Ti Grade 12 Gr12Titanium Head Disc Titanium Hemispherical Head Dish Shaped Titanium Equipment

Ti Grade 12 Gr12Titanium Head Disc Titanium Hemispherical Head Dish Shaped Titanium Equipment

The dish head (also known as a dish end, hemispherical head, or elliptical dish end) is a type of head used to close the end of cylindrical containers, ensuring the separation between the internal and external media. It serves as a structural component in various containers and equipment, such as storage tanks, heat exchangers, reactors, boilers, and separation equipment. These heads are critical for maintaining the integrity of the container, allowing it to withstand internal pressure and external forces.

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.

Types of Welding for Dish Heads

Dish heads are typically welded to the cylindrical body of the container, and the welding methods can vary depending on the design and material requirements. The most common types of welding used for dish heads include:

1. Butt Welding Heads:

   • Butt welding involves joining the edge of the dish head directly to the cylindrical body without overlapping the edges. This creates a stronger joint, suitable for high-pressure applications.
   • Butt welds are often used for spherical, oval, and disc heads, as they provide a clean, smooth connection.

2. Socket Welding Heads:

   • In socket welding, the edge of the dish head is placed inside a matching socket on the cylindrical body, and the joint is welded around the circumference of the head and socket.
   • Socket welding is generally used for lower-pressure applications where a simpler and more cost-effective solution is acceptable.

(Titanium dish head )DIN28013:

Titanium Grade 12 (also known as Ti-0.3Mo-0.8Ni) is a titanium alloy that belongs to the α+β (alpha-beta) alloy family. It is a high-performance material known for its excellent corrosion resistance, strength, and good weldability, making it ideal for use in various industrial applications, especially where resistance to aggressive environments and high temperatures is required.

Composition of Titanium Grade 12

Titanium Grade 12 is primarily composed of:

• Titanium (Ti): The base element, typically around 98.9% to 99.4%.
• Molybdenum (Mo): 0.30% (provides strength and improves resistance to corrosion, particularly in sulfuric acid and other aggressive environments).
• Nickel (Ni): 0.80% (enhances strength and resistance to corrosion).
• Iron (Fe): 0.25% max (contributes to the alloy’s overall strength).
• Other trace elements like oxygen, carbon, and nitrogen.

Key Properties of Titanium Grade 12

1. Corrosion Resistance:

   • Excellent resistance to a wide range of corrosive environments, particularly in sulfuric acid, hydrochloric acid, and seawater. This makes it suitable for chemical processing and marine applications.
   • Its corrosion resistance is superior to that of Grade 2 titanium and other common alloys like stainless steel.

2. Strength and Toughness:

   • Titanium Grade 12 offers good strength-to-weight ratios, making it ideal for applications where both strength and low weight are important.
   • It exhibits higher strength than commercially pure titanium (Grade 2), making it a better choice for structural applications where more strength is required.

3. Weldability:

   • It has good weldability, meaning it can be easily welded using standard methods, including TIG (tungsten inert gas) welding and MIG (metal inert gas) welding, without significant loss of properties.
   • Special care is required during welding to avoid contamination by oxygen, nitrogen, or hydrogen, which could degrade the properties of the alloy.

4. Heat Resistance:

   • Titanium Grade 12 is resistant to high temperatures, making it suitable for use in applications that involve elevated temperatures.
   • It retains its mechanical properties and corrosion resistance at higher temperatures better than some other titanium alloys.

5. Machinability:

   • It is relatively easy to machine using conventional methods like turning, milling, and grinding.
   • However, titanium alloys are prone to work hardening during machining, so careful attention to cutting speed, feed rate, and tool choice is required.

6. Density:

   • Titanium Grade 12 has a lower density than stainless steel and other materials, which contributes to its lightweight nature. This makes it beneficial in industries where weight is a concern, such as aerospace and automotive sectors.

7. Biocompatibility:

   • Like other titanium alloys, Grade 12 is biocompatible, meaning it is non-toxic and will not cause adverse reactions when in contact with human tissues. This property makes it suitable for use in medical implants.

Applications of Titanium Grade 12

Due to its outstanding properties, Titanium Grade 12 is widely used in industries that require materials with high strength, good weldability, and exceptional corrosion resistance. Some of the primary applications include:

1. Chemical Processing:

   • Heat exchangers, reactors, tanks, and piping used in the chemical industry, particularly where aggressive acids (like sulfuric acid, hydrochloric acid) or other corrosive substances are present.
   • It is commonly used for components in refineries, pharmaceutical manufacturing, and petrochemical plants.

2. Aerospace:

   • Titanium Grade 12 can be used in aircraft components, particularly in high-temperature and corrosion-resistant applications, such as engine parts, turbine blades, and exhaust systems.
   • It is particularly beneficial in aerospace applications where both strength and weight reduction are essential.

3. Marine:

   • Components used in seawater environments, such as propeller shafts, heat exchangers, valves, and other structural components in ships and offshore platforms.

4. Power Generation:

   • It is used in nuclear power plants for components that require high corrosion resistance to both the internal environment and high temperatures, such as steam generators and cooling systems.

5. Medical Devices:

   • Implants like hip joints, knee replacements, and dental implants benefit from titanium Grade 12's biocompatibility and strength.
   • Used in surgical instruments and prosthetics.

6. Desalination Plants:

   • Titanium Grade 12 is ideal for applications in desalination plants where it is exposed to saltwater and other corrosive agents. Its resistance to chloride-induced stress corrosion cracking is a key benefit.

Advantages of Titanium Grade 12:

• Excellent Corrosion Resistance: Superior to many other materials in aggressive environments like acids and seawater.
• Good Weldability: Easier to weld compared to other titanium alloys, making it versatile for fabrication.
• Strong and Lightweight: Offers high strength while being lighter than many other alloys, especially stainless steel, which is essential for aerospace and marine applications.
• Biocompatibility: Safe for medical use, offering a long lifespan and minimal rejection in human bodies.

Disadvantages of Titanium Grade 12:

• Cost: Titanium alloys, including Grade 12, are more expensive than many other materials like stainless steel or aluminum, which can limit their use in cost-sensitive applications.
• Machining Difficulties: While it is machinable, titanium alloys are prone to work hardening, and special care must be taken during machining to avoid damage to tools and workpieces.
• Limited Availability: Titanium Grade 12 may not be as widely available as more common grades of titanium, and sourcing the material can sometimes be more difficult or expensive.

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.

Applications of titanium Elliptical Heads:

Specifications of Titanium Heads:

Chemical composition

Mechanical Property