WEAR RESISTANT THERMAL SPRAY ALLOY

Information

  • Patent Application
  • 20240301538
  • Publication Number
    20240301538
  • Date Filed
    March 08, 2024
    a year ago
  • Date Published
    September 12, 2024
    5 months ago
Abstract
A thermal spray alloy system that is more resistant to corrosion and erosion and hard-wear abrasion than conventional alloy compositions, and may be applied to a substrate by conventional welding techniques or thermal spray. The alloy may comprise carbon, nitrogen, and boron, in addition to chromium and other elements. The object to be coated may be any downhole component used in the oil and gas industry, or may be applied to any object or tool that needs an increased wear and/or corrosive protection layer including in diverse fields such as marine, chemical processing, and refining. A thermal spray coating with the alloy composition provides increased strength and resistance to spalling, breaking, cracking, deforming, and crack formation.
Description

This application claims priority to U.S. provisional patent application No. 63/489,475, filed on Mar. 10, 2023, and claims priority to U.S. provisional patent application No. 63/518,746, filed on Aug. 10, 2023, the entire contents of which is incorporated herein by reference.


BACKGROUND OF THE INVENTION
Field of the Invention

The invention relates to coatings applied to equipment and other substrates, and more particularly to an improved wear and corrosion resistant alloys for a wide range of substrates, including downhole equipment in oil and gas wells.


Description of the Related Art

Drilling wells for oil and gas recovery, as well as for other purposes, involve the use of drill pipes and other downhole equipment necessary for the exploration and production of oil and gas. Downhole equipment is exposed to severe abrasive wear conditions and corrosive environments.


Thermal spray coatings have been used to help prevent (or mitigate) wear conditions for downhole components, but existing alloys are not particularly helpful for corrosive applications. As is known in the art, the term “thermal spray” is a generic term for a group of processes in which metallic, ceramic, cermet, and some polymeric materials in the form of powder, wire, or rod are fed to a torch or gun with which they are heated to near or somewhat above their melting point. The resulting molten or nearly molten droplets of materials are projected against the surface to be coated. Upon impact, the droplets flow into thin lamellar particles adhering to the surface, overlapping and interlocking as they solidify. The total coating thickness is usually generated in multiple passes of the coating device; depending on the application, the layer may be applied in thick deposits exceeding 0.100,″ although ranges in the amount between 0.020″ up to 3.0″ are possible. Various thermal spray techniques may include flame spraying, flame spray and fuse, electric-arc (wire-arc) spray, and plasma spray. Thermal spray may be applied to a wide variety of tools, equipment, structures, and materials, and is not limited to merely downhole components. Thermal spray with special alloys is applied to drill pipe, casing, sucker rods and other components used in the drilling, completion and production of oil and natural gas. Among other benefits, this application is used to mitigate wear, reduce friction, and to create a standoff from the annulus of the hole.


The prior art discloses various methods for thermal spraying. For example, U.S. Pat. No. 7,487,840 (“the '840 patent”), incorporated herein by reference, discloses a protective wear coating on a downhole component for a well through a thermal spraying process in combination with an iron-based alloy. The thermal spraying process melts the material to be deposited while a pressurized air stream sprays the molten material onto the downhole component. The coating operation takes place at low temperatures without fusion or thermal deterioration to the base material. The wear resistance is increased while providing a lower coefficient of friction by the wear resistant layer relative to a coefficient of friction of the downhole equipment without the wear resistant layer. FIG. 3 of the '840 patent is reproduced in the present disclosure as FIG. 1A as an exemplary thermal spraying process that may be used in conjunction with the present invention.


Likewise, U.S. Pat. No. 9,920,412 (“the '412 patent”), incorporated herein by reference, discloses a similar thermal spray technique with a chromium free composition of thermally sprayed material. The '412 patent discloses applying this composition onto tubulars to form centralizers. While conventional thermally sprayed layers (such as that disclosed in the '840 patent and the '412 patent) are useful in numerous instances, such compositions are not helpful for corrosive environments. There is a need in the oil industry for a highly corrosion resistant thermal spray product. Many oil wells contain highly corrosive compounds, including hydrogen sulfide, carbon dioxide, salt water, and microbes. Each of these induces destructive corrosion leading to leaks and failure of metal components that are used for flow control and pumping. Failure requires that a work over rig be contracted and the components pulled from the well and replaced, resulting in production down time and the expense of the work over rig as well as the replacement of the component. These oil production components stay in the well and remain in constant contact with the oil and corrosive agents.


