Materials

Forged Hastelloy C276 (N10276) Gate Valves

Our Forged Hastelloy C276 Gate Valves are engineered for the most aggressive corrosive environments, where standard stainless steels fail. Hastelloy C276 is a nickel-molybdenum-chromium superalloy with an addition of tungsten, designed to have excellent corrosion resistance in a wide range of severe environments.

1. Design & Construction Features

• Design Standard: Manufactured in accordance with API 602 (for forged steel gate valves) and ASME B16.34.

• Rising Stem (OS&Y): Outside Screw and Yoke design ensures the stem threads are not in contact with the process fluid, preventing corrosion and easing lubrication.

• Bolted Bonnet: Features a high-integrity gasketed joint for ease of maintenance and reliable sealing under high pressure (Class 800 to 2500).

• Full Bore Design: Maximizes flow capacity and minimizes pressure drop across the valve.

• Body & Bonnet: Precisely forged for superior grain structure and increased strength over cast alternatives.

2. Technical Specifications

Feature	Specification
Material	Hastelloy C276 (ASTM B564 UNS N10276)
Size Range	1/2" to 2" (Larger sizes available in cast construction)
Pressure Class	Class 800, 1500, 2500
End Connections	Socket Weld (SW), NPT Threaded, or Flanged (RF/RTJ)
Face-to-Face	ASME B16.10
Wall Thickness	ASME B16.34

3. Manufacturing Excellence

The manufacturing process for Hastelloy C276 requires specialized expertise due to the material's work-hardening characteristics:

• Precision Forging: Bodies are forged at controlled temperatures to prevent "hot shortness" and ensure a uniform metallurgical structure.

• Solution Annealing: Post-forging heat treatment is performed to restore maximum corrosion resistance and ductility.

• Advanced Machining: Utilizing high-torque CNC centers to achieve the tight tolerances required for API 602 compliance.

4. Quality Testing & Compliance

Every valve undergoes a rigorous verification process to ensure zero-leakage performance in critical service:

• Hydrostatic Testing: Conducted per API 598 (Shell and Seat test) to ensure structural integrity and bubble-tight shutoff.

• Pneumatic Testing: Low-pressure air testing to detect minute leaks in the seating surfaces.

• Material Verification: 100% Positive Material Identification (PMI) to guarantee the alloy composition meets UNS N10276 standards.

• Non-Destructive Testing (NDT): Including Liquid Penetrant Testing (LPI) on welds and critical forged surfaces.

• Certification: Full MTC (Material Test Certificate) to EN 10204 3.1 providing chemical and mechanical properties.

5. Applications

These valves are ideal for:

• Chemical Processing (Hydrochloric and Sulfuric acid service).

• Flue Gas Desulfurization (FGD) plants.

• Offshore Oil & Gas (Sour gas and high-chloride environments).

• Pharmaceutical and Waste Treatment.

Mechanical & Physical Properties (UNS N10276)

These properties ensure the valve can withstand both high-pressure mechanical stress and extreme thermal fluctuations.

Property	Value (Typical)
Tensile Strength	$\ge 100 \text{ ksi } (690 \text{ MPa})$
Yield Strength (0.2% Offset)	$\ge 41 \text{ ksi } (283 \text{ MPa})$
Elongation	$40\%$
Density	$8.89 \text{ g/cm}^3$
Melting Range	$1325°C – 1370°C$
Hardness (Rockwell B)	$\le 100 \text{ HRB}$

The "Betterness": Why Choose C276 Over Other Alloys?

Hastelloy C276 is often referred to as the "Universal Corrosion-Resistant Material." Here is how it outperforms standard stainless steels and other nickel alloys:

1. Superiority Over Stainless Steel (316L/317L)

• Pitting Resistance: In chloride-rich environments (like seawater), 316L often suffers from localized pitting. C276 has a much higher PREN (Pitting Resistance Equivalent Number), typically $> 65$, compared to 316L's \approx 24.

2. Superiority Over Monel® 400

3. Resistance to Stress Corrosion Cracking (SCC)

4. Stability During Welding

Falcon Forged Hastelloy C-276 Globe Valves Product Overview

The Falcon Series Forged Globe Valve in Hastelloy C-276 (UNS N10276) is engineered for precision throttling and high-integrity shut-off in the world’s most hostile chemical environments. Unlike standard cast valves, our forged construction provides a dense, non-porous grain structure, making it the premier choice for high-pressure, high-temperature, and "critical-leakage" applications.

1. Design & Engineering Excellence

Every Falcon globe valve is designed with a focus on durability and ease of maintenance:

• Outside Screw and Yoke (OS&Y): Protects the stem threads from the process media, preventing thread corrosion and ensuring smooth operation.

