May 30, 2006, corrosion of valves is typically understood as the degradation of metal valve materials due to chemical or electrochemical interactions with their surrounding environment. Since corrosion occurs naturally when metals come into contact with their surroundings, one common approach has been to isolate the metal from its environment or to replace it with non-metallic synthetic materials. As we know, metal corrosion significantly affects the service life, reliability, and performance of valves. The combined effects of mechanical wear and corrosion can greatly increase surface damage and reduce the longevity of the valve.
During operation, the friction surfaces of a valve are subjected to both mechanical forces and chemical or electrochemical reactions with the surrounding medium. In complex environments such as oil, gas, and reservoir water, the presence of hydrogen sulfide, carbon dioxide, and organic acids accelerates the deterioration of metal surfaces, leading to rapid loss of functionality. The rate of chemical corrosion in metals depends on factors such as temperature, mechanical stress, the type of lubricant used, acid resistance, exposure time to the medium, and the catalytic effect of the metal during nitriding processes.
Because of these challenges, anti-corrosion methods for metal valves and the use of synthetic materials have become key areas of research in the valve industry. One way to protect metal valves is by applying protective coatings like paint, pigments, or lubricants. These coatings help prevent corrosion throughout the entire lifecycle of the valve—whether it's being manufactured, stored, transported, or in operation. The choice of coating method depends on the required protection period, storage conditions, valve design, and cost-effectiveness.
There are four main approaches to anti-corrosion for metal valves: using volatile corrosion inhibitors, applying water- or alcohol-based solutions, coating the surface with protective materials, and applying thin films or polymer coatings. Currently, many manufacturers rely on lubricants and water-resistant compounds for corrosion prevention.
Synthetic materials offer significant advantages over traditional metal valves in corrosive environments. They are lighter, more resistant to chemicals, and can be engineered to meet specific strength requirements based on fiber composition and arrangement. For example, glass or graphite-reinforced polymers are commonly used in chemical process valves. These materials include thermoplastics like PVC, PVDF, PPS, and thermosets such as polyester, epoxy, and vinyl ester resins. Thermosetting resins generally have better thermal stability than thermoplastics, making them suitable for high-temperature applications.
In terms of performance, synthetic materials often compare favorably with corrosion-resistant metals like 316SS and Hastelloy C. While their tensile strength may be lower, thicker sections and reinforced designs can match the performance of metal valves. Due to their durability, light weight, and corrosion resistance, synthetic valves provide an economical alternative to traditional metal or fiberglass piping systems in harsh environments.
The valve industry is now exploring a wide range of new materials, including ceramics (which can withstand temperatures above 1200°C), plastics with excellent corrosion resistance, advanced composites, and even shape-memory alloys that offer unique properties like high elasticity and temperature responsiveness. These innovations are driving the development of high-performance valves tailored for specialized applications. With ongoing advancements in material science and engineering, the future of valve technology looks promising and increasingly diverse.
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