Four material systems for erosion, corrosion, elevated temperature and lightweight fluid-control parts.
Reference values from the technical proposal. Results depend on the material, component, processing condition and operating duty; the drawing and agreed acceptance plan govern each order.
TC4 · Titanium alloy · mining slurry trim
| Property | Conventional forging + machining | SLM / LPBF | Reported improvement |
|---|---|---|---|
| Mechanical properties | Tensile: 850–950 MPa Yield: 780–850 MPa | Tensile: 950–1050 MPa Yield: 880–950 MPa | Strength +10–15%; density >99.5% |
| Surface / flow channels | Ra 6.3–12.5 μm; straight holes / simple cavities | Ra ≤1.6 μm after polishing; conformal variable-section channels | Roughness −75–87%; greater design freedom |
| Delivery / life | 5–8 weeks; 4–6 months under cavitation | 1–2 weeks; ≥12 months | Delivery time −70–75%; longer service life |
Inconel 625 · Nickel alloy · H₂S/CO₂ injection valve seats
| Property | Conventional forging + machining | SLM / LPBF | Reported improvement |
|---|---|---|---|
| Mechanical properties | Tensile: 900–1050 MPa Yield: 550–700 MPa | Tensile: 1030–1200 MPa Yield: 650–850 MPa | Strength +14–20%; HIP densification |
| Surface / flow channels | Ra 6.3–12.5 μm; sharp turns | Ra ≤1.6 μm after polishing; sinusoidal curvature | Roughness −75–87%; pressure loss −20–35% |
| Delivery / sour service | 8–12 weeks; conventional sour-service performance | 1–2 weeks; NACE MR0175 requirements reviewed for the order | Delivery time −80–85%; corrosion-resistant material route |
Inconel 718 · Nickel alloy · turbine bypass valve internals
| Property | Conventional forging + machining | SLM / LPBF | Reported improvement |
|---|---|---|---|
| High-temperature properties | Tensile 1050–1200 MPa; yield at 650 °C ≈800 MPa | Tensile 1250–1400 MPa; yield at 650 °C >1000 MPa | Room-temperature strength +19%; hot yield +25% or more |
| Surface / flow channels | Ra 6.3–12.5 μm; abrupt section changes | Ra ≤1.6 μm after polishing; six-stage pressure reduction | Roughness −75–87%; pressure loss −20–35% |
| Delivery / creep resistance | 8–12 weeks; ageing treatment governs γ″ precipitation | 1–2 weeks; controlled γ″ ageing treatment | Delivery time −80–85%; creep-resistant condition |
AlSi10Mg · Aluminium alloy · lightweight valve trim
| Property | Conventional forging + machining | SLM / LPBF | Reported improvement |
|---|---|---|---|
| Mechanical properties | Tensile: 280–350 MPa Yield: 180–240 MPa | Tensile: 350–420 MPa Yield: 240–310 MPa | Strength +25%; improved isotropy |
| Surface / flow channels | Ra 6.3–12.5 μm; limited drilling / milling access | Ra ≤1.6 μm after polishing; conformal cooling channels | Roughness −75–87%; integrated internal cavities |
| Weight / delivery | 5–8 weeks; machining constraints | 1–2 weeks; topology-optimised geometry | Weight −30–50%; delivery time −70–75% |
Material and operating-duty selection
| Material | Operating duty | Material reference | Design route |
|---|---|---|---|
| TC4 | Iron / copper ore slurry; ambient temperature | Density 4.43 g/cm³; application reference tensile ≥1000 MPa | Conformal channels + Stellite wear / corrosion-resistant layer |
| Inconel 625 | H₂S / CO₂ and sand; ≤200 °C | Ni-Cr-Mo; corrosion-resistant alloy | Sloped floor + 45° spiral features |
| Inconel 718 | Steam / feedwater; ≤600 °C operating reference | γ″ strengthening; yield at 650 °C >1000 MPa | Variable-section pressure reduction + abrasive-flow polishing |
| AlSi10Mg | Hydraulic oil / water; ambient temperature, low pressure | Density 2.68 g/cm³; application reference tensile 400–480 MPa | Topology optimisation; integrated walls ≥0.3 mm |
The comparison table and application reference give different tensile ranges for AlSi10Mg (350–420 and 400–480 MPa). They are retained as separate references; confirm the required material condition and tested value for the part.
For non-pressure-retaining wear parts: valve trim, seats and sealing surfaces. Pressure-retaining components require project-specific qualification before acceptance.