PILOT #2 Circular Manufacturing of Industrial Valve Parts

From broken valve to certified component — closing the material loop with recycled powder and additive manufacturing.

The Challenge

Industrial valves for oil and gas applications are precision-critical components. A key part of each valve is the obturator — the element that maintains the valve closed. As with any mechanical part subject to operational stress, obturators eventually wear out and may reach a point of irreparability.

Replacing such components through conventional manufacturing takes time. To reduce equipment downtime in case of failure, operators must maintain a physical stock of spare parts — a practice that carries both ecological and economic costs: material consumption, energy use, warehouse management, and logistics.

There is currently no established pathway to produce replacement valve parts on demand, locally, and from recycled material. The manufacturing approach does not yet support the level of circularity these applications would require.

THE DIAMETER APPROACH

Circularity strategy

Repair for reuse and recycling to close the material loop

AM process

Laser DED (Direct Energy Deposition) combined with milling

Valland SpA and Trentino Sviluppo Spa are working together to cover the complete manufacturing and recycling life cycle of industrial valves, using stainless steel and nickel-based alloys. VLL uses the DIAgonal platform to assess which damaged valves are repairable and which are beyond repair, and qualifies the manufactured parts. TTS fabricates the components by combining laser DED and milling, characterising the mechanical properties and microstructures of the output parts.

PARTNERS INVOLVED

Pilot lead. Design optimisation, valve assessment, functional testing, qualification, EU DPP and LCA reporting

Manufacturing via DED + milling, mechanical and microstructure characterisation

EXPECTED OUTCOMES

  • Demonstrated on-demand production of valve obturators from recycled stainless steel / nickel-based alloy powder
  • Validated powder quality meeting ASTM International standards
  • Characterised mechanical properties and microstructures of DED+milling manufactured valve parts
  • Demonstrated full circular loop: broken part → recycled powder → qualified component
  • LCA comparison between circular (DED+milling from recycled powder) and conventional manufacturing
  • Part ready for EU Digital Product Passport (EU DPP) integration

STATUS: IN PROGRESS

Process parameter development is underway. Trentino Sviluppo Spa has completed deposition using 316 stainless steel as a proxy material for the target super duplex stainless steel, and samples have been extracted for mechanical testing and microstructure characterisation. Progress on the actual pilot use case is pending the delivery of the final super duplex stainless steel powder. Machining of the pilot geometry is planned in coordination with Sabancı University to ensure consistency across pilots.

This section will be updated as the pilot advances