Titanium Hemispherical Head Grade 1 Grade 2 Grade 5 Titanium Head Disc Titanium Hemispherical Head Dish Shaped Titanium Equipment

Titanium Hemispherical Head Grade 1 Grade 2 Grade 5 Titanium Head Disc Titanium Hemispherical Head Dish Shaped Titanium Equipment

Titanium Hemispherical Head (also called Titanium Dish Shaped Head or Titanium Dish Head) is a critical component in pressure vessels, storage tanks, and other industrial equipment where the shape and material properties are essential for withstanding internal pressure, corrosion, and other mechanical stresses. These heads are often used in the chemical, petrochemical, and power generation industries due to their excellent corrosion resistance and strength-to-weight ratio.

Types of Titanium Hemispherical Heads Based on Titanium Grades

Titanium hemispherical heads can be manufactured from various titanium grades, and each grade offers distinct advantages depending on the application. The common grades used for these heads are Grade 1, Grade 2, and Grade 5.

1. Titanium Grade 1 Hemispherical Head

Titanium Grade 1 is commercially pure titanium with the lowest alloying content. It offers excellent corrosion resistance, especially in aggressive environments such as seawater and various acids. It has good formability and weldability but lower strength compared to other titanium alloys.

• Key Properties:

  • Corrosion Resistance: Excellent resistance to most acids, seawater, and oxidizing environments.
  • Strength: The lowest strength of the titanium grades, but still stronger than many other metals like aluminum and stainless steel.
  • Weldability: Very good weldability and is ideal for forming complex shapes like hemispherical heads.
  • Applications: Ideal for applications requiring corrosion resistance but where high strength is not a primary concern.

• Typical Uses:

  • Heat exchangers, tanks, vessels, and piping in chemical processing.
  • Marine equipment, especially in seawater environments.

2. Titanium Grade 2 Hemispherical Head

Titanium Grade 2 is the most widely used titanium alloy. It has a slightly higher strength than Grade 1 and retains similar excellent corrosion resistance properties. It is also very easy to weld and form into complex shapes like hemispherical heads.

• Key Properties:

  • Corrosion Resistance: Outstanding resistance to various acids, seawater, and chemicals.
  • Strength: Higher strength than Grade 1, which makes it suitable for more demanding structural applications.
  • Weldability: Good weldability, commonly used in applications requiring high-quality welding.
  • Formability: It can be easily cold-worked, making it suitable for forming hemispherical and other complex shapes.

• Typical Uses:

  • Pressure vessels, heat exchangers, and tanks in the chemical, petrochemical, and power generation industries.
  • Aerospace and marine applications.

3. Titanium Grade 5 Hemispherical Head (Ti-6Al-4V)

Titanium Grade 5 is an alloy consisting of 90% titanium, 6% aluminum, and 4% vanadium. It is one of the strongest titanium alloys, offering superior strength and higher heat resistance compared to Grade 1 and Grade 2. This makes it suitable for applications where both high strength and corrosion resistance are required.

• Key Properties:

  • Strength: One of the strongest titanium alloys, with a tensile strength of about 900 MPa (compared to around 400-550 MPa for Grade 1 and Grade 2).
  • Corrosion Resistance: Excellent resistance to corrosion, although slightly less than that of Grade 1 and Grade 2 in extremely aggressive environments.
  • Heat Resistance: Superior resistance to high temperatures compared to other titanium grades, making it suitable for high-temperature applications.
  • Weldability: Moderate weldability. While it can be welded, care must be taken to avoid issues like hydrogen absorption, which could affect its mechanical properties.

• Typical Uses:

  • Aerospace and high-performance industrial applications where high strength and corrosion resistance are critical.
  • Pressure vessels and heat exchangers in high-temperature environments, like those in the oil and gas and power generation industries.

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.

Specifications of Titanium Heads:

Chemical composition

Mechanical Property