Numerical Investigation Of Cavitation Phenomena In Check Valves Using Multi-Phase CFD Modeling

Abstract

Swing check valves are extensively used in industrial piping systems to prevent reverse flow; however, cavitation occurring within the valve can lead to erosion, vibration, noise, pressure losses, and reduced service life. In this study, a 4-inch swing check valve was designed using CATIA V5 and analyzed using ANSYS Workbench to investigate cavitation behavior, structural integrity, and thermal performance under an inlet pressure of 300 kPa and a fluid temperature of 375 K (101.85°C). A multiphase CFD analysis employing water-liquid and water-vapor phases with the Zwart–Gerber–Belamri cavitation model was performed at a valve opening angle of 30°. The baseline valve exhibited severe cavitation, characterized by a minimum pressure of 1.07 × 10⁴ Pa and a maximum vapor volume fraction of 0.185. To mitigate cavitation, the valve geometry was optimized by modifying the flow passage in critical regions, resulting in an increase in minimum pressure to 1.15 × 10⁵ Pa and a reduction in maximum vapor volume fraction to 0.04512, corresponding to approximately 75.6% reduction in cavitation intensity. Static structural analysis was subsequently carried out using the pressure load obtained from the CFD study to compare the performance of conventional SS304 stainless steel with a Hybrid SS304–Aluminum Alloy Metal Matrix Composite (MMC) developed using ANSYS Material Designer. The hybrid material exhibited comparable stress levels with the added benefits of lower density and improved thermal properties. Furthermore, steady-state thermal analysis was performed on the hybrid valve with and without a 0.1 mm Yttria-Stabilized Zirconia (YSZ) thermal barrier coating. The coated valve demonstrated improved thermal insulation, reducing the average valve body temperature from 104.79°C to 99.89°C. The results indicate that the combination of geometric optimization, hybrid composite materials, and thermal barrier coatings can significantly reduce cavitation effects, maintain structural safety, improve thermal management, and enhance the overall performance and durability of swing check valves operating under high-temperature and cavitating flow conditions.