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Oil and Gas Applications
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Proceedings Papers
ITSC2012, Thermal Spray 2012: Proceedings from the International Thermal Spray Conference, 515-520, May 21–24, 2012,
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Cold-gas dynamic spraying (“cold-spraying”) at low pressure (1034kPa/150 psig) was used to fabricate WC-Ni-Cu metal matrix composite (MMC) coatings. Tungsten carbide (WC)- based powder was mechanically blended with nickel (Ni) and copper (Cu) powder at various compositions. X-ray diffraction (XRD), scanning electron microscopy (SEM), and Vickers micro-hardness testing were conducted on the cold-sprayed coatings. Image analysis was used to determine the WC content in the coatings. XRD profiles showed that no decarburization or oxidation of the WC reinforcing particles occurred in any of the coatings. The WC content in the coatings increased as the WC content in the powder increased, but did not increase further beyond 96 wt. % WC content in the powder blend. The results from Vickers micro-hardness testing confirmed that the coatings with the highest amount of WC had the highest hardness value. The coatings fabricated with a powder composition of 96 wt. % WC + 2 wt. % Ni + 2 wt. % Cu yielded a hardness of 385 ± 73 HV 0.3 /10 (n = 50). These results suggest that it is possible to use cold-spraying at low pressure to fabricate WC-based MMC coatings with improved hardness.
Proceedings Papers
ITSC2012, Thermal Spray 2012: Proceedings from the International Thermal Spray Conference, 521-528, May 21–24, 2012,
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Thermally sprayed ceramic coatings such as plasma-sprayed alumina exhibit a composite microstructure due to the presence of defects such as pores, interlamellar and intra-lamellar cracks. These second phase typed features influence the mechanical behaviour of the coating dramatically. In this study, an excimer laser surface treatment of plasma-sprayed alumina surface was developed for the optimization of component properties of a wireline tool used in the oil industry. In contrast to liquid phase treatment realized with CO 2 or YAG laser, an excimer laser processing presents short wavelength which means that for ceramic materials, the energy is absorbed in a region of the surface. This condition leads to surface treatment free of cracks. Effect of laser operating parameters, i.e. wavelength, pulse number and power density, on microstructure and the sealing quality of the coating are discussed. First, surfaces and cross sections of the microstructures were studied using image analysis of scanning electron microscope (SEM). Surface roughness and coating ablation were characterized according to laser treatment. Then, three dimensional (3D) microstructures were obtained using X-ray microtomography to evaluate the 3D porosity after laser treatment. Finally, nanoindentation and Electrochemical Impedance Spectroscopy (EIS) were carried out to characterize respectively the mechanical and electrical properties of the modified coating microstructure. The excimer laser surface processing was shown to be an innovative process to control the insulating characteristics of plasma-sprayed alumina.
Proceedings Papers
ITSC2012, Thermal Spray 2012: Proceedings from the International Thermal Spray Conference, 529-534, May 21–24, 2012,
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Recent developments of High-Velocity Air-Fuel (HVAF) spraying and blasting focused on a substantial increase of spray particles velocity. The efforts further improved coating quality, allowing deposition of metallic and carbide-base coatings non-permeable to gas at thickness as low as 40-50 micron. The coatings demonstrate low dissolved oxygen content, a favorable combination of high hardness and toughness. Coupled with the enhanced technological efficiency of modern HVAF equipment, this initiated not only the acceptance of HVAF technologies in established thermal spray markets in the oil and gas industry, but also the development and successful implementation of new coating applications. The examples are wear and corrosion resistant tungsten carbide-based coatings on hydraulics rods of dock cranes, corrosion resistant Ni-Cr-Mo-type coatings on vessels of sulfur removal equipment, tungsten carbide coatings on restriction grid plates and slide gates of catalyst towers, high-temperature erosion resistant chromium carbide- based coatings on thermowells and valve stems, wear and cavitation resistant Co-Cr-W-C-type and carbide coatings on housing wear rings and impeller hubs of high-temperature pumps.
Proceedings Papers
ITSC2012, Thermal Spray 2012: Proceedings from the International Thermal Spray Conference, 535-539, May 21–24, 2012,
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The processing of oil sand and heavy oil deposits is a highly aggressive environment. The combination of abrasive sands and corrosive media can lead to shortened and unpredictable component lives. A common method to try and extend the operational life of equipment is the application of tungsten carbide-based coatings by HVOF spraying. A number of commercial nanostructured coatings have been developed for this type of application. In this study, results will be presented that assess the effects of using a nanostructured tungsten carbide-based powder on the mechanical and wear-resistant properties of a HVOF-deposited coating.
