Baoji Lihua Nonferrous Metals Co., Ltd.
Baoji Lihua Nonferrous Metals Co., Ltd.
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Titanium flanges, specifically ANSI/ASME B16.5 Class 2500 Long Weld Neck Flanges, are widely used in high-pressure, high-strength, and corrosive environments due to the material's excellent performance. These flanges, made from Titanium Grade 1 and Titanium Grade 2, are critical components in industries like aerospace, chemical processing, marine engineering, and power generation. In this article, we will delve into the features, applications, and benefits of these titanium flanges, particularly focusing on the differences between Grade 1 and Grade 2 titanium.
Titanium is known for its remarkable corrosion resistance and strength-to-weight ratio. Two commonly used grades of titanium in flange manufacturing are Grade 1 and Grade 2, each with distinct properties suitable for different applications.
Titanium Grade 1 is commercially pure titanium with excellent formability and corrosion resistance. It has lower strength compared to Grade 2, but it is ideal for applications where resistance to corrosion in seawater, chlorine, and other aggressive environments is crucial. Grade 1 is also favored for applications that require a lightweight yet strong material.
Titanium Grade 2 offers better strength than Grade 1, making it suitable for applications that require higher strength, durability, and resistance to fatigue. It is commonly used in industries that demand materials to withstand higher stresses and extreme environmental conditions, while still maintaining a balance of corrosion resistance.
The ANSI/ASME B16.5 standard outlines the specifications for flanges used in high-pressure systems, and the Class 2500 Long Weld Neck Flange is specifically designed for applications that require superior performance in terms of pressure, temperature, and mechanical stresses. The following features and specifications define these titanium flanges:
Class 2500 Pressure Rating: These flanges are rated for Class 2500, meaning they can withstand up to 2500 lbs per square inch (psi). This high-pressure rating makes them suitable for high-stress applications where conventional flanges may not perform adequately.
Flange Design: The Long Weld Neck design offers an extended neck that allows for smooth and stress-free connections to pipes. This design minimizes the risk of leaks and ensures robust mechanical strength under pressure. The long neck also allows for easy alignment with the piping system.
Flange Face Types: These flanges are available with several face types including:
Size Range: ANSI/ASME B16.5 Class 2500 Long Weld Neck Flanges are available in a broad size range from 1/2″ (15 NB) to 48″ (1200 NB), catering to both small and large-scale industrial applications.
Due to their exceptional properties, Titanium Grade 1 and Titanium Grade 2 flanges are used in industries that require reliable and durable materials under harsh conditions. Some common applications include:
Marine Industry: Titanium is highly resistant to seawater corrosion, making it an ideal material for shipbuilding, offshore platforms, and subsea equipment. These flanges provide long-lasting, reliable connections in seawater and salt-rich environments.
Aerospace and Aircraft: The lightweight yet strong nature of titanium makes it essential for the aerospace industry. These flanges are used in fuel systems, propulsion components, and high-pressure systems where strength and corrosion resistance are critical.
Chemical Processing Plants: In environments dealing with aggressive chemicals and high temperatures, titanium flanges offer an unbeatable combination of strength and corrosion resistance. They are commonly used in reactors, heat exchangers, and pipelines.
Power Generation: Titanium flanges are employed in power plants, especially in systems that involve high-pressure steam or corrosive chemicals. Their ability to withstand extreme temperatures and pressures makes them invaluable in maintaining system integrity.
The use of Titanium Grade 1 and Grade 2 flanges in these critical industries offers several significant advantages:
Corrosion Resistance: Titanium flanges are highly resistant to corrosion from both environmental and chemical factors. This property makes them especially useful in marine, chemical, and offshore applications.
High-Strength-to-Weight Ratio: Titanium has one of the highest strength-to-weight ratios among metals. This characteristic allows for reduced structural weight without compromising on strength, which is particularly important in aerospace and military applications.
High-Temperature Resistance: Titanium flanges maintain their structural integrity even in high-temperature environments. This makes them suitable for power generation facilities, where temperature control is critical.
Long Service Life: Titanium’s resistance to fatigue and corrosion significantly extends the service life of flanges, reducing maintenance needs and downtime.
5. Specifications of Titanium Long Weld Flanges:
| Specification | ASTM B381 / ASME SB381 |
|---|---|
| Standard | ANSI/ASME B16.5, B16.47 Series A & B, B16.48, BS4504, BS 10, EN-1092, DIN, ANSI Flanges, ASME Flanges, BS Flanges, DIN Flanges, EN Flanges, GOST Flange, ASME/ANSI B16.5/16.36/16.47A/16.47B, MSS SP44, ISO70051, JISB2220, BS1560-3.1, API7S-15, API7S-43, API605, EN1092 |
| Size Range | 1/2″ (15 NB) to 48″ (1200NB), DN10 ~ DN5000 |
| Class | 150 LBS, 300 LBS, 600 LBS, 900 LBS, 1500 LBS, 2500 LBS, DIN Standard ND-6,10, 16, 25, 40, Etc. |
| Connect Type/Flange Face Type | Raised Face (RF), Ring Type Joint (RTJ), Flat Face (FF), Large Male-Female (LMF), Small Male-Female (SMF) |
| JIS Standards | JIS B2220, JIS B2221, 5K, 10K, 16K, 20K, 30K, 40K, 63K |
| DIN Standards | DIN 2527, DIN 2566, DIN 2573, DIN 2576, DIN 2641, DIN 2642, DIN 2655, DIN 2656, DIN 2627, DIN 2628, DIN 2629, DIN 2631, DIN 2632, DIN 2633, DIN 2634, DIN 2635, DIN 2636, DIN 2637, DIN 2638, DIN 2673 |
| BS Standards | BS 4504, BS 1560, BS 10 |
| Pipe | O.D. | Thk. Of | Diameter | Hub |
| Diameter | Length | Diam. of | Number | Diam. of | |||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Normal | Flange | of Raised | Diameter | Bolt |
| ||||||||
| Flange | of Bore | Through Hub |
| of Bolts | Holes | ||||||||
| Diam. |
| Min | Face |
| at Bevel |
|
|
| Circle |
|
| ||
| inch | O | C | R |
| A |
| B | H | H1 | BC |
| n | d |
| 1" | 159. 0 | 34.9 | 50.8 | 57.2 | 25.4 | 25.4 | 304. 8 | 108. | 0 | 4 | 25.5 | ||
| 1-1/4" | 184. 0 | 38.1 | 63.5 | 73 | 31.8 | 31.8 | 304. 8 | 130. | 2 | 4 | 28.5 | ||
| 1-1/2" | 203. 0 | 44.5 | 73 | 79.4 | 38.1 | 38.1 | 304. 8 | 146. | 1 | 4 | 31.8 | ||
| 2" | 235. 0 | 50.8 | 92.1 | 95.3 | 50.8 | 50.8 | 304. 8 | 171. | 5 | 8 | 28.5 | ||
| 2-1/2" | 267. 0 | 57.2 | 104. | 8 | 114. | 3 | 63.5 | 63.5 | 304. 8 | 196. | 9 | 8 | 31.8 |
| 3" | 305. 0 | 66.7 | 127. | 0 | 133. | 4 | 76.2 | 76.2 | 304. 8 | 228. | 6 | 8 | 35 |
| 4" | 355. 5 | 76.2 | 157. | 2 | 165. | 1 | 101. 6 | 101. 6 | 304. 8 | 273. | 1 | 8 | 41 |
| 5" | 419. 0 | 92.1 | 185. | 7 | 203. | 2 | 127. 0 | 127. 0 | 304. 8 | 323. | 9 | 8 | 48 |
| 6" | 483. 0 | 108. 0 | 215. | 9 | 235. | 0 | 152. 4 | 152. 4 | 304. 8 | 368. | 3 | 8 | 54 |
| 8" | 552. 5 | 127. 0 | 269. | 9 | 304. | 8 | 203. 2 | 203. 2 | 304. 8 | 438. | 2 | 12 | 54 |
| 10" | 673. 0 | 165. 1 | 323. | 9 | 374. | 7 | 254. 0 | 254. 0 | 406. 4 | 539. | 8 | 12 | 66.5 |
| 12" | 762. 0 | 184. 2 | 381. | 0 | 441. | 3 | 304. 8 | 304. 8 | 406. 4 | 619. | 1 | 12 | 73 |
Material Selection: The first step in manufacturing titanium flanges involves selecting high-quality titanium alloys, either Grade 2 or Grade 5, based on the application’s specific requirements. Grade 2 is chosen for its excellent corrosion resistance and weldability, while Grade 5 is selected for higher strength demands.
Forming and Machining: The titanium billets are heated to a high temperature and then formed into flange shapes using techniques like forging or casting. Once the shape is formed, the flange undergoes precision machining to achieve the correct dimensions, including the raised face and bolt holes.
Heat Treatment: Both Grade 2 and Grade 5 titanium alloys may undergo heat treatment processes to enhance their mechanical properties. For Grade 5, this typically involves a solution treatment followed by aging to increase strength.
Surface Finishing: The flange surfaces, especially the raised face, are polished to a smooth finish to improve the sealing surface when paired with gaskets. This step is critical to ensuring leak-tight performance and meeting the required surface finish standards.
Inspection and Testing: Each flange is subjected to rigorous quality control, including visual inspections, dimensional checks, and non-destructive testing such as ultrasonic or X-ray inspection to ensure there are no internal defects. Pressure testing may also be performed to verify the flange’s ability to withstand the specified pressure rating.