Rather than manufacturing the components from solid corrosion resistant alloys, low alloy steels are often specified and then coated with a corrosion resistant alloy using the thermal spray process. For example, one current approach is to use twin wire arc spray (TWAS) where one wire is AWS A5.11 ERNiCu-7 (commonly known as Monel) and the second wire is stainless steel, such as AWS A5.9 ER316L. However, this combination, while better than other alloys, still corrodes at rates faster than desired.


Various alloys have utilized copper and nickel alloys for different purposes and different compositions than described herein. For example, U.S. Pat. No. 9,631,157, incorporated herein by reference, discloses a copper-nickel-tin alloy that is focused on friction and wear (not corrosion prevention), and the deposit is heat treated after deposition on a surface. U.S. Pat. No. 4,641,976, incorporated herein by reference, also discloses a copper-nickel-tin alloy that is used on a metal bearing and is focused on friction and wear protection as opposed to corrosion prevention. U.S. Patent Publication No. 2002/0197132, incorporated herein by reference, discloses a copper-nickel alloy that is used for sucker rod coupling. It is heat treated after deposition on a surface and has a different composition than that described herein.


Various data exists that displays various corrosive effects of different materials and/or compositions with different corrosive media. For example, Oilfield Metallurgy and Corrosion (4th Edition), available from National Association of Corrosion Engineers (NACE) International, provides a table of different corrosive media that causes stress-corrosion cracking. See, e.g., Table 2-5 on page 83, incorporated herein by reference. As illustrated in Table 2-5, copper nickel is referenced as material no. 11 and Monel is referenced as material no. 13, and these alloys provide corrosion resistance to the vast majority of corrosive media tested, and particularly those likely to be found in downhole conditions. The following corrosive media are potentially problematic in downhole conditions: hydrogen sulfide, carbon dioxide, carbonic acid, and chloride salts (sodium chloride and potassium chloride), among others. Further, micro-biologicals downhole have been known to emit chemicals that corrode downhole components.


Applicant produces a product labeled CUNIA, which is a copper-based alloy that can be thermally sprayed on various items, including downhole pipe. Such a product and method of use is disclosed in U.S. Pat. No. 10,982,310 (“the '310 patent”), incorporated herein by reference. FIG. 2B of the '310 patent is reproduced in the present disclosure as FIG. 1B. Another thermally sprayed composition in the prior art is found in U.S. Pat. No. 10,577,685, incorporated herein by reference.



FIG. 1C illustrates one example of spalling found on drill pipes that exists in the prior art. Spalling is a widely recognized problem for downhole equipment, such as drill pipes. Thermally sprayed wear bands have been applied to the mid-tube region but have failed by spalling. Due to chloride corrosion that enters micro-cracks inherent in the coating, free iron is converted to rust (iron oxide) which swells, thereby opening up the micro-cracks even further. The cracks develop generally vertically to near the bond line with the steel substrate, then further develop horizontally until patches of the coating detach.


The modern drilling of oil and gas wells incorporates a tool called a power section, also known as a motor or mud motor. This tool utilizes the Moyno Pump principle to rotate the drill bit. Drilling fluids pass through the tool causing a fluted rotor to rotate inside a fluted tube. The fluted tube is a steel or stainless steel pipe that has a fluted rubber like material bonded inside. The crowns of the flutes on the interior rotor mate closely with the crowns on the rubber like fluted pipe lining. Further, the flutes on the rotor are thermally sprayed with a thin tungsten carbide coating or are hard chromium plated to reduce wear and prevent corrosion and erosion. The flutes on the rotor are routinely damaged by small rocks or debris in the drilling fluid such that chips or flakes of the tungsten carbide or chromium coating are cracked and dislodged leaving a sharp edge and exposing the now non-coated area to corrosion and erosion. As rough spots occur in the pipe, the loss of thickness allows fluid pressure loss and leads to erosion. Further, even though the rotor is made from a precipitation hardened stainless steel, it corrodes rapidly during exposure to brine in the drilling fluid. Corrosion and erosion is further accelerated because of the high pressures and temperatures in downhole environments, which further decrease the efficiency of the tool until it has to be replaced. FIG. 1D illustrates one example of a rotor defect found on drill pipes that exists in the prior art.


