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The following are the detailed technical requirements for high-pressure plunger pump housings (generally referring to the pump's outer shell or overall structure), covering aspects such as materials, design, manufacturing processes, and performance:

1. Structural Strength and Rigidity

- High-pressure load-bearing capacity: The housing must withstand the system's maximum operating pressure, avoiding deformation or cracking.

- Fatigue-resistant design: Under periodic pressure fluctuations, the housing must have fatigue resistance to prevent failure in stress concentration areas (such as bolt holes and corners).

- Rigid support: Ensure the installation accuracy of moving parts such as plungers and valve groups, preventing changes in mating clearances due to housing deformation.

- Material Selection:

- Medium and high-pressure conditions: High-strength cast iron, low-alloy steel.

- Ultra-high pressure/heavy load conditions: Forged steel, stainless steel, or titanium alloy.

2. Sealing Performance

- Static sealing: The connections between the housing and end caps, flanges, etc., must use metal wound gaskets or O-rings (fluororubber, hydrogenated nitrile rubber).

- Dynamic sealing: The seal between the plunger rod and the housing must be resistant to high pressure and wear (such as composite sealing rings, silicon carbide ceramic sealing rings).

- Leak-proof design:

- Housing castings must be free from sand holes, pores, and other defects;

- Key sealing surfaces require precision machining (Ra≤0.8μm).

3. Heat Dissipation and Thermal Management

- Temperature control:

- Natural heat dissipation: The housing is designed with cooling fins (increased surface area) or ventilation holes;

- Forced cooling: Built-in cooling jacket or external circulating cooling system.

4. Vibration Resistance and Noise Reduction

- Vibration reduction design:

- Install damping pads (rubber or polyurethane) between the housing and the base;

- Optimize internal flow channels to reduce resonance caused by fluid pulsation.

- Noise reduction measures:

- Increase housing wall thickness (such as ≥20mm) and fill with damping material;

- Adopt sound-absorbing structures (honeycomb sandwich design).

5. Corrosion Resistance and Surface Protection

- Base material selection:

- Corrosive media: 316L stainless steel, duplex steel, or Hastelloy;

- Seawater/salt spray environment: Titanium alloy (Gr5) or super austenitic stainless steel (254SMO).

- Surface treatment:

- Spray coating: Epoxy resin, polytetrafluoroethylene (PTFE) coating;

- Electroplating: Electroless nickel plating (ENP) or Dacromet corrosion protection;

- Anodizing (aluminum alloy housing).

6. Manufacturing Process Requirements

- Casting process:

- High-pressure housings must use precision casting (lost wax or investment casting) to ensure uniform wall thickness;

- Castings require 100% penetration testing (PT) and ultrasonic testing (UT).

- Machining accuracy:

- Key mounting surface flatness ≤0.02mm;

- Plunger hole coaxiality ≤φ0.01mm.

- Welding requirements:

- Welds require 100% X-ray inspection to avoid unfused areas, pores, and other defects;

- Dissimilar material welding requires a pre-placed transition layer (such as nickel-based welding wire).

7. Installation and Maintenance Convenience

- Modular design: The housing has a separable structure, facilitating quick replacement of wearing parts (such as seals and plungers).

- Inspection window: Set up observation holes or removable cover plates to facilitate internal condition inspection.

- Standardized interfaces: Inlet and outlet ports, sensor interfaces conform to SAE, DIN, and other standards.

8. Environmental Adaptability

- Explosion-proof requirements: Flammable and explosive environments must comply with ATEX/IECEx standards, and the housing joints are designed with explosion-proof grooves.

- Deep-sea application: The housing must withstand external water pressure (e.g., 3000-meter water depth requires 30MPa pressure resistance).

9. Industry Standards and Certifications

- Pressure vessel standards: Comply with ASME BPVC VIII, PED 2014/68/EU.

- Material certification: Provide material reports (such as EN 10204 3.1/3.2).

- Performance testing: Must pass burst test (1.5 times working pressure), durability test (≥5000 hours).

10. Typical Application Cases

1. Engineering machinery: Uses ductile iron housing + copper alloy lining, combining strength and wear resistance.

2. Oil fracturing pump: Forged steel housing (34CrNiMo6) + inner wall tungsten carbide coating, resistant to high pressure and sand erosion.

3. Ship Deck Machinery: Aluminum alloy housing (5083-H116) + sacrificial anode protection, combining lightweight design with corrosion protection.

Future Development Trends

1. Lightweight Design: Using topology optimization structure or carbon fiber reinforced polymer (CFRP).

2. Intelligent Integration: Embedding pressure/temperature sensors to achieve real-time status monitoring.

3. Green Manufacturing: Housing materials are recyclable (such as magnesium alloy, recycled steel).

Summary

High-pressure plunger pump housings must comprehensively meet four core requirements: strength, sealing, heat dissipation, and corrosion resistance, while also considering manufacturability and ease of maintenance. The design requires structural optimization through finite element analysis (FEA), and material and surface treatment options should be selected based on actual operating conditions. For special environments (such as deep sea, nuclear industry), customized development and strict reliability verification are required.