An Erosion-Corrosion Investigation of Coated Steel for Applications in the Oil and Gas Field, Based on Bipolar Electrochemistry

Mele, Claudio; Lionetto, Francesca; Bozzini, Benedetto

doi:10.3390/coatings10020092

Cited by 14 publications

(8 citation statements)

References 27 publications

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“…Presently, in developed countries such methods are used to extend the service life of mining and drilling tools as well as to make corrosion resistant layers. The powder plasma transferred arc welding (PPTAW) or the laser metal deposition (LMD) are used by, among others, General Electric Oil&Gas and Honeywell International, i.e., leading oil and gas producers [ 23 , 24 ], as well as by many manufacturers of plasma arc welding systems. Various plasma arc welding methods can be applied to make surface layers using nearly any metallic material.…”

Section: Introductionmentioning

confidence: 99%

Microstructure and Abrasive Wear Resistance of Metal Matrix Composite Coatings Deposited on Steel Grade AISI 4715 by Powder Plasma Transferred Arc Welding Part 1. Mechanical and Structural Properties of a Cobalt-Based Alloy Surface Layer Reinforced with Particles of Titanium Carbide and Synthetic Metal–Diamond Composite

Czupryński

2021

Materials

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The article discusses test results concerning an innovative surface layer obtained using the cladding with powder plasma transferred arc welding (PPTAW) method. The above-named layer, being a metal matrix composite (MCM), is characterised by high abrasive wear resistance, resistance to pressure and impact loads, and the possibility of operation at elevated temperatures. The layer was made using powder in the form of a cobalt alloy-based composite reinforced with monocarbide TiC particles and superhard spherical particles of synthetic metal–diamond composite provided with tungsten coating. The surface layer was deposited on a sheet made of low-alloy structural steel grade AISI 4715. The layer is intended for surfaces of inserts of drilling tools used in the extraction industry. The results showed the lack of the thermal and structural decomposition of the hard layer reinforcing the matrix during the cladding process, its very high resistance to metal-mineral abrasive wear and its resistance to moderate impact loads. The abrasive wear resistance of the deposited layer with particles of TiC and synthetic metal–diamond composite was about than 140 times higher than the abrasive wear resistance of abrasion resistant heat-treated steel having a nominal hardness of 400 HBW. The use of diamond as a metal matrix reinforcement in order to increase the abrasive resistance of the PPTAW overlay layer is a new and innovative area of inquiry. There is no information related to tests concerning metal matrix surface layers reinforced with synthetic metal–diamond composite and obtained using PPTAW method.

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Section: Introductionmentioning

confidence: 99%

Microstructure and Abrasive Wear Resistance of Metal Matrix Composite Coatings Deposited on Steel Grade AISI 4715 by Powder Plasma Transferred Arc Welding Part 1. Mechanical and Structural Properties of a Cobalt-Based Alloy Surface Layer Reinforced with Particles of Titanium Carbide and Synthetic Metal–Diamond Composite

Czupryński

2021

Materials

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“…Table 1 presents some metal matrix composite (MMC) powders used for PPTAW surface modification, as reported by other studies. The use of MMC with carbide reinforcements, such as WC, TiC, etc., fosters the combination of the properties of the metal matrix, such as plasticity, corrosion resistance and wear resistance, with that of the hard carbide reinforcement [ 16 ]. In application, such surface layers enable the material to withstand high impact loads and to perform better against abrasive wear.…”

Section: Introductionmentioning

confidence: 99%

Powder Plasma Transferred Arc Welding of Ni-Si-B+60 wt%WC and Ni-Cr-Si-B+45 wt%WC for Surface Cladding of Structural Steel

