5 Critical Quality Tests Every Nozzle Must Pass

In industrial automation systems, nozzles are small components, yet they frequently perform critical tasks such as precise spraying, liquid cooling, gas distribution, and atomization. Particularly in industries like spraying, chemicals, food processing, papermaking, and power generation, the demands on nozzle performance are extremely rigorous. Consequently, comprehensive testing before they leave the factory has become the unwavering quality standard for Xinhou's series of nozzle products.

Why do nozzles need systematic quality testing?

Nozzles are precision-machined parts that usually have to withstand the following complex working conditions:

• Frequent start-stop cycles and pressure shocks

• Long-term erosion by complex media (such as acidic and alkaline fluids, particles, and steam)

• Strict requirements for spray angle, coverage, and droplet size

• High reliance on air tightness and flow control accuracy

Even a minor deviation can reduce the overall system's efficiency or cause potential accidents. To prevent this, Xinhou employs a comprehensive 'five-dimensional detection system' that assesses materials, structures, performance, and lifespan before nozzles are shipped from the factory. This ensures each component functions correctly and meets its intended purpose.

Appearance and dimensional accuracy inspection

Objective

To ensure the machining accuracy and structural consistency of nozzle components, guaranteeing that subsequent assembly and sealing performance meet standards.

Inspection Method

Utilize a Coordinate Measuring Machine (CMM) for measuring complex surfaces and cone angles. Employ high-magnification microscopic imaging systems to capture micro-defects on small-sized openings. Standard tolerances control precision up to ±0.005mm, significantly exceeding industry averages.

Inspection Content Includes

Material surface roughness (Ra value) to ensure compliance with design spray requirements. Nozzle orifice diameter, inlet and outlet thread dimensions, cone angle, and other critical parameters.

Seal integrity and air tightness testing

Purpose

It is one of the most critical safety tests to verify whether there is a risk of leakage in the nozzle under working pressure.

Testing principle

Use static pressure method or micro-pressure differential method to pressurize the inner cavity of the nozzle (usually 1.5 times the rated pressure) and measure whether there is gas/liquid leakage.

Use bubble method and water bath method to observe micro-leakage points, and the limit detection capability can reach 0.1cc/min micro-leakage.

Testing standard

Adhere to GB/T 4214, ISO 20485, and other sealing test standards. All high-pressure nozzle products must be certified as leak-free after continuous pressurization for at least 15 minutes.

Flow rate and spray precision testing

Objective

Verify whether the core functions of the nozzle meet the standards, including spray angle, uniformity of flow rate, and distribution of droplet size.

Testing tool

Use an automatic spray analysis system that includes a flow meter, high-speed camera, and image analysis software. This system can simulate different pressures and fluid media, allowing for comparisons between theoretical spray curves and actual measurement patterns.

Testing metrics

Spray angle deviation ≤ ±2°.

Droplet size control Dv50 ≤ 100μm (depending on different models).

Flow rate deviation ≤ ±1.5%, better than the industry average of ±3%.

Material and surface corrosion resistance testing

Objective

Ensure the stability of the nozzle in a long-term chemical environment and prevent failure due to corrosion or material stress cracking.

Test method

Run the neutral salt spray tester (NSS) continuously for 96-168 hours. Confirm the material composition ratios using a spectrometer to avoid using recycled or inferior steel. Introduce laser confocal technology to monitor microscopic surface changes before and after corrosion.

Material Selection

Commonly used corrosion-resistant polymer materials include 316L, Hastelloy C-276, PVDF, and PEEK.

Fatigue life and high-frequency impact testing

Objective

Simulate the start-stop shocks and micro-vibrations that a nozzle experiences during actual use to predict its long-term reliability.

Testing platform

Using a servo control test system, simulate the opening and closing cycles of nozzles or hydraulic shocks. Each nozzle must run at least 50,000 to 100,000 continuous cycles, combined with temperature rise monitoring and thermal fatigue analysis.

Lifespan standard

High-load models must ensure no structural changes or spray offset during continuous use for one year.

Conclusion

For Xinhou, every nozzle is not just a product but also a commitment to the reliability of industrial systems. From raw material selection to high-precision manufacturing, and through rigorous quality control in five core inspection processes, we consistently adhere to the design philosophy of 'letting customers worry-free.'

- Xinhou insists on data-driven quality, integrating testing into every production step.

- A 100% pre-delivery full inspection system, with zero sampling inspections.

- Fully compliant with ISO 9001 quality system, ISO 14001 environmental system, and other certification standards.

 Contact Xinhou's technical team for more information on nozzle product testing standards and sample applications.