During the drilling of oil and gas wells, drill pipe is subject to wear on the tool joints and in the center of the pipe. Modern old and gas wells are drilled in three increments, which are the vertical hole, the curved or build section where the well transitions from vertical to horizontal, and the horizontal section. In the horizontal section, the pipe is subject to bending from compressive loading and gravity causing the center of the drill pipe tube to repeatedly contact the abrasive formation. This induces substantial wear on the drill pipe. As the pipe wears, the wall thickness is reduced to where the pipe is no longer trusted to perform. This limit is typically seventy percent of new wall thickness. Currently, drill pipe is in short supply and expensive.


A need exists for an improved alloy for downhole components. A need exists for an improved method and system for thermally sprayed layers that are more resistant to corrosion. A need exists for an improved method and system for thermally sprayed layers on downhole components that is more corrosion resistant to conditions existing in downhole environments. A need exists for a new alloy and method for repairing downhole components. A need exists for a new thermal spray alloy that is applied in bands near the center of the pipe.


SUMMARY OF THE INVENTION

The present disclosure provides a thermal spray alloy system that is more resistant to corrosion and erosion and hard-wear abrasion than conventional alloy compositions, and may be applied to a substrate by conventional welding techniques or thermal spray. The disclosed alloy may comprise carbon, nitrogen, and boron, in addition to chromium and other elements. The object to be coated may be any downhole component used in the oil and gas industry, or may be applied to any object or tool that needs an increased wear and/or corrosive protection layer including in diverse fields such as marine, chemical processing, and refining. A thermal spray coating with the disclosed alloy composition provides increased strength and resistance to spalling, breaking, cracking, deforming, and crack formation.


Disclosed is an iron-based alloy, the composition comprising the following components: about 0.2 wt % to about 2.0 wt % of carbon, about 0.2 wt % to about 2.0 wt % of nitrogen, about 0.4 wt % to about 7.0 wt % of boron, about 0.0 wt % to about 5.0 wt % of manganese, about 0.0 wt % to about 7.0 wt % of chromium, about 0.0 wt % to about 5.0 wt % of titanium, about 0.0 wt % to about 2.5 wt % of aluminum, and about 0.0 wt % to about 2.0 wt % of zirconium, with iron being a principal remaining element of the composition. The composition may comprise about 0.3 wt % to 1.5 wt % of carbon and 0.3 wt % to 1.5% nitrogen. The composition may comprise about 0.3 wt % to 1.15 wt % of carbon and 0.3 wt % to 1.15% nitrogen. The composition may comprise about 1.0 wt % carbon and about 1.0 wt % nitrogen, or other compositions where the composition of carbon and nitrogen is approximately the same. The composition may comprise about 1.5 wt % to about 6.0 wt % of boron. The composition may comprise at least 2.0 wt % of boron. The composition may comprise at least 5.0 wt % of boron. The composition may comprise about 0.5 wt % to about 2.0 wt % of manganese. The composition may comprise about 0.5 wt % to about 2.0 wt % of chromium. The composition may comprise about 0.3 wt % to about 3.0 wt % of titanium. The composition may comprise about 0.3 wt % to about 1.0 wt % of aluminum. The composition may comprise about 0.3 wt % to about 1.0 wt % of zirconium.


The composition may be contained within a cored wire. The amount of boron may be configured to provide hardness to the alloy. The amount of carbon and nitrogen may be configured to keep carbon in solution to the alloy. The composition may be configured for being thermally sprayed on a substrate. The composition may be configured for being welded on a substrate. The composition is effective to prevent micro-cracks from forming in the alloy.


Also disclosed is a stainless steel alloy, wherein the composition comprising the following components: about 0.2 wt % to about 1.5 wt % of carbon, about 0.2 wt % to about 1.5 wt % of nitrogen, about 10.0 wt % to about 35.0 wt % of chromium, about 0.0 wt % to about 35.0 wt % of nickel, about 0.0 wt % to about 3.0 wt % of silicon, about 0.0 wt % to about 7.5 wt % of molybdenum, about 0.0 wt % to about 8.0 wt % of copper, and about 0.1 wt % to about 2.0 wt % of boron, with iron being a principal remaining element of the composition. The composition may comprise about 0.4 wt % to 1.15 wt % of carbon and 0.3 wt % to 1.15% nitrogen. The composition may comprise about 2.0 wt % to about 25.0 wt % of nickel. The composition may comprise at least 0.5 wt % of boron.