• Rising Stem: Provides a clear visual indication of the valve position (Open/Closed).

• Plug-Type Disc: Features a precision-contoured seating surface for linear flow control and high-velocity throttling.

• Bolted Bonnet: Secured with high-strength fasteners and a high-integrity gasket for safe, repeatable maintenance access.

2. Technical Specifications

Feature	Details
Material	Forged Hastelloy C-276 (ASTM B564 / UNS N10276)
Sizes	1/2" (DN15) through 2" (DN50)
Pressure Class	ASME Class 800, 1500, 2500
End Connections	Socket Weld (SW), NPT Threaded, or Flanged
Standard Compliance	API 602, ASME B16.34, API 598
Trim Material	Integral C-276 or Hard-faced (Stellited) for erosion resistance

3. Material Properties & Performance

Hastelloy C-276 is widely regarded as the "Universal Alloy" for corrosion resistance. By utilizing the Falcon forged process, we enhance these natural properties:

• Total Corrosion Immunity: Exceptional resistance to pitting and crevice corrosion in chloride-rich environments.

• Aggressive Acid Handling: Stable in the presence of wet chlorine gas, hypochlorite, and oxidizing salts.

• Mechanical Integrity: * Tensile Strength: 690 MPa

  • Yield Strength:  283 MPa

  • Hardness: 100 HRB (Maintains ductility in cryogenic and high-temp service).

4. Manufacturing & Quality Control Protocol

At Falcon, quality is not an inspection; it is a manufacturing standard.

• Forging Process: Bodies are forged using controlled thermal cycles to prevent grain growth and maintain maximum alloy toughness.

• Precision Machining: CNC-machined seats and discs ensure a mirror-finish for bubble-tight sealing.

• 100% PMI Verification: Every single pressure-retaining part is verified via Positive Material Identification to ensure 0% material substitution.

• NACE Compliance: All Falcon C-276 valves are processed to meet NACE MR0175/ISO 15156 for sour service.

5. Testing Standards

Before a Falcon valve is shipped, it must pass a rigorous testing battery:

1. Shell Hydro-Test: Tested at 1.5 times the rated working pressure.

2. High-Pressure Seat Test: To ensure zero-leakage closure.

3. Low-Pressure Air Test: To verify seal integrity at the molecular level.

4. Visual Inspection: Checked for surface finish and dimensional accuracy according to ASME B16.11 (for SW ends).

6. Industrial Applications

Falcon Forged Globe Valves are the preferred choice for:

• Chemical Processing: Metering and throttling of Sulfuric, Hydrochloric, and Phosphoric acids.

• Oil & Gas: High-pressure "Sour Gas" injection and control lines.

• Pharmaceuticals: Handling reactive catalysts and aggressive cleaning agents.

• Environmental: Flue Gas Desulfurization (FGD) and wastewater neutralization.

 

Falcon UNS N04400 (Monel 400) forged ball valves are the ultimate solution for high-pressure isolation in marine and hydrofluoric acid environments. By combining the rapid, quarter-turn operation of a ball valve with the superior mechanical properties of a Nickel-Copper forge, Falcon provides a valve that is practically immune to the corrosive effects of brackish water and high-velocity brine.

Falcon Forged Monel 400 Ball Valves 1. Specialized Design & Engineering

Falcon ball valves are engineered for "Zero-Leakage" performance in hazardous conditions.

 

• Forged Body Integrity: Manufactured per ASTM B564, our forged bodies offer a high-density molecular structure, ensuring zero porosity and superior resistance to thermal shock compared to cast alternatives.

• Blow-out Proof Stem: The stem is designed to be bottom-entry, ensuring it remains securely inside the valve even under extreme pressure surges.

• Self-Cleaning Seats: The wiping action of the ball against the seat during operation clears away scale and debris—essential for marine applications where bio-fouling can occur.

• Anti-Static Protection: Features an internal grounding mechanism to prevent static electricity discharge, a critical safety requirement for refinery and gas services.

2. Manufacturing Excellence

• Precision Lapping: The Monel 400 ball is diamond-lapped to a mirror finish. This reduces operating torque and prevents premature seat wear, ensuring the valve remains easy to operate over thousands of cycles.

• High-Strength Stem: We use high-tensile Monel 400 or Monel K-500 for the stem to provide the extra torque capacity needed for high-pressure sealing.

• Advanced Seating Options:

  • PTFE/RPTFE: For general chemical and marine service (up to 200°C).

  • PEEK/Devlon: For high-pressure "Sour Gas" or abrasive media.

  • Metal-to-Metal: For high-temperature or slurry applications.

3. Quality & Performance Testing

Every Falcon Monel 400 valve is a product of rigorous quality control:

• PMI Verification: 100% Positive Material Identification confirms the 63% Ni / 30% Cu ratio, ensuring no "dilution" of the alloy's properties.

• Hydrostatic & Pneumatic Testing: All valves are tested to API 598 standards for both high-pressure shell integrity and low-pressure bubble-tight seating.

• HF Acid Service Preparation: For refinery orders, valves are specially cleaned and degreased to meet stringent UOP or Phillips HF Alkylation specifications.

• Traceability: Full EN 10204 3.1 certification is provided for all pressure-retaining parts.

4. Technical Specifications

Specification	Detail
Body Material	Forged Monel 400 / UNS N04400 / ASTM B564
Pressure Rating	Class 150, 300, 600, 800, 1500, 2500
End Connections	Threaded (NPT), Socket Weld (SW), Flanged (RF/RTJ)
Design Standards	API 6D, ASME B16.34, BS 5351

5. Expertise & Experience

Falcon holds deep domain expertise in deploying Monel 400 valves across several niche sectors:

• HF Alkylation Units: Decades of experience supplying valves that resist the highly aggressive "Reducing" nature of hydrofluoric acid.

• Subsea & Offshore: Expertise in designing valves for seawater cooling systems and fire-water loops where bio-fouling and chloride-ion cracking are the primary threats.

• Salt Processing: Proven reliability in brine heaters and evaporation plants where standard stainless steel fails within months.

Why Choose Falcon Monel 400?

 

The "Falcon" brand is a mark of durability. Our forged Monel 400 ball valves are specifically chosen by engineers who prioritize long-term Life Cycle Cost (LCC) over cheap initial price, as our valves significantly reduce maintenance intervals and unplanned shutdowns in corrosive environments.

Falcon Forged Monel 400 (UNS N04400) Check Valves are the definitive "backflow prevention" solution for high-salinity and acidic environments. In these critical services, a check valve must be reliable; if it fails to close, the resulting backflow can destroy expensive pumps or cause hazardous chemical leaks.

Falcon Monel Check Valve Design Variations

Falcon manufactures Monel check valves in several configurations to handle different flow velocities, pipeline orientations, and media viscosities.

1. Piston (Lift) Check Valves

The most common choice for small-bore high-pressure piping.

• Mechanism: Uses a forged Monel piston that is lifted by the fluid pressure.

• Best For: High-pressure gas or liquid service.

• Falcon Specialization: Typically spring-loaded to ensure fast closure in vertical or horizontal lines and to prevent "water hammer."

2. Swing Check Valves

Designed for systems where "Full Flow" and minimal pressure drop are the priority.

• Mechanism: A hinged Monel disc swings open with forward flow and is forced shut by gravity and back-pressure.

• Best For: High-volume liquid systems with low-to-medium pressure.

• Falcon Specialization: Features an internal hinge pin design to eliminate external leak paths, a critical safety feature for HF acid service.

3. Ball Check Valves

The ultimate design for viscous fluids or "dirty" service.

• Mechanism: A free-rotating Monel ball acts as the sealing element.

• Best For: Applications with particulates or high viscosity where a piston might get "stuck."

• Falcon Specialization: The ball rotates during operation, ensuring even wear and a constantly refreshed sealing surface for longer life.

4. Stop-Check Valves (Non-Return)

A specialized "hybrid" valve used in power and steam systems.

• Mechanism: Functions as a check valve automatically, but can be manually closed using a handwheel (like a globe valve) to isolate the line entirely.

• Best For: Boiler feedwater systems and high-pressure steam.

Manufacturing Specialization

Falcon’s expertise in Monel forging allows us to offer these valves with specialized construction methods:

• Bolted Cover (BC): The standard design for easy internal maintenance and cleaning.

• Welded Cover (WC): A "leak-proof" design where the cover is seal-welded to the body—preferred for lethal gas or HF Alkylation service.

• Pressure Seal Cover: Used for Class 1500 and 2500 high-pressure applications where the internal pressure helps tighten the seal.

Technical Specifications

Feature	Details
Material	Forged Monel 400 (ASTM B564 UNS N04400)
Sizes	1/2" to 8" (Forged Range)
Pressure Class	800lb, 1500lb, 2500lb
Standards	API 602, ASME B16.34, BS 5352
Ends	Socket Weld (SW), NPT Threaded, Flanged (RF/RTJ)

Why Falcon Monel Check Valves?

In industries like desalination or HF Alkylation, the check valve's internal trim is under constant attack. Falcon uses Monel K-500 for the springs and seat overlays to provide the extra hardness required to resist erosion and fatigue, ensuring that the "heart" of your piping system remains secure.

Pressure and Performance Testing

Every Falcon valve must pass a multi-stage testing sequence before it is certified for shipment.

Test Type	Standard	Procedure
Hydrostatic Shell Test	API 598	Performed at 1.5x the rated pressure to verify the structural integrity of the body and bonnet.
High-Pressure Seat Test	API 598	Performed at 1.1x the rated pressure to ensure the primary seal (metal-to-metal) is leak-free.
Low-Pressure Air Test	MSS SP-61	A pneumatic test at 80-100 PSI to detect minute leaks that high-pressure water might miss.
Fugitive Emission Test	ISO 15848-1	(Optional) Measures the leak rate of the stem packing to ensure environmental compliance (Class A or B).
Backseat Test	API 598	Verifies that the internal backseat seals correctly, allowing for packing replacement under pressure.

Falcon UNS N04400 (Alloy 400) Forged Gate Valves

Falcon’s UNS N04400 forged gate valves are high-strength, solid-solution hardened valves that offer exceptional resistance to a wide range of corrosive environments. While Alloy 825 is the specialist for sulfuric acid, Alloy 400 is the industry benchmark for marine engineering and hydrofluoric (HF) acid service.

 

1. Advanced Design Characteristics

• Optimized Flow Path: Our forged gate valves feature a full-port design that minimizes turbulence and pressure drop, critical for high-velocity liquid flow.

• Wedge Geometry: Precision-machined solid wedges provide high structural stability, while flexible wedges are available for larger sizes to prevent "thermal binding" in high-temperature cycles.

• Outside Screw & Yoke (OS&Y): The rising stem design ensures that the stem threads are never in contact with the corrosive media, extending the service life of the valve.

   

   

• Fugitive Emission Control: Standard graphite or PTFE packing sets are engineered to meet stringent environmental leakage standards.

2. Manufacturing Excellence

• ASTM B564 Precision Forging: Falcon utilizes closed-die forging to ensure a refined grain structure. This eliminates the porosity and shrinkage defects often found in Monel castings (ASTM A494 M35-1), providing superior toughness and weldability.

• Cold-Work Strengthening: Alloy 400 gains its strength through cold working during the manufacturing process, and Falcon’s thermal management ensures the material retains its high ductily and impact strength.

• CNC Machining & Lapping: Seats and wedges are precision-lapped to a mirror finish, ensuring a metal-to-metal seal that exceeds API 598 requirements.

3. Quality & Testing Regime

Every Falcon valve is a "Safety-Critical" component. Our testing protocol includes:

• Hydrostatic Testing: High-pressure shell and seat tests at 1.5x and 1.1x the pressure rating.

• Pneumatic Testing: Low-pressure air testing to verify bubble-tight integrity.

• PMI (Positive Material Identification): 100% verification to ensure the 63% Nickel and 28-34% Copper ratio is exact.

• NACE Compliance: Available for "sour" service in accordance with NACE MR0175/ISO 15156.

• Traceability: Heat numbers are hard-stamped on the valve body, linked to EN 10204 3.1 Mill Test Reports.

4. Application Area Expertise

Falcon has decades of experience deploying UNS N04400 valves in the world’s most punishing environments:

• Marine & Shipbuilding: Handling seawater in high-velocity piping, fire-main systems, and brine heaters where standard stainless steel would pit instantly.

• HF Alkylation Units: A specialized application in oil refineries where Monel 400 is the only material capable of resisting hydrofluoric acid.

• Chemical Production: Handling chlorinated solvents and non-oxidizing chloride salts.

• Power Generation: Used in boiler feedwater heaters and other heat exchangers.

Technical Specifications

Feature	Details
Material	Nickel-Copper Alloy (ASTM B564 UNS N04400)
Sizes	1/2" to 2" (Forged)
Pressure Class	800lb, 1500lb, 2500lb
Design Standards	API 602, ASME B16.34
Connections	Socket Weld (SW), Threaded (NPT), Integral Flange (RF/RTJ)

The Falcon Experience

 

With over 15 years of experience in exotic alloy fabrication, Falcon doesn't just supply valves; we provide material consultation to ensure your project uses the right alloy for the right environment. Our Alloy 400 valves are trusted by global leaders in the Navy, desalination, and petrochemical industries.

 

Falcon's "Double-Verify" Quality Policy

Regardless of the alloy, Falcon applies the same Precision Forging (ASTM B564) and API 598 Testing standards. Our engineering team is available to review your Media Data Sheets to ensure the metallurgical selection matches your pipeline's life-cycle requirements.

Falcon UNS N04400 (Monel 400) forged globe valves are specifically engineered for high-precision throttling and flow regulation in environments where seawater or hydrofluoric acid would rapidly degrade standard alloys. While ball valves are excellent for quick isolation, the Falcon globe valve is the "workhorse" for controlling the flow rate and pressure with extreme accuracy.

Falcon Forged Monel 400 Globe Valves 1. Specialized Design for Regulation

Falcon globe valves are designed to provide superior control under high-pressure differentials.

• Plug-Type Disc: Features a heavy-duty, tapered disc that allows for fine-tuned throttling. The disc and seat are precision-lapped to ensure a bubble-tight shutoff when closed.

• Outside Screw & Yoke (OS&Y): The rising stem design keeps the actuator threads outside the flow stream, protecting them from the corrosive "reducing" media typical of Monel applications.

• Integral Backseat: Allows the stem packing to be replaced while the valve is under full pressure, ensuring maximum safety and system uptime.

• Forged Structural Integrity: By using ASTM B564 forgings, Falcon eliminates the risk of "hot shortness" or internal casting defects, ensuring the valve body can withstand high-velocity fluid impact.

2. Manufacturing & Material Science

• Nickel-Copper Strength: The 63% Nickel and 30% Copper composition of Monel 400 provides a unique blend of high strength and excellent weldability.

   

   

• Erosion Resistance: Globe valves often face high-velocity flow at the seat. Falcon uses Monel K-500 for the stem and internal trim to provide extra hardness and resistance to "wire-drawing" (erosive wear).

• Titanium-Stabilized Forging: Our forging process ensures the material retains its ductility and corrosion resistance even at sub-zero or elevated temperatures.

3. Rigorous Quality & Testing

Each Falcon globe valve is subjected to a comprehensive testing regime:

• Hydrostatic Testing (API 598): Every valve undergoes a shell test at 1.5x the pressure rating and a seat test at 1.1x.

• HF Acid Service Cleaning: For refinery applications, valves are meticulously cleaned and dried to prevent any reaction between residual oils and hydrofluoric acid.

• PMI (Positive Material Identification): 100% verification of all pressure-retaining parts to ensure the chemical signature matches UNS N04400.

• Dimensional Precision: Machined on high-precision CNC centers to ensure a perfect fit for the bolted bonnet and gasket.

4. Key Applications

• Marine Engineering: Controlling seawater flow in fire-main systems and heat exchangers.

• HF Alkylation Units: Precision throttling of hydrofluoric acid in oil refineries.

• Salt Production: Regulating the flow of boiling brine and salt slurries.

• Chemical Processing: Handling non-oxidizing chlorides and caustic solutions.

Technical Summary

Feature	Details
Material	Forged Monel 400 (ASTM B564 UNS N04400)
Design Standards	API 602, ASME B16.34, BS 5352
Pressure Ratings	Class 800lb, 1500lb, 2500lb
Connections	NPT, Socket Weld (SW), Flanged (RF/RTJ)

The Falcon Advantage

Falcon's expertise lies in understanding the metallurgical behavior of Monel. We ensure that our forging process avoids the "hot-shortness" (brittleness during forging) that often plagues lower-quality manufacturers, resulting in a valve that is as tough as the environment it serves.

While the standard globe valve is a powerhouse,Falcon leverages the unique properties of Monel 400 (UNS N04400) to manufacture specialized configurations for "Extreme Service" applications. Because Monel is both highly ductile and resistant to specific acids, it allows for designs that standard stainless steel cannot support.

Various design available are Y-Pattern (Flow-Efficient) Monel Globe Valves, Bellows-Seal Monel Globe Valves, Needle-Type Throttling Monel Valves, Cryogenic Monel Globe Valves, Stop-Check (Non-Return) Monel Globe Valves

Falcon UNS N08825 (Alloy 825) forged ball valves represent the pinnacle of high-pressure, quarter-turn isolation technology. Designed specifically for severe service where standard stainless steel or duplex alloys fail, these valves combine the rapid operation of a ball valve with the extreme chemical resistance of a nickel-iron-chromium-molybdenum-copper alloy.

Falcon Forged Alloy 825 Ball Valves Specialized Design Features

• Precision Forged Body: Manufactured to ASTM B564, our forged bodies provide a high-strength, non-porous structure that is significantly more reliable than cast valves in high-pressure gas applications.

• Quarter-Turn Efficiency: Designed for fast, 90-degree actuation with low torque requirements, even at maximum differential pressure.

• Floating & Trunnion Designs: Available in Floating Ball (for standard high-pressure service) and Trunnion Mounted (for larger sizes or extremely high pressures) to ensure seat integrity.

• Blow-out Proof Stem: Engineered for maximum safety, the stem is designed to remain secure within the valve body even under extreme pressure surges.

• Fire-Safe Design: Standard construction includes secondary metal-to-metal seating to maintain seal integrity in the event of a fire.

Precision Manufacturing

• Mirror-Finished Ball: Each Alloy 825 ball is diamond-lapped to a mirror finish. This reduces friction, extends the life of the seats, and ensures a bubble-tight seal.

• Titanium Stabilization: Our manufacturing process preserves the titanium-stabilized matrix of Alloy 825, preventing intergranular corrosion after machining or welding.

   

   

• Seat Material Versatility: While the body is forged Alloy 825, we offer specialized seat inserts (PTFE, RPTFE, Devlon, or PEEK) to match the specific temperature and chemical needs of your process.

Testing to Top Industry Standards

Every Falcon ball valve is subjected to a rigorous "Zero-Leakage" testing regime before dispatch:

• API 598 Pressure Testing: Includes high-pressure hydrostatic shell and seat tests, and low-pressure air seat tests.

• API 607 Fire Testing: Certified designs that ensure performance during and after high-temperature exposure.

• Fugitive Emission Testing (ISO 15848-1): Verifies that the stem seal prevents hazardous gas leakage into the atmosphere.

• PMI Verification: 100% Positive Material Identification of all pressure-retaining components to confirm the Alloy 825 chemical signature.

Technical Specifications

Feature	Detail
Material	Forged Nickel-Iron-Chromium Alloy (ASTM B564 UNS N08825)
Pressure Ratings	Class 150lb up to 2500lb
Sizes	1/2" to 12" (Forged Range)
Compliance	API 6D, ASME B16.34, NACE MR0175/ISO 15156
End Connections	Threaded (NPT), Socket Weld (SW), Flanged (RF/RTJ)

Primary Industry Use

• Offshore Oil & Gas: High-pressure chemical injection and manifold isolation.

• Petrochemical Plants: Managing highly corrosive acids and volatile organic compounds.

• Water Treatment: Handling concentrated chlorine and brine solutions in desalination.

Falcon Alloy 825: Chemical Compatibility Guide

The unique chemistry of Alloy 825 (Ni-Fe-Cr-Mo-Cu) allows it to bridge the gap between standard stainless steels and expensive high-nickel alloys. Below is a breakdown of how Falcon valves perform against the most aggressive industrial chemicals.

1. Performance in Acidic Media

 

• Sulfuric Acid (H2SO4): Exceptional resistance to all concentrations up to 80% at boiling temperatures. The addition of Copper in the Falcon alloy matrix specifically enhances resistance to this "reducing" acid.

• Phosphoric Acid (H3PO4): Outperforms 316L and Duplex in fertilizer production lines, resisting pitting even in the presence of fluoride impurities.

• Nitric Acid (HNO3): The high Chromium content ensures the valve remains passivated (protected) in oxidizing environments.

• Hydrochloric Acid (HCl): Resistant to dilute concentrations at moderate temperatures.

Falcon Forged UNS N08825 (Alloy 825) Check Valves

Falcon Alloy 825 check valves are engineered for automatic protection against flow reversal. By utilizing the unique Nickel-Iron-Chromium chemistry of Alloy 825, these valves remain functional and corrosion-free in environments that would typically cause standard valves to seize or leak.

Available Types of Falcon Check Valves

We offer three primary configurations to suit different flow velocities and piping orientations:

1. Piston (Lift) Check Valves

• Design: Utilizes a forged piston that "lifts" off the seat via fluid pressure.

• Best For: High-pressure gas or liquid service in smaller pipelines (typically up to 2").

• Feature: Usually spring-loaded to ensure rapid closure and prevent "slamming."

2. Swing Check Valves

• Design: Features a hinged disc that swings open with forward flow and closes when flow stops.

• Best For: Full-flow applications where low pressure drop is required.

• Feature: Designed with an internal hinge pin to minimize leak paths to the atmosphere.

3. Ball Check Valves

• Design: Uses a free-moving forged Alloy 825 ball to seal against the seat.

• Best For: Highly viscous fluids or applications where "chattering" is a concern.

• Feature: Exceptionally simple design with minimal moving parts for long-term reliability.

Key Features & Design Standards

• Forged Construction: Manufactured to ASTM B564, ensuring a rugged, high-density body that eliminates the risk of "pinhole" leaks common in castings.

• Gravity & Spring Assisted: Precision-calibrated springs ensure the valve closes the moment flow velocity drops, protecting upstream pumps.

• Metal-to-Metal Seating: Precision-lapped seats provide a tight seal even in high-temperature and high-acid environments.

• Zero-Leakage Sealing: Compliant with API 598 pressure testing requirements.

Technical Specifications

Feature	Details
Size Range	1/2" to 2" (Forged)
Pressure Class	800lb, 1500lb, 2500lb
Standard	API 602 / ASME B16.34
Ends	NPT, Socket Weld (SW), Flanged (RF/RTJ)

Common Applications

• Chemical Injection Lines: Preventing chemicals from backing up into the supply pumps.

• Desalination High-Pressure Pumps: Protecting expensive reverse osmosis (RO) pumps from back-pressure.

• Sour Gas Processing: Preventing H2S gas migration during system shutdowns.

• Offshore Scrubber Systems: Handling corrosive seawater and acidic condensates.

Falcon Quality Assurance: Integrity You Can Trust

At Falcon, quality is the cornerstone of our manufacturing process. Our UNS N08825 (Alloy 825) check valves are designed and tested to meet the stringent demands of the global energy and chemical sectors, ensuring they act as a fail-safe barrier against backflow in the most aggressive media.

1. Material Integrity & Verification

• PMI (Positive Material Identification): Every valve body, cover, and internal component is verified using X-ray fluorescence (XRF) to ensure the Nickel (38–46%), Chromium (19.5–23.5%), and Molybdenum (2.5–3.5%) content exactly matches the UNS N08825 specification.

• ASTM B564 Forging Standards: We exclusively use forged blanks that are free from the porosity and structural defects common in cast alternatives.

• Full Traceability: Each valve is stamped with a heat number and accompanied by an EN 10204 3.1 Mill Test Certificate (MTC).

Specialized Performance Testing (Optional)

For critical or "severe service" applications, Falcon provides advanced testing options:

• Fugitive Emission Testing: To ISO 15848-1, ensuring the cover-to-body seal meets environmental safety standards.

• NACE MR0175 / ISO 15156 Compliance: Verification that the valve is resistant to Sulfide Stress Cracking (SSC) for "sour" gas service.

• Dye Penetrant Testing (DP): Non-destructive testing on all forged surfaces to ensure the absence of surface cracks or fissures.

The Falcon Quality Commitment

We understand that a check valve failure can lead to catastrophic pump damage or hazardous leaks

Falcon UNS N08825 Forged Gate Valves Precision-Engineered for Severe Corrosive Isolation

Falcon’s UNS N08825 (Alloy 825) forged gate valves are the industry standard for reliable, full-bore flow control in environments where standard stainless steel fails. By utilizing a high-nickel, molybdenum, and copper alloy forged to ASTM B564 standards, these valves offer unparalleled resistance to sulfuric and phosphoric acids, as well as chloride-induced stress corrosion.

Design & Construction

• Forged Body Integrity: Unlike cast valves, our forged bodies eliminate porosity and offer a refined grain structure capable of withstanding extreme pressure cycles.

• Outside Screw & Yoke (OS&Y): Designed with a rising stem and non-rising handwheel to keep stem threads out of the process media, ensuring longevity and ease of lubrication.

• Wedge Options: Available in Solid Wedge (for high-pressure stability) or Split Wedge (for better sealing in fluctuating temperatures).

• Sealing Excellence: Precision-ground seating surfaces minimize friction and ensure a bubble-tight shutoff.

Key Features

• Superior Corrosion Resistance: Specifically stabilized with titanium to resist intergranular corrosion after welding or thermal processing.

• Robust Bonnet Design: Choice of Bolted Bonnet (BB) for ease of maintenance or Welded Bonnet (WB) for high-pressure, leak-proof security.

• Integral Backseat: Allows for the repacking of the stem under pressure (safety precautions apply).

• Full Port Design: Minimizes pressure drop and turbulence across the valve.

Technical Specifications

Specification	Detail
Material	Nickel-Iron-Chromium Alloy (ASTM B564 UNS N08825)
Sizes	1/2" to 2" (Standard Forged Range)
Pressure Class	800lb, 1500lb, 2500lb
Ends	Socket Weld (SW), Threaded (NPT), Integral Flanged
Design Std	API 602 / ASME B16.34

Quality & Compliance

Every Falcon Gate Valve is subjected to rigorous API 598 pressure testing. We provide full documentation, including:

• MTR (Mill Test Reports) to EN 10204 3.1.

• NACE MR0175/ISO 15156 compliance for Sour Gas service.

• PMI (Positive Material Identification) to verify alloy composition.

Falcon UNS N08825 (Alloy 825) valves are high-performance solutions designed for the world’s most demanding industrial environments. Because this alloy provides exceptional resistance to both oxidizing and reducing acids (like sulfuric and phosphoric acids) and is immune to chloride-ion stress corrosion, it is a staple in critical infrastructure.

 

Below are the primary industries and specific applications where Falcon Alloy 825 valves are deployed:

1. Oil & Gas (Onshore & Offshore)

Incoloy 825 is a "frontline" material for the energy sector, particularly in "sour" environments containing hydrogen sulfide (H2S).

 

• Sour Gas Service: Used in valves for wellheads and gathering systems where $H_2S$ and $CO_2$ levels are high.

• Subsea Systems: Ideal for subsea manifolds, flowlines, and risers due to its resistance to seawater pitting and high pressure.

• Refining: Applied in hydrotreater units and crude distillation where sulfuric acid corrosion is a constant threat.

2. Chemical & Petrochemical Processing

This is the most common application for Alloy 825, thanks to its unique Nickel-Iron-Chromium-Copper-Molybdenum balance.

• Acid Production: Handling and storage of sulfuric, phosphoric, and nitric acids.

   

   

• Fertilizer Manufacturing: Used in the production of ammonium sulfate and phosphoric acid evaporators.

• Pickling Operations: Forged valves in steel pickling lines that use hot sulfuric acid solutions.

• Specialty Chemicals: Reactive vessels and piping systems involving organic and inorganic chlorides.

3. Marine & Desalination

The high copper and nickel content makes these valves virtually immune to the corrosive effects of stagnant and flowing seawater.

 

• Desalination Plants: Used in brine heaters and heat exchangers where high-salinity water is processed.

Falcon Forged UNS N08825 (Alloy 825) Globe Valves

Falcon Globe Valves are purpose-built for high-precision flow regulation and frequent operation in highly corrosive environments. Manufactured from premium Nickel-Iron-Chromium-Molybdenum-Copper alloy, these valves provide the "Gold Standard" in durability for acid-handling and sour-gas applications.

1. Advanced Design Features

• Throttling Excellence: Designed with a spherical body and a contoured plug-type disc, allowing for fine-tuned flow control and minimal seat erosion during partial opening.

• Outside Screw & Yoke (OS&Y): The stem threads are isolated from the process media, preventing thread corrosion and ensuring smooth operation even in harsh chemical environments.

   

   

• High-Integrity Sealing: Features a tapered, metal-to-metal seat, precision-lapped to achieve a bubble-tight shutoff and prevent "wire-drawing" of the seal.

• Integral Backseat: Allows for stem packing replacement while the valve is in service, enhancing safety and reducing downtime.

2. Manufacturing Process

• Precision Forging (ASTM B564): Unlike casting, which can leave internal voids (porosity) and brittle structures, Falcon’s forging process compresses the alloy. This creates a continuous, directional grain flow that follows the contours of the valve body, resulting in maximum impact strength and fatigue resistance.

   

   

• Stabilized Metallurgy: Our Alloy 825 is titanium-stabilized during the forging process to prevent intergranular corrosion in the heat-affected zones (HAZ) after welding.

• CNC Machining: All critical tolerances, including the seat and stem threads, are finished on high-precision CNC centers to ensure 100% interchangeability of parts.

3. Rigorous Testing & Quality

At Falcon, quality is verified, not just promised. Each Globe Valve undergoes a multi-stage testing protocol:

• Hydrostatic Shell & Seat Test: Performed at 1.5x and 1.1x the rated pressure respectively, according to API 598 standards.

• Fugitive Emission Testing: Available for critical service to ensure zero leakage from the stem packing (ISO 15848-1 compliance).

• Positive Material Identification (PMI): Every single valve body and bonnet is verified via X-ray fluorescence to ensure the exact chemical composition of Alloy 825.

• Dye Penetrant Inspection: All forged surfaces are inspected for surface irregularities to guarantee a defect-free finish.

Technical Summary

Feature	Specification
Material	Incoloy 825 / UNS N08825 / ASTM B564
Design Standards	API 602, ASME B16.34, BS 5352
Pressure Ratings	Class 800lb, 1500lb, 2500lb
Connection Types	Socket Weld (SW), NPT Threaded, Raised Face (RF)

Key Industrial Applications for Falcon Alloy 825 Globe Valves 1. Chemical Processing & Acid Handling

The most critical application for Alloy 825 globe valves is in the regulation of highly corrosive acids.

• Sulfuric Acid Plants: Used in the concentration and piping of sulfuric acid, where the alloy's resistance to "reducing" environments is vital.

   

   

• Phosphoric Acid Production: Essential for throttling flow in fertilizer production lines where phosphoric acid causes severe pitting in standard stainless steels.

• Pickling Lines: Regulating the flow of heated acid baths in steel mills and metal finishing plants.

2. Oil & Gas (Sour Service & Midstream)

In the energy sector, these valves manage fluids that are both high-pressure and chemically "sour."

• Gas Dehydration Units: Regulating the flow of glycols and other chemicals used to remove water from natural gas.

• Sour Gas Throttling: Managing the flow of gas containing high concentrations of $H_2S$ and $CO_2$, where resistance to Sulfide Stress Cracking (SSC) is required.

• Acid Gas Injection: Used in carbon capture and storage (CCS) and enhanced oil recovery.

4. Marine & Offshore Engineering

• Desalination Plants: Precise control of high-salinity brine flow. The globe valve’s ability to throttle is critical for maintaining pressure across desalination plant