Proceedings Papers
ITSC2012, Thermal Spray 2012: Proceedings from the International Thermal Spray Conference, 540-543, May 21–24, 2012,
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An important problem for the petrochemical industry is the behaviour of materials in aggressive environments, when hydrogen sulphide, carbon dioxide and sand, which contribute to corrosion erosion of the surface, are present. Generally, the use of hard materials such as thermal sprayed tungsten carbide and chromium carbide reduces this problem. Cemented carbides are quite suitable for this purpose: they are composite materials of pure carbides with binder metal alloys of low melting point and high ductility; the selection of the binder metals depends mostly on its ability to wet the surface of the carbide particles to ensure secure coating adhesion. Among the cemented carbides, namely tungsten carbide cobalt-chromium based (WC/CoCr) is considered as the standard for application to ball valve bodies and seats in the petrochemical field, while chromium carbide nickel-chromium based (Cr 3 C 2 /NiCr) is suitable for particular applications. Inconel 625 is also used in this field and usually applied by welding. This paper addresses the characterization of corrosion behavior of HVOF coated samples of WC/CoCr, Cr 3 C 2 /NiCr and Inconel 625 in aggressive environments, and in particular ferric chloride test according to standard ASTM G48-92 and H 2 S/CO 2 test based on NACE standards has been carried out. According to the test results, WC/CoCr based coatings show the best behavior both in terms of corrosion, thus confirming to be very versatile and useful for the application in petrochemical field.
Proceedings Papers
ITSC2012, Thermal Spray 2012: Proceedings from the International Thermal Spray Conference, 544-549, May 21–24, 2012,
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In this paper evaluation of sealed and unsealed thermally sprayed aluminum (TSA) for the protection of 22%Cr duplex stainless steel (DSS) from corrosion in aerated, elevated temperature synthetic seawater is presented. The assessments involved general and pitting corrosion tests, external chloride stress corrosion cracking (SCC), and Hydrogen induced stress cracking (HISC). These tests indicate that DSS samples which would otherwise fail on its own in a few days do not show pitting or fail under chloride SCC and HISC conditions when coated with TSA (with or without a sealant). TSA-coated specimens failed only at very high stresses (>120% proof stress). In general, TSA offered protection to the underlying or exposed steel by cathodically polarizing it and forming a calcareous deposit in synthetic seawater. The morphology of the calcareous deposit was found to be temperature dependent and in general is of duplex nature. The free corrosion rate of TSA in synthetic seawater was measured to be ~5-8 µm/year at ~18°C and ~6-7 µm/year at 80°C.
Proceedings Papers
ITSC2012, Thermal Spray 2012: Proceedings from the International Thermal Spray Conference, 550-555, May 21–24, 2012,
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Twin wire arc spray (TWAS) coatings were produced under varying spray conditions (spray angle, traverse rate, and spray distance) to simulate on-site hand spraying operations typically used to coat existing refinery vessels. Two materials, Alloy C276 (commonly used for corrosion protection of refinery vessels) and the newly developed Nicko-Shield 200 chemistry (designed to reduce porosity and oxide content under arc spray conditions) were compared in the testing. Alloy C276 coatings showed good coating performance (>40 MPa adhesion) when sprayed under ideal conditions, but showed a sharp drop off in coating integrity (<20 MPa adhesion) when sprayed at lower traverse rates, sharper angles, and closer spray distances. Deviating from non-ideal conditions resulted in increased porosity and oxide content leading to increased permeability. It was concluded that non-ideal conditions, which intermittently occur in hand spraying operations on large surface areas, can lead to coating patches with unacceptably low adhesion, potential spalling, and high permeability when spraying Alloy C276. Patches of low coating quality require additional maintenance or result in coating failure, creating a lack of confidence in thermal spray technology as a protective solution in the industry. This study shows the results of an effort to develop an alloy solution which is more reliable in spraying large surface areas by hand for corrosion protection. The developed Ni-based material showed improved adhesion (70+ MPa) and greatly reduced permeability (as measured by ferroxyl exposure). This performance was stable across the wide range of spray conditions used in this study. This suggests that alloy design can be used to increase the reliability for twin wire arc spray coatings, and enable confidence for expanded use in this industry.
Proceedings Papers
ITSC2012, Thermal Spray 2012: Proceedings from the International Thermal Spray Conference, 556-561, May 21–24, 2012,
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Computational metallurgy is a technique being used and developed in the field of bulk alloys to design and develop novel amorphous and nanocrystalline materials. This technology can be transitioned to develop chemistries for both wear and corrosion resistant thermal spray coatings. Using computational metallurgy and small scale laboratory experiments, nanostructured and amorphous chemistries can be designed to specifically accommodate one of the many environmental conditions challenging the oil and gas industry. This study reviews the design procedures behind developing three unique chemistries intended to function in different environments: 1) an Fe-based chemistry designed for metal to metal sliding wear resistance, 2) an Fe-based chemistry containing elevated refractory content intended specifically for spray and fuse applications to resist sulfurous corrosion, and 3) a Ni-based chemistry similar to Alloy C276 for high temperature corrosion resistance. All three alloys were designed using computational techniques and eventually manufactured into cored wires for use within the twin wire arc spray (TWAS) process. The fine grained structure provides unique benefits to each application including 1) high hardness, 2) ability to rapidly form protective scale, 3) low melting temperature and creep resistance.