Also disclosed is a thermally sprayed coating on a substrate, wherein the coating comprises a coating of thermally sprayed metallic material on a substrate, wherein the coating is formed by one or more layers of metallic material that comprises the following components: about 0.2 wt % to about 2.0 wt % of carbon, about 0.2 wt % to about 2.0 wt % of nitrogen, and about 0.1 wt % to about 7.0 wt % of boron, with iron being a principal remaining element of the composition. The metallic material may comprise the following composition: about 0.3 wt % to 1.15 wt % of carbon, about 0.3 wt % to 1.15% nitrogen, and at least 0.5 wt % of boron. The substrate may be a downhole component, such as a band on a tubular or a downhole rotor.


Also disclosed is a method for applying a coating to a substrate, wherein the method comprises comprising thermally spraying metallic material on an external surface of a substrate to form a thermal spray layer on the substrate, wherein the material, at least prior to being sprayed, comprises the following components: about 0.2 wt % to about 2.0 wt % of carbon, about 0.2 wt % to about 2.0 wt % of nitrogen, and about 0.1 wt % to about 7.0 wt % of boron, with iron being a principal remaining element of the composition. The substrate may be a downhole component, such as a band on a tubular or a downhole rotor.





BRIEF DESCRIPTION OF THE DRAWINGS

The following drawings form part of the present specification and are included to further demonstrate certain aspects of the present invention. The invention may be better understood by reference to one or more of these drawings in combination with the detailed description of specific embodiments presented herein.



FIG. 1A illustrates one prior art method of thermally spraying a downhole component, which is taken from FIG. 3 of U.S. Pat. No. 7,487,840.



FIG. 1B illustrates one prior art method of thermally spraying a downhole component, which is taken from FIG. 2B of U.S. Pat. No. 10,982,310.



FIG. 1C illustrates one example of spalling found on drill pipes that exists in the prior art.



FIG. 1D illustrates one example of a rotor defect found on drill pipes that exists in the prior art.



FIGS. 2A-2C illustrate cross-sectional views of a thermally sprayed layer of the disclosed stainless steel alloy composition, according to one embodiment of the present disclosure.



FIG. 3 illustrates a cross-sectional view of a thermally sprayed layer of the disclosed iron-based alloy composition, according to one embodiment of the present disclosure.



FIGS. 4A-4C illustrate cross-sectional views of thermally sprayed layers of different alloys, according to one embodiment of the present disclosure.



FIG. 5 illustrates a downhole tool with a repair weld made with the disclosed alloy after field tests, according to one embodiment of the present disclosure.



FIG. 6 illustrates a downhole tool with thermally sprayed bands of the disclosed iron-based alloy composition sprayed on drill pipe, according to one embodiment of the present disclosure.





DETAILED DESCRIPTION

Various features and advantageous details are explained more fully with reference to the nonlimiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well known starting materials, processing techniques, components, and equipment are omitted so as not to unnecessarily obscure the invention in detail. It should be understood, however, that the detailed description and the specific examples, while indicating embodiments of the invention, are given by way of illustration only, and not by way of limitation. Various substitutions, modifications, additions, and/or rearrangements within the spirit and/or scope of the underlying inventive concept will become apparent to those skilled in the art from this disclosure. The following detailed description does not limit the invention.


Reference throughout the specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with an embodiment is included in at least one embodiment of the subject matter disclosed. Thus, the appearance of the phrases “in one embodiment” or “in an embodiment” in various places throughout the specification is not necessarily referring to the same embodiment. Further, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.


