Gr2 Gr5 Titanium Dish Hemispherical Head Titanium Head Dish Titanium Hemispherical Head Dish Shaped Titanium Equipment

Gr2 Gr5 Titanium Dish Hemispherical Head Titanium Head Dish Titanium Hemispherical Head Dish Shaped Titanium Equipment

Titanium Dish Shaped Hemispherical Heads (Gr2 & Gr5) are critical components in various industrial applications, especially in the fields of chemical processing, petrochemical industries, pressure vessels, and heat exchangers. These heads are formed from titanium alloys, typically Grade 2 (Gr2) and Grade 5 (Gr5), which are known for their excellent mechanical properties, resistance to corrosion, and high strength-to-weight ratios.

Titanium Dish Shaped Hemispherical Heads (Gr2 & Gr5)

1. Titanium Grade 2 (Gr2) Dish Shaped Hemispherical Head

Titanium Grade 2 is a commercially pure titanium alloy, offering excellent corrosion resistance and high strength, making it suitable for general industrial applications. It is one of the most common grades used for titanium dish shaped hemispherical heads due to its excellent weldability and corrosion resistance in a wide range of environments, including acidic, alkaline, and marine conditions.

• Key Characteristics:

  • Corrosion Resistance: Gr2 titanium is highly resistant to corrosion from most acids, chlorides, and saltwater. This makes it suitable for use in corrosive environments, such as chemical tanks, storage vessels, and marine applications.
  • Strength: While not as strong as Grade 5, Gr2 offers sufficient strength for most pressure vessel applications.
  • Formability and Weldability: Gr2 titanium is easy to form and weld, making it ideal for creating complex shapes like dish heads and hemispherical heads.
  • Cost-Effective: Compared to Grade 5, Gr2 is generally more affordable, making it an attractive option for applications where high strength is not a critical requirement.

• Applications:

  • Pressure Vessels: Used in tanks and reactors where corrosion resistance is a priority.
  • Chemical Storage: Common in the chemical processing industry, especially in tanks and reactors handling aggressive substances.
  • Marine and Seawater Equipment: Used in seawater desalination plants, marine piping systems, and other aquatic applications.
  • Heat Exchangers: Ideal for heat exchangers where corrosion resistance is needed.

2. Titanium Grade 5 (Gr5) Dish Shaped Hemispherical Head (Ti-6Al-4V)

Titanium Grade 5, also known as Ti-6Al-4V, is the most widely used titanium alloy for applications requiring high strength and excellent performance under stress. It is composed of 90% titanium, 6% aluminum, and 4% vanadium, which gives it superior strength, high-temperature resistance, and fatigue resistance compared to Grade 2.

• Key Characteristics:

  • High Strength: Gr5 is much stronger than Gr2, with a tensile strength of around 900 MPa, making it ideal for heavy-duty applications such as high-pressure vessels and aerospace components.
  • Corrosion Resistance: Like Gr2, Gr5 offers excellent corrosion resistance, though it is not quite as resistant in extremely aggressive environments like concentrated acids.
  • Heat Resistance: Gr5 performs better than Gr2 at higher temperatures, making it ideal for applications involving heat or elevated temperatures.
  • Weldability: Although Gr5 is more challenging to weld than Gr2, it still has good weldability with proper techniques and care.
  • Durability: Gr5 is highly durable and can withstand long-term exposure to mechanical stress, making it suitable for critical applications.

• Applications:

  • Pressure Vessels: Used in high-pressure applications where additional strength is needed.
  • Aerospace: Common in aerospace for components such as fuel tanks, aircraft structures, and pressure systems.
  • Chemical Industry: Ideal for use in reactors and high-pressure equipment dealing with corrosive chemicals.
  • Oil & Gas: Gr5 is used in the oil and gas industry for subsea equipment, high-pressure pipelines, and gas storage vessels.

Advantages of Titanium Dish Shaped Hemispherical Heads (Gr2 & Gr5)

• Corrosion Resistance: Both Gr2 and Gr5 titanium alloys are highly resistant to corrosion from aggressive chemicals, acids, and seawater, making them ideal for harsh environmental conditions.

