Valve with integral insert-cast seat and related method

A method for molding a valve body having a valve seat of dissimilar material sealingly molded therein, comprising the steps of:

• providing a hollow valve seat comprised of a metal and having an upper lip configured to engage a sealing valve member, a bottom edge spaced from the upper lip at a lower portion of the seat, and a projection extending away from an outer surface of the seat intermediate the upper lip and bottom edge;
• placing the seat in a mold;
• and
• pouring a molten metal into the mold to form a valve body surrounding at least a portion of the seat, including the projection, such that the upper lip of the seat is exposed, and forming a fluid flow pathway through an inlet of the valve body, through the seat and to an outlet of the valve body;
• wherein the metal of the valve body is of a different material than the metal of the seat;
• and
• wherein a volume of a mass of the valve body surrounding the seat is at least twice a volume of at least an embedded portion of the seat so as to minimize chill effects of the seat material while the molten metal of the valve body cools and hardens such that a pressure tight and waterproof interface is formed between adjacent surfaces of the valve body and the seat.