OVERVIEW

The present disclosure provides a thermal spray alloy system that is more resistant to corrosion and erosion and hard-wear abrasion than conventional alloy compositions. The alloy may be an iron-based alloy or a stainless-steel based alloy, both of which are disclosed embodiments of the present application. In one embodiment, the present disclosure discloses an alloy that comprises both carbon and nitrogen. The nitrogen and carbon combination is utilized to enhance hardness of the alloy. In one embodiment, the present application relies on the synergistic effect of carbon and nitrogen added in high levels


The prior art alloys typically do not include nitrogen, as it is hard to stay in solution of the composition. In arc welding, nitrogen is used in small amounts, such as 0.10-0.25 weight percent, in stainless steel. Duplex alloys are used create a stronger and more corrosion resistant weld on similarly alloyed base metals. These duplex alloys typically have very low carbon content such as 0.025-0.06 weight percent. But when nitrogen is above 0.35 percent the nitrogen is rejected on solidification into trapped bubbles or porosity, rendering the weld defective.


In one embodiment of the present disclosure, carbon in the right proportions to nitrogen allows both elements to stay in solution. For example, when carbon and nitrogen are added in similar amounts, such as 0.75 weight percent as one example, the nitrogen remains in solution. The alloy may also contain boron, which is used to increase the hardness and wear resistance of the alloy. In one embodiment, the disclosed alloy relies on the synergistic effect of carbon, nitrogen, and boron in a low alloy steel matrix.


The alloy may be hardband welded to a substrate or thermally sprayed on a substrate, such as via twin wire arc spray application processes, as is known in the art. Any number of substrates may be applied with the alloy, including but not limited to downhole components. In one embodiment, the alloy can be used for repair of power section rotors and other similar components. Multiple layers of the same material may be applied to the substrate for increased protection and/or layers.


Stainless steel alloys having high carbon and high nitrogen have been explored academically by individuals such as Gavriljuk, Rawers, and Raj. Such academic work teaches that nitrogen strengthens a stainless steel alloy but in welding alloys the amount of nitrogen is limited to a maximum of 0.30 percent or less. In the prior art, higher levels of nitrogen do not stay in solution during solidification and exhibit porosity, which requires mandatory repair of the weld.


The disclosed alloy provides numerous advantages and benefits over conventional techniques and alloys. For example, the disclosed nitrogen-carbon alloy is more corrosion resistant and wear resistant than existing alloys and thermally sprayed coatings. The relative proportions of carbon and nitrogen, in addition to boron, greatly increases the hardness of the alloy. The disclosed alloy can be welded onto carbon steels, low alloy steels, and nickel alloys. The disclosed alloy can be used to repair components for repeated use without having to incur substantial costs on creating a new component. In other words, rather than ordering a new mud motor or drill pipe (which could result in numerous delays, not to mention costs), the downhole component can be readily and easily repaired and reused. The present disclosure provides a very cost and time effective repair opportunity so that the tool can be used again, and again. This is important because material for new tools is in short supply and is very expensive.


The disclosed alloy also allows application of thick deposits or layers of the alloy on a substrate. In other words, in addition to the superior wear and corrosion resistant properties, the disclosed alloy can be sprayed (or welded) to achieve thick deposits (e.g., greater than 0.100″), deposits which may be formed up to 3.0″. The thick depositions can be used on existing tools or substrates to form centralizers or other shapes as desired.


In one embodiment, the disclosed alloy may be applied in bands near the center of drill pipe. These wear resistant bands prevent the drill pipe tube from contacting the formation and thus preventing destruction of the tube. These bands may be applied in groups of one to eight bands. Additionally, the bands perform like bearings, where they lower the friction (torque and drag) of the horizontal section thus reducing drilling time.


ALLOY SYSTEM

In one embodiment, the form of the thermally sprayed material is a cored wire, which comprises an outer sheath of a first material that encloses a second material formed of powdered elements, as is known in the art. In one embodiment, the outer sheath may comprise substantively copper and nickel in one embodiment. In one embodiment, the inner core comprises the powdered ingredients of the alloy, and include powdered materials such as borides, carbides, tin, iron oxide, aluminum, etc. In one embodiment, the powdered ingredients comprise aluminum and iron oxide. The making of such outer sheaths and inner cores of a cored wire is known to those of skill in the art. Such a cored wire and composition is disclosed in the '310 patent, incorporated herein by reference.