• Strength-to-Weight Ratio: Titanium offers a high strength-to-weight ratio, meaning that even though the material is lightweight, it can withstand high internal pressures, which is important for applications like pressure vessels and storage tanks.

• Longevity and Durability: Titanium’s ability to withstand long-term exposure to extreme conditions, including high temperatures and pressures, translates to longer service life for equipment, reducing maintenance costs and downtime.

• Biocompatibility: Gr2 titanium is known for its biocompatibility, making it suitable for medical applications, although Gr5 can also be used where higher strength is required.

• Versatility: The versatility of titanium alloys allows for their use across a wide range of industries, from chemical processing and petrochemical to aerospace and marine applications.

Manufacturing Process of Titanium Dish Shaped Hemispherical Heads

The process of manufacturing titanium dish shaped hemispherical heads involves several steps, including:

1. Material Selection: Sheets of Grade 2 or Grade 5 titanium are selected based on the specific requirements of the application.

2. Forming: The titanium sheet is heated to a temperature suitable for forming, and then it is mechanically pressed or drawn into the hemispherical shape. This can be done using deep drawing, hot forming, or pressing techniques.

3. Welding: If the dish head needs to be welded to other parts, such as a cylindrical body, precision welding techniques like TIG welding (Tungsten Inert Gas welding) are used to join titanium parts. Care must be taken to avoid contamination and maintain the integrity of the material.

4. Post-Processing: After the head is formed and welded, it may undergo additional processes such as pickling to remove oxides, polishing to improve surface finish, or passivation to enhance corrosion resistance.

5. Testing and Inspection: The finished heads are subjected to rigorous quality control checks, including non-destructive testing (NDT) like X-ray, ultrasonic testing, or pressure testing, to ensure they meet the required strength and durability standards.

Titanium Hemispherical Head Manufacturing Process

Titanium hemispherical heads are typically produced using processes like deep drawing, hot forming, or pressing. The general process includes:

1. Sheet Preparation: Titanium alloy sheets are cut to the required size.
2. Forming: The titanium sheet is heated and then pressed or drawn into the hemispherical shape using a press or a forming die.
3. Welding: If needed, the hemispherical head is welded to the cylindrical body of the vessel or tank. Titanium welding requires careful control of heat and the welding environment to prevent contamination.
4. Post-Processing: After forming and welding, the titanium hemispherical heads may undergo treatments such as pickling, polishing, or passivation to enhance corrosion resistance and surface quality.

Advantages of Titanium Hemispherical Heads

1. Corrosion Resistance:
   • Titanium alloys, particularly Grade 1 and Grade 2, are known for their superior corrosion resistance, which is crucial in chemical and marine environments.
2. Strength-to-Weight Ratio:
   • Titanium offers a high strength-to-weight ratio, meaning that the heads can withstand high internal pressures without adding significant weight, which is important in industries like aerospace and marine.
3. Longevity:
   • Due to titanium’s excellent resistance to corrosion, hemispherical heads made from this material have a long service life with minimal maintenance.
4. High Temperature Resistance:
   • Titanium Grade 5, in particular, is suitable for high-temperature applications, ensuring structural integrity in extreme heat environments.
5. Biocompatibility:
   • Grade 1 and Grade 2 titanium are biocompatible, making them ideal for applications in medical equipment, such as implants and surgical instruments.

Applications of Titanium Hemispherical Heads

1. Pressure Vessels:
   • Used in industries such as petrochemical, pharmaceuticals, and food processing where internal pressure needs to be safely contained.
2. Heat Exchangers:
   • Titanium heads are used in heat exchangers due to their resistance to corrosion and ability to withstand high thermal loads.
3. Storage Tanks:
   • Used in storage tanks that require excellent resistance to corrosion from chemicals or acids.
4. Aerospace:
   • The strength and lightweight properties of titanium make it ideal for aerospace applications, including in fuel tanks and pressurized components.
5. Marine Applications:
   • Ideal for seawater contact, where titanium’s resistance to chloride-induced corrosion is crucial.
6. Power Generation:
   • Used in the construction of reactors and other high-pressure, high-temperature components in the power generation industry.

