caustic solutions, weak acids and aqueous solutions

Disadvantages
• Partial coatings are not possible
• Chrome steel is not suitable for metallurgical bonding
• The base material is subject to significant temperature stresses
• The component geometry is subject to restrictions

Applications
• Severe service
• High operating cycles
• High pressure
• Low temperature (< -40°C)
• Low leakage rates
• Resistance to high thermal cycling and shock

2.2.1.1 Flame spray and fusing coating Nickel based

Suitable base materials self-fluxing alloys

Composition 70%Ni / 17%Cr / 4%Fe / 4%Si
Thickness < 600 µm
Maximum temperature 750°C
Hardness 58 / 62 HRC
Bond strength > 150 MPa

2.2.1.2 Flame spray and fusing coating Tungsten carbide based

Suitable base materials self-fluxing alloys

Composition 50%WC / 26%Ni / 7%Cr / 3,5%Si
Thickness < 600 µm
Maximum temperature 750°C
Hardness 62 / 65 HRC
Bond strength > 150 MPa

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2.2.1.3 Flame spray and fusing coating Cobalt based

Suitable base materials self-fluxing alloys

Composition 42%Co / 13%Ni / 19%Cr / 15%W / 3Si
Thickness < 600 µm
Maximum temperature 800°C
Hardness 59 / 62 HRC
Bond strength > 150 MPa

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2.2.2 High Velocity Oxygen Fuel (HVOF)

Consists in the melting and acceleration of the spray particles by high pressure combustion of fuel and
oxygen and spray through special designed expansion nozzles that lead to supersonic gas and particle
velocities (up to 900m/s).

The short dwell time in the flame minimizes decomposition and oxidation of the coating material
obtaining a low porosity (<1-2%) and good bond strength (>75Mpa).
Most versatile process regarding coating selection and base materials.
Low thermal load of the coated parts eliminates shape distortion

Advantages
• Applicable on any metallic base material
• Highest hardness and wear resistance

Disadvantages
• Some porosity and mechanical bond
• Cracking and spalling happen very seldom

Applications
• General service
• For gas pressure <150bar
• Moderate operating cycles
• Higher leakage rates for gas at pressure >150 bar

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2.2.2.1 HVOF coating chromium carbide based

Suitable base materials Any metal

Composition Chromium Carbide with Nickel Chromium Matrix Cr3C2-NiCr 75:25
Thickness < 200 µm
Maximum temperature 650°C
Hardness > 68 HRC
Bond strength > 75 Mpa

2.2.2.2 HVOF coating tungsten carbide based

Suitable base materials Any metal

Composition WC 10Ni 5Cr
Thickness < 200 µm
Maximum temperature 450°C
Hardness > 70 HRC
Bond strength > 75 Mpa

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2.2.3 Atmospheric Plasma Spraying (APS)

This type of application is used mainly for ceramic coatings.

The melting and acceleration of the spray particles is produced by high and hot plasma gas
flow (up to 20000K).
Special designed expansion nozzles lead to supersonic gas and particle velocities (up to
450m/s).
Short dwell time in the flame minimizes decomposition and oxidation of the coating material
Porosity (1-10%).

Good bond strength (>45Mpa).

Low thermal load of the coated parts eliminates shape distortion.

Advantages
• Applicable on any metallic base material
• High hardness and wear resistance
• Highest corrosion resistance

Disadvantages
• Porosity and lower mechanical bond and danger of brittle
• Cracking and spalling happen very seldom

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Suitable base materials Any metal
Composition Bond coating: Ni Cr
Top coating: TiO2 (99,9%)
Thickness Bond coating: 0,1 mm
Top coating: 0,2 mm
Maximum temperature 450°C
Hardness 58 / 63 HRC
Bond strength > 45 Mpa

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