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Butt Weld Flange
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Name: Butt Weld Flange
Standard: ASME B16.5
Material: Carbon Steel
Pressure: 150LB to 2500LB
Size: 1/2 to 24 Inch
Process Method: Forged
Face: RF
Usage: Used in the Fields of Construction, Chemical Engineering, Petroleum and Natural Gas.
Standard: ASME B16.5
Material: Carbon Steel
Pressure: 150LB to 2500LB
Size: 1/2 to 24 Inch
Process Method: Forged
Face: RF
Usage: Used in the Fields of Construction, Chemical Engineering, Petroleum and Natural Gas.
Quantity
The Butt Weld Flange conforms to ASME B16.5, available in sizes from ½ inch to 24 inches and pressure ratings from 150LB to 2500LB. Manufactured through hot-forging of carbon steel, it ensures high strength and exceptional sealing performance. Featuring an RF (Raised Face) sealing design, it is widely used in construction, chemical, petroleum, and natural gas industries, particularly suited for high-pressure, high-temperature, and harsh operating conditions, delivering long-term safety and durability to piping systems.
1. Hot-Forging Process: The Core Manufacturing Advantage
The Butt Weld Flange achieves superior performance through hot-forging at 950°C~1250°C, which enhances material density, refines grain structure, and optimizes mechanical properties, ensuring long-term reliability under high pressure, low temperatures, and corrosive environments.
The Butt Weld Flange achieves superior performance through hot-forging at 950°C~1250°C, which enhances material density, refines grain structure, and optimizes mechanical properties, ensuring long-term reliability under high pressure, low temperatures, and corrosive environments.
(1) Three Key Advantages of Hot-Forging
① Elimination of Internal Defects & Improved Density
During forging, the Butt Weld Flange billet remains in the austenitic phase zone, where triaxial compressive stress effectively closes pores, shrinkage cavities, and other defects, achieving a density close to the theoretical value (7.85 g/cm³).
① Elimination of Internal Defects & Improved Density
During forging, the Butt Weld Flange billet remains in the austenitic phase zone, where triaxial compressive stress effectively closes pores, shrinkage cavities, and other defects, achieving a density close to the theoretical value (7.85 g/cm³).
- Compared to cast flanges, hot-forged Butt Weld Flange exhibits superior macrostructure ratings (ASTM E381 ≤ Grade 1), far exceeding cast products (≥ Grade 3).
- Significantly reduces hydrogen-induced cracking (HIC) risk.
② Grain Refinement & Enhanced Mechanical Properties
Through dynamic recrystallization, the Butt Weld Flange transforms coarse grains (100~200μm) into fine, equiaxed grains (20~50μm), significantly improving strength and toughness.
Through dynamic recrystallization, the Butt Weld Flange transforms coarse grains (100~200μm) into fine, equiaxed grains (20~50μm), significantly improving strength and toughness.
Example (A105 Carbon Steel Butt Weld Flange):
- Tensile Strength: ≥ 485 MPa
- Yield Strength: ≥ 250 MPa
- Elongation: ≥ 22%
- Low-Temperature Impact Energy (-20°C): ≥ 27 J
These properties far exceed those of cast or cold-forged flanges.
- Tensile Strength: ≥ 485 MPa
- Yield Strength: ≥ 250 MPa
- Elongation: ≥ 22%
- Low-Temperature Impact Energy (-20°C): ≥ 27 J
These properties far exceed those of cast or cold-forged flanges.
③ Optimized Grain Flow & Extended Fatigue Life
The hot-forging process aligns metal grain flow along the flange contour, avoiding the fiber cutting effect seen in machined parts.
The hot-forging process aligns metal grain flow along the flange contour, avoiding the fiber cutting effect seen in machined parts.
- Compared to cast flanges, hot-forged Butt Weld Flange exhibits 30%~50% longer fatigue life (ASTM E466 verified).
- Stress concentration factor (Kt) reduced from 2.5 to below 1.8, making it ideal for high-pressure cyclic conditions.
- Stress concentration factor (Kt) reduced from 2.5 to below 1.8, making it ideal for high-pressure cyclic conditions.
(2) Critical Process Control in Hot-Forging Butt Weld Flange
- Temperature Control:
- Initial forging temp: 1150°C±50°C
- Final forging temp: ≥ 850°C (prevents grain coarsening/work hardening).
- Forging Ratio: Deformation ratio ≥ 3:1 (e.g., DN300 Butt Weld Flange requires ≥Φ250mm billet upset forging).
- Heat Treatment: Normalization (900°C±20°C, air cooling) to relieve internal stress, hardness maintained at HB 137~187 (compliant with ASTM A105).
- Temperature Control:
- Initial forging temp: 1150°C±50°C
- Final forging temp: ≥ 850°C (prevents grain coarsening/work hardening).
- Forging Ratio: Deformation ratio ≥ 3:1 (e.g., DN300 Butt Weld Flange requires ≥Φ250mm billet upset forging).
- Heat Treatment: Normalization (900°C±20°C, air cooling) to relieve internal stress, hardness maintained at HB 137~187 (compliant with ASTM A105).
2. Butt Weld Flange vs. Other Manufacturing Methods
| Manufacturing Process | Key Drawbacks | Advantage of Hot-Forged Butt Weld Flange |
| Cast Flange | Prone to shrinkage cavities & inclusions, limited pressure capacity (≤ PN40) | Superior density, suitable for high pressure (Class 1500+) |
| Cold-Forged Flange | Work hardening reduces toughness (brittle fracture risk below -10°C) | Excellent low-temperature toughness (≥27J @ -20°C) |
| Fabricated (Welded) Flange | HAZ embrittlement, requires 100% RT inspection | No welding defects, eliminates additional inspection costs |
Conclusion:
The Butt Weld Flange, produced via hot-forging, combines high density (porosity <0.2%), superior mechanical properties, and extended fatigue life (≥10^6 cycles), making it the optimal choice for high-pressure, low-temperature, and corrosive environments.
The Butt Weld Flange, produced via hot-forging, combines high density (porosity <0.2%), superior mechanical properties, and extended fatigue life (≥10^6 cycles), making it the optimal choice for high-pressure, low-temperature, and corrosive environments.
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