Extending Life of Frac, Stimulation (acid), Gravel Packing, and Mud Pump Valves through Design and Materials: Phase & Chemistry Controlled Alloy Body with Meta Material Seals

A reciprocating valve for use in hydraulic fracturing, the valve comprising:

• a seat having an interior volume and a seat strike face;
• a valve body having a head and a tail, the tail being positioned in the interior volume of the seat and being configured to maintain the valve body in alignment with the seat as the valve body reciprocates between an open position and a closed position, the head having a valve strike face that is complementary with the seat strike face such that the seat strike face and the valve strike face contact one another when the valve is in the closed position, and wherein a space between the seat strike face and the valve strike face defines a fluid path through the reciprocating valve;
• and
• a seal insert formed onto the valve body and forming a seal insert strike face that is complementary with the valve strike face, wherein the seal insert protrudes from the valve strike face such that the seal insert strike face contacts the seat strike face before the valve strike face.

A valve for use with a suction or discharge valve assembly of a pump fluid end, the valve comprising:

• a seat having an interior volume and a seat strike face;
• a valve body having a head and a tail, the tail being positioned in the interior volume of the seat and being configured to maintain the valve body in alignment with the seat as the valve body reciprocates between an open position and a closed position, the head having a valve strike face that is complementary with the seat strike face such that the seat strike face and the valve strike face contact one another when the valve is in the closed position, and wherein a space between the seat strike face and the valve strike face defines a fluid path through the reciprocating valve;
• and
• a seal insert formed onto the valve body and forming a seal insert strike face that is complementary with the valve strike face, wherein the seal insert protrudes from the valve strike face such that the seal insert strike face contacts the seat strike face before the valve strike face.

A valve for use with a suction or discharge valve assembly of a pump fluid end, the valve comprising:

• a valve seat having a seat strike face;
• a valve body having a valve strike face, wherein the pump fluid end oscillates the valve between an open and closed position, wherein the valve strike face contacts the seat strike face when the valve is in a closed position;
• and
• a seal insert attached to the valve body and forming at least a portion of the valve strike face, the seal insert comprising a scaffold portion made of a foaming material having open cells formed therein, and a filler portion made of a moldable material that substantially fills the open cells of the foaming material.