Valve Coating
Thermal spray coating is 300 µ m thick, porous and mechanically bonded— Prone to delamination.
Figure 4 Cross-sectional comparison of conventional thermal spray( left) and FM-1500™( right).
FM-1500 TM is 1900 μm thick, fully dense, and metallurgically bonded— Eliminating the risk of delamination.
wear volume loss by up to 90 % compared to untreated titanium trim.
• Corrosion testing in 98wt % sulphuric acid at 200 ° C: where the technology demonstrated excellent corrosion resistance, maintaining structural integrity.
A persistent problem: the six-month shutdown cycle
In a HPAL plant, a 14-inch Class 600 ball valve in the autoclave discharge line was a known weak point. Every six months, the valve would require a full changeout, forcing costly shutdowns. The culprit? The thermal spray coating, which routinely delaminated under extreme conditions. Once the coating failed, high-velocity acidic slurry would rapidly erode the titanium substrate, leaving the plant operators with no choice but to replace the valve entirely. In pursuit of a more durable, longlasting valve solution, the client conducted consecutive trials with advanced coating technologies from two alternative OEMs. This cycle of failure and replacement was not only expensive but also a major operational headache. Process engineers sought a long-term solution— one that could
To solve these problems, FM-1500 TM offers a breakthrough solution.
Looking ahead for severe service valve trim
FM-1500 TM is a titanium nitride surface modification technology that provides exceptional wear and corrosion resistance. Unlike conventional thermal spray coatings, it metallurgically bonds to the titanium substrate, eliminating the risks of coating delamination, porosity and premature wear. FM-1500 TM is available for both new valves and retrofit applications, making it a costeffective upgrade for existing severe service ball valves. a)
c) b)
d)
Outperforming testing
The technology was subjected to rigorous laboratory and field testing in real-world HPAL environments. The testing procedure used internationally standardised ASTM test methodologies, including:
• Hardness testing( ASTM E92): where the FM-1500 TM valve trim exhibited surface hardness, outperforming standard titanium( 210 HV).
• Erosion resistance( ASTM G65 & ASTM B611): where the valve trim reduced
Figure 5 Visual inspection of FM-1500 TM trim in( a) as-new condition, and after( b) 6 months,( c) 12 months, and( d) 18 months in service. No signs of delamination or galling are observed, indicating excellent wear and corrosion resistance over time.
38 Valve World May 2025 www. valve-world. net