et al. 2022

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Increasing demand for sustainable approaches to mining and raw material extraction, has prompted the need to explore advanced methods of surface modification for structural steels used in the extractive industry. The technology of powder plasma transferred arc welding (PPTAW), was used in this study as a surface modification technique to improve upon the abrasive wear resistance of structural steel grade EN S355. PPTAW process parameters, namely, plasma transferred arc (PTA) current and plasma gas flow rate (PGFR), were varied, and the effects of the variation were studied and used as criteria for selecting optimum conditions for further studies and parametric reproducibility. Two metal matrix composite (MMC) powders were used in the process, having compositions of Ni-Si-B+60wt%WC (PG) and Ni-Cr-Si-B+45wt%WC (PE). Microstructural observation under a scanning electron microscope (SEM) revealed a dendritic, multi-directional microstructure consisting of partially dissolved primary tungsten carbide particles and secondary tungsten carbide precipitates within the MMC solid solution. The hardness of the surface layers was higher than that of a reference AR400 steel by more than 263 HV. Final surface layers obtained from the MMC powders had abrasive wear resistance up to 5.7 times that of abrasion-resistant reference AR400 steel. Alloying the MMC matrix with chromium increased the hardness by 29.4%. Under the same process conditions, MMC powder with 60wt% WC reinforcement had better abrasive wear resistance by up to 45.8% more than the MMC powder with 45wt% WC.

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“…Metal matrix composite (MMC) layers reinforced with, e.g., TiC, WC, B 4 C, Cr 3 C 2 , NbC, etc. particles, combine the properties of the plastic, abrasive wear and corrosion resistant matrix with the properties of hard carbide ceramics [ 27 ]. Surface layers of the aforesaid type can be used where it is necessary to ensure high abrasive wear resistance combined with resistance to dynamic impact loads.…”

Section: Introductionmentioning

confidence: 99%

Microstructure and Abrasive Wear Resistance of Metal Matrix Composite Coatings Deposited on Steel Grade AISI 4715 by Powder Plasma Transferred Arc Welding Part 2. Mechanical and Structural Properties of a Nickel-Based Alloy Surface Layer Reinforced with Particles of Tungsten Carbide and Synthetic Metal–Diamond Composite

Czupryński

2021

Materials

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The article is the continuation of a cycle of works published in a Special Issue of MDPI entitled “Innovative Technologies and Materials for the Production of Mechanical, Thermal and Corrosion Wear-Resistant Surface Layers and Coatings” related to tests concerning the microstructure and mechanical properties of innovative surface layers made using the Powder Plasma Transferred Arc Welding (PPTAW) method and intended for work surfaces of drilling tools and machinery applied in the extraction industry. A layer subjected to tests was a metal matrix composite, made using powder based on a nickel alloy containing spherical fused tungsten carbide (SFTC) particles, which are fused tungsten carbide (FTC) particles and spherical particles of tungsten-coated synthetic metal–diamond composite (PD-W). The layer was deposited on the substrate of low-alloy structural steel grade AISI 4715. The results showed that the chemical composition of the metallic powder as well as the content of the hard phase constituting the matrix enabled the making of a powder filler material characterised by very good weldability and appropriate melting. It was also found that the structure of the Ni-WC-PD-W layer was complex and that proper claddings (characterised by the uniform distribution of tungsten carbide (WC)) were formed in relation to specific cladding process parameters. In addition, the structure of the composite layer revealed the partial thermal and structural decomposition of tungsten carbide, while the particles of the synthetic metal–diamond composite remained coherent. The deposited surface layer was characterised by favourable resistance to moderate dynamic impact loads with a potential energy of 200 J, yet at the same time, by over 12 times lower metal–mineral abrasive wear resistance than the previously tested surface layer made of cobalt-based composite powder, the matrix of which contained the hard phase composed of TiC particles and synthetic metal–diamond composite. The lower abrasive wear resistance could result from a different mechanism responsible for the hardening of the spherical particles of the hard phase susceptible to separation from the metal matrix, as well as from a different mechanism of tribological wear.

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An Erosion-Corrosion Investigation of Coated Steel for Applications in the Oil and Gas Field, Based on Bipolar Electrochemistry

Cited by 14 publications

References 27 publications

Powder Plasma Transferred Arc Welding of Ni-Si-B+60 wt%WC and Ni-Cr-Si-B+45 wt%WC for Surface Cladding of Structural Steel

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