Types of Dish Heads Based on Shape

Dish heads are classified based on their geometric shapes, and each type serves specific structural or functional needs.

Convex Heads:

• These heads feature an outwardly convex surface and are commonly used to ensure the structural integrity of containers that must withstand internal pressure.
• Examples include hemispherical heads, oval heads, disc heads, and unflanged spherical heads.
• Hemispherical heads are often used in high-pressure vessels because their shape can evenly distribute the internal pressure.
• Oval heads and disc heads can also be used depending on the design and pressure requirements.
• Some gas cylinders use convex inward heads, sometimes referred to as combined bottom heads, which enhance strength and safety by providing a more efficient load distribution.

Conical Heads:

• Conical heads feature a tapered shape and are typically used in applications where a smooth transition between cylindrical and conical shapes is necessary, such as in certain types of reactors and towers.
• These heads are particularly useful in handling both internal and external stresses due to their tapered nature.

Flat Heads:

• Flat heads are less common than convex or conical heads and are used in containers where internal pressure is relatively low or absent. They are simpler to manufacture and weld but are generally less effective at handling high internal pressure.

Combination Shapes:

• Some heads combine different geometric shapes to achieve specific design or structural benefits. These heads may combine convex and conical shapes, or use flat and convex elements, to meet the functional needs of the vessel.

(Titanium dish head )DIN28013:

Production Procedures for Titanium Dish Heads

The production of titanium dish heads involves several critical steps to ensure the material meets the stringent requirements of strength, corrosion resistance, and surface finish. Here's a breakdown of the production process:

Initial Production of Titanium Plates or Clad Steel Plates

• Process: The production begins with the creation of titanium plates or clad steel plates, which will be formed into dish heads. These plates are either pure titanium or titanium alloys and may also involve cladding with other metals for enhanced properties.
• Inspection: The initial plates are inspected for any defects in the material such as cracks, inconsistencies, or impurities.

Cleaning and Grinding Plate Surface

• Process: The surfaces of the titanium plates are thoroughly cleaned to remove any oxidation, grease, or other contaminants. After cleaning, the surfaces are ground to a smooth finish to prepare for the forming process.

Coat Protection & Paint

• Process: A protective coating is applied to the plate to prevent any damage during the forming and handling process. In some cases, paint may be applied to provide further corrosion resistance or for aesthetic purposes.

Forming (Hot or Cold Forming)

• Process: The titanium plate is then formed into a dish shape, either through hot forming (at elevated temperatures to increase malleability) or cold forming (at room temperature). This process shapes the plate into the desired dish head configuration, which could be hemispherical, elliptical, or conical.

Preparation for Cutting & Grinding

• Process: After forming, the dish head is prepared for cutting. Excess material is trimmed, and the edges are ground to ensure a clean, uniform finish.

Pickling

• Process: Pickling involves immersing the titanium dish head in an acid bath to remove any scale, oxide layer, or contaminants formed during the forming and welding process. This step ensures the dish head has a clean surface for further processing.

UT & PT Testing

• Process: Ultrasonic Testing (UT) and Penetrant Testing (PT) are carried out to detect any internal or surface flaws, respectively. These non-destructive testing methods ensure the structural integrity of the titanium dish head.

Surface Polishing as Requested

• Process: If a specific surface finish is required (e.g., high-gloss or satin), polishing is done to achieve the desired appearance and smoothness. This also enhances the corrosion resistance of the surface.

Final Inspection

• Process: A final inspection is conducted to ensure that the titanium dish head meets all specified requirements, including dimensions, quality standards, and performance criteria. Any defects or discrepancies are addressed before moving to the next stage.

Packing

• Process: Once the titanium dish head passes all inspections, it is carefully packed for shipment. The packaging protects the dish heads from damage during transport, ensuring that they arrive in excellent condition at the installation site.

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Specifications of Titanium Heads:

Chemical composition

Mechanical Property