Metal Seated Ball Valve

Falcon High-Performance Metal Seated Ball Valves

Engineered for Zero Leakage in Extreme Environments

Falcon Metal Seated Ball Valves are precision-engineered solutions designed specifically for severe service applications where standard soft-seated valves fail. Built to withstand extreme temperatures and aggressive media, these valves combine robust metallurgy with state-of-the-art manufacturing processes to deliver Class VI shut-off capabilities, ensuring safety and efficiency in the most demanding industrial processes.

Key Technical Advantages

• Severe Service Design: Optimized for high-temperature service and abrasive environments where thermal stability and mechanical strength are critical.

• Superior Metallurgy: Manufactured in a wide range of Nickel Alloy grades (such as Inconel, Monel, and Hastelloy) to provide exceptional resistance to corrosion, oxidation, and thermal shock.

• Precision Manufacturing: We utilize specialized, proprietary machinery for the grinding and lapping of both the ball and seat. This "mate-lapping" process ensures a perfect 360-degree contact patch between the sealing surfaces.

• Class VI / Zero Leakage: Through our advanced lapping techniques, Falcon achieves a sealing performance that rivals soft-seated valves (ANSI/FCI 70-2 Class VI), providing a "bubble-tight" seal even at elevated temperatures.

 

To achieve Class VI (Zero Leakage) performance in metal-seated valves with interchangeable seats, Falcon employs a specialized combination of precision manufacturing and mechanical design.

Unlike traditional metal-seated valves where the ball and seat are "mate-lapped" as a matched pair (meaning if one fails, you must replace both), Falcon's design utilizes advanced 360° CNC lapping technology to achieve true interchangeability.

 

Here is the breakdown of the special designs used:

1. 360° Multi-Axis Rotary Lapping (The "Interchangeable" Secret)

The core innovation is the manufacturing process itself. Standard lapping often moves in a single plane, creating microscopic directional grooves. Falcon uses specialized Multi-Axis Lapping Machines that rotate the ball and seat in a random, non-repeating 360° pattern.

• Perfect Sphericity: This process grinds the ball to a roundness tolerance of < 5 microns ($< 0.005$ mm).

• Non-Directional Finish: It creates a uniform, matte surface finish with no "grain" for leak paths to form.

• Result: Because the geometry is mathematically perfect rather than "hand-matched," you can replace just the seat or just the ball during maintenance without losing the zero-leakage seal.

2. Live-Loaded "Floating" Seat Design

To maintain Zero Leakage (Class VI) under the thermal expansion of high-temperature Nickel Alloys, Falcon uses a dynamic seat loading system.

• Spring Energization: Behind the metal seat, Inconel X-750 or 718 Belleville disc springs apply constant mechanical pressure.

• Low-Pressure Sealing: At low pressures (where metal seats usually leak), the springs force the seat against the ball to create the seal.

• Thermal Compensation: As the valve heats up to extreme temperatures (e.g., 600°C+), the springs compress to absorb the thermal growth of the ball, preventing the valve from seizing while maintaining the seal.

3. HVOF "Super-Hard" Coating Technology

A metal-to-metal seal requires surfaces that will not gall (weld together) under high friction. Falcon utilizes High Velocity Oxygen Fuel (HVOF) coating.

 

• Micro-Hardness: The sealing surfaces are coated with Chrome Carbide or Tungsten Carbide, achieving hardness levels > 68 HRC.

• Surface Tension: The coating is polished to a mirror-like finish (Ra < 0.2), which creates high surface tension that liquid/gas cannot easily penetrate, mimicking the sealing capability of a soft elastomer.

4. Knife-Edge (Scraper) Seat Profile

 

For high-temperature service which often involves polymerization or coking (common in Nickel Alloy applications), Falcon employs a Sharp Edge Seat design.