In one embodiment, the disclosed alloy is an iron-based alloy. In one embodiment, the iron-based wire composition, prior to melting, is about 0.2 wt % to about 2.0 wt % of carbon, about 0.2 wt % to about 2.0 wt % of nitrogen, about 0.4 wt % to about 7.0 wt % of boron, about 0.0 wt % to about 5.0 wt % of manganese, about 0.0 wt % to about 7.0 wt % of chromium, about 0.0 wt % to about 5.0 wt % of titanium, about 0.0 wt % to about 2.5 wt % of aluminum, and about 0.0 wt % to about 2.0 wt % of zirconium, with iron being a principal remaining element of the composition. The composition may comprise about 0.3 wt % to 1.15 wt % of carbon and 0.3 wt % to 1.15% nitrogen. The composition may comprise at least 2.0 wt % of boron.


In one embodiment, the disclosed alloy is a stainless-steel based alloy. In one embodiment, the stainless-steel based wire composition, prior to melting, may comprise about 0.2 wt % to about 1.5 wt % of carbon, about 0.2 wt % to about 1.5 wt % of nitrogen, about 10.0 wt % to about 35.0 wt % of chromium, about 0.0 wt % to about 35.0 wt % of nickel, about 0.0 wt % to about 3.0 wt % of silicon, about 0.0 wt % to about 7.5 wt % of molybdenum, about 0.0 wt % to about 8.0 wt % of copper, and about 0.0 wt % to about 2.0 wt % of boron, with iron being a principal remaining element of the composition. The composition may comprise about 0.4 wt % to 1.15 wt % of carbon and 0.3 wt % to 1.15% nitrogen. The composition may comprise about 2.0 wt % to about 25.0 wt % of nickel. The composition may comprise at least 0.1 wt % of boron. Other potential elements in the disclosed wire composition include aluminum, zirconium, manganese, and/or tin.


In one embodiment, any copper and nickel elements are located substantially within an outer sheath of a cored wire and may not be present in the inner core. Depending on the application, these alloys may be changed and substituted to achieve the desired level of corrosion, wear, and/or friction resistance.


METHODS OF USE AND APPLICATION

As described above, the present disclosure is generally directed to forming a durable coating on a substrate that includes one or more layers of the disclosed alloy, either by welded hardbanding or thermal spray. Both techniques are well known in the art.


In general, the methods of thermal spray are well known in the relevant art and a variety of different thermal spray techniques may be utilized to apply the disclosed alloy as a coating on a substrate. In one embodiment, to apply a thermal spray coating for a tool the following steps may be generally taken as is known in the art: (i) provide the necessary consumables and equipment, (ii) prepare the tool to be coated, (iii) clean and/or degrease the tool, (iv) sand blast the tool, (v) thermally spray the tool, and (vi) store the tool.


The process of thermal spray is well known to those of skill in the art. Thermal spray is a flexible process and can be applied to a wide variety of substrates and/or surfaces, such as irregular, tubular, or flat surfaces and to virtually any metal or non-metal substrate. In general, the process involves cleaning the substrate and forming a rough surface profile on the substrate, which may be done by grit blasting, chemical etching, or mechanical means. Once profiled, the surface is coated with the disclosed alloy using any of a variety of thermal spray processes, such as High Velocity Oxy-Fuel (HVOF), Twin Wire Arc Spray (TWAS), Cold Spray, and Kinetic Metallization. Each of these different thermal spray processes is well known to those of skill in the art. In one embodiment, the utilized spray gun may be traversed along a cylindrical object where the object is rotating in a fixture such as a lathe or riding on pipe rollers. Traversing of the spray gun may be done manually by a human operator, automatically by robot, or by affixing the gun to a traversing mechanism.


The disclosed coating may be applied to a room temperature substrate or the substrate may be pre-heated to approximately 200-400 degrees Fahrenheit. While typically the coating may be approximately 0.015″ thick, the disclosed coating can be applied both thinner and thicker as required. For example, the coating may be as small as 0.006″ or as large (or greater) than 0.100″ thick and up to approximately 3.0″ thick. The tool being coated and the particular application of the tool will dictate the coating thickness.


As discussed above, prior art coatings develop micro-cracks in the coating, some of which may extend to the surface of the coating. To address these cracks, conventional techniques typically paint or treat the coating surface with a low surface tension liquid to penetrate and seal the cracks. In one embodiment, the disclosed thermal spraying process does not require this subsequent treatment of the coating because it has no micro-cracks that open to the surface, so there is no path to absorb the low viscosity sealing liquids. In other words, the disclosed embodiment does not require a subsequent sealing step of the resultant thermally sprayed coating as is typical in conventional techniