Customized High-Temperature Alloy Bends for Industrial Use

Product Application: Customized High-Temperature Alloy Bends in Industrial Systems

Customized high-temperature alloy bends are essential components in industrial piping systems, enabling smooth directional changes in high-temperature fluid or gas flows. WALKSON’s bends are engineered for the following applications:

· Petrochemical Industry:

Reforming Furnaces and Hydrogenation Heaters: Bends manage hot gas flows at temperatures up to 950°C, resisting corrosive hydrocarbons and hydrogen-rich environments.

Styrene Steam Superheaters: Ensure reliable flow redirection in high-temperature steam systems, withstanding thermal cycling and oxidation.

· Oil Refining Industry:

Catalytic Cracking Furnaces: Facilitate hydrocarbon flow in high-temperature cracking processes, enduring pressures up to 50 bar and carburizing conditions.

Atmospheric-Vacuum Distillation Units: Support high-temperature crude oil processing, maintaining integrity in corrosive environments.

· Metallurgical Industry:

Cold Rolling Continuous Annealing Lines: Bends connect radiant tubes and burners, handling high-temperature gases and thermal stress.

Rotary Hearth Furnaces: Enable gas flow in screw discharging systems, resisting abrasive residues and extreme heat.

· Additional Applications:

 Heat exchangers, pressure vessels, and EDC cracking furnaces in refining projects, where bends ensure robust performance under high-temperature conditions.

These bends are designed to operate in extreme environments, including temperatures up to 1000°C, pressures up to 50 bar, and exposure to corrosive and erosive media, delivering unmatched reliability in industrial systems.

Functions of WALKSON Customized High-Temperature Alloy Bends

WALKSON’s customized high-temperature alloy bends provide critical functionality in industrial systems:

· Efficient Flow Redirection: Precision-engineered bends ensure smooth, low-resistance flow transitions, optimizing system performance and energy efficiency.

· Extreme Heat Resistance: Crafted from high alloy and nickel-based materials (e.g., Inconel 600, Hastelloy C22, HP alloys), bends maintain structural stability at elevated temperatures.

· Corrosion and Wear Protection: Nickel-based alloys shield against oxidation, sulfidation, and carburization, ensuring durability in aggressive environments.

· Robust Mechanical Performance: The centrifugal casting process yields a compact, uniform microstructure, enhancing creep resistance and structural strength.

· Bespoke Configurations: Available in custom angles (e.g., 45°, 90°), diameters, and wall thicknesses to suit specific piping system designs.

Manufacturing Process: Excellence and Standards Compliance

WALKSON’s customized high-temperature alloy bends are produced using cutting-edge technology and strict adherence to international standards, reflecting our ISO 9001, ISO 14001, ISO 45001, and O/TSY 1002.1 certifications. Below is a detailed overview of the production stages, leveraging our expertise as a high-tech enterprise with 11 state invention patents, including centrifugal casting technology for Inconel 600:

1. Material Procurement and Verification

· Standards: ASTM A351, ASTM A494, DIN EN 10295, and client-specific requirements.

· Materials: High alloy steels (e.g., HH, HK) and nickel-based alloys (e.g., Inconel 625, Hastelloy B2).

· Process: Materials are sourced from certified vendors and analyzed for chemical composition per ASTM E350 to ensure alloy purity and compliance.

· Equipment: High-precision optical emission spectrometers for material analysis.

2. Alloying and Melting

· Standards: ISO 9001 and ASME Section IX for melt quality assurance.

· Process: Alloys are melted in electric arc or induction furnaces, purified to remove contaminants, and conditioned for uniform composition.

· Equipment: High-efficiency electric arc furnaces (EAF) and vacuum induction melting systems.

· Quality Control: Melt samples are tested to meet ASTM E350 standards.

3. Centrifugal Casting

· Standards: ASTM A781, EN 12680, and API 934 for casting integrity.

· Process: Molten alloy is poured into a rotating mold shaped for the bend’s geometry. Centrifugal force compacts the material, forming a dense, defect-free component with a refined microstructure. This process, refined through our collaboration with the Chinese Academy of Sciences, ensures exceptional quality.

· Equipment: Automated horizontal centrifugal casting machines with precise control over rotation and temperature.

· Benefits: Produces bends with superior strength, thermal stability, and accurate geometry.

4. Thermal Processing

· Standards: ASTM A703, ASME Section VIII, and client-defined protocols.

· Process: Bends undergo heat treatments like solution annealing or tempering to optimize creep resistance, toughness, and corrosion properties.

· Equipment: Programmable heat treatment furnaces with real-time monitoring.

· Quality Control: Thermal cycles are tracked to comply with ISO 9001 standards.

5. Machining and Finishing

· Standards: ISO 2768 for dimensional accuracy, ASME B16.9 for fittings, and ASTM A999 for surface quality.

· Process: Bends are machined to precise specifications using CNC equipment, with surface finishes optimized for performance. Flanges or welded joints are added as needed.

· Equipment: CNC milling machines, lathes, and polishing systems.

· Quality Control: Dimensional checks are performed using coordinate measuring machines (CMM).

6. Quality Control and Testing

WALKSON’s rigorous testing protocols, supported by our comprehensive quality management system and partnerships with research universities, ensure bend reliability. We offer full transparency to clients and third-party inspectors (e.g., SGS, Bureau Veritas), with clients invited to witness all tests as outlined in our Inspection and Test Plan (ITP).

Non-Destructive Testing (NDT)

· 100% X-Ray Inspection:

Standard: ASTM E142, EN 12681.

Purpose: Detects internal flaws like voids, cracks, or inclusions.

Equipment: High-resolution digital X-ray systems.

Process: Full scanning of bends with detailed reporting of results.

· 100% Eddy Current Testing:

Standard: ASTM E309, EN 1971.

Purpose: Identifies surface and near-surface defects, such as micro-cracks or pitting.

Equipment: Multi-frequency eddy current testing units.

Process: Comprehensive surface testing for defect-free assurance.

· Ultrasonic Testing (UT):

Standard: ASTM A388, EN 12680.

Purpose: Verifies wall thickness consistency and internal integrity.

Equipment: Automated ultrasonic scanners with high-frequency probes.

Process: Full scanning to ensure structural compliance.

Destructive Testing (where applicable)

· Tensile Strength Testing:

Standard: ASTM E21.

Purpose: Evaluates strength and ductility under stress.

Equipment: High-capacity tensile testing machines.

· Creep Resistance Testing:

Standard: ASTM E292.

Purpose: Assesses performance under sustained high-temperature loads.

Equipment: Specialized creep testing ovens.

· Microstructure Analysis:

Standard: ASTM E1351.

Purpose: Verifies grain structure and material uniformity.

Equipment: Metallographic microscopes with digital imaging.

Hydraulic Pressure Testing

· Standard: ASME B31.3, API 934, and client requirements.

· Purpose: Confirms the bend’s ability to withstand design pressures (e.g., up to 50 bar for high-temperature systems).

· Process: Bends are pressurized with water to 1.5 times the design pressure and held to check for leaks or deformation.

· Equipment: Automated hydraulic testing systems with digital pressure gauges.

· Client Witnessing: Clients or third-party inspectors are invited to observe testing for compliance verification.

Documentation

· Inspection and Test Plan (ITP): Detailed ITP outlines all inspection and testing phases, available for client review.

· Welding Procedure Specification (WPS) and Procedure Qualification Record (PQR): Pre-qualified per ASME Section IX for welded components, provided upon request.

· Material Test Reports (MTR): Issued per EN 10204 Type 3.1 or 3.2, documenting chemical, mechanical, and test data.

· Inspection Reports: Comprehensive records of NDT, pressure tests, and dimensional checks, certified by third-party inspectors if required.

· Reference List: Available to showcase WALKSON’s successful delivery of alloy bends to global refining and metallurgical projects.

Advantages of Choosing WALKSON

Choosing WALKSON for customized high-temperature alloy bends offers distinct advantages, positioning us as the preferred supplier for industrial applications:

1. Unmatched Quality: Our bends meet stringent international standards, backed by 100% NDT and a robust quality management system certified to ISO 9001, ISO 14001, and ISO 45001.

2. Bespoke Engineering: Custom bend designs, alloy formulations, and configurations to meet specific high-temperature system needs, leveraging our 11 state invention patents.

3. Global Credibility: Trusted by industry leaders like SINOPEC, CNPC, and CNOOC, with a reference list highlighting successful deliveries to large refining and industrial projects worldwide.

4. Transparent Processes: Third-party inspections (e.g., SGS, BV) and client-witnessed testing ensure trust and accountability.

5. Innovative Technology: Advanced centrifugal casting, CNC machining, and NDT systems, developed in collaboration with the Chinese Academy of Sciences, deliver precision and durability.

6. Expert Support: Our expert team, backed by our Academician Workstation, provides end-to-end guidance from design to installation.

7. Timely Delivery: Streamlined production and logistics ensure fast turnaround without compromising quality, supporting critical project timelines.

8. Sustainable Practices: Eco-friendly manufacturing aligns with ISO 14001 standards, minimizing environmental impact.

9. Cost Efficiency: Durable bends reduce maintenance and downtime, lowering long-term operational costs for refining and metallurgical plants.

Consult with WALKSON Today

Elevate your high-temperature industrial systems with WALKSON’s high alloy and nickel-based customized alloy bends. Engineered for thermal resilience, corrosion resistance, and compliance with rigorous industry standards, our bends deliver outstanding performance in petrochemical, oil refining, and metallurgical applications.

Contact WALKSON now to explore your project requirements, request a quote, or arrange a consultation with our technical specialists. Visit www.walkson.com or email info@walkson.com (mailto:info@walkson.com). Partner with WALKSON, a high-tech enterprise recognized by Jiangsu Province, for high-quality centrifugal casting solutions trusted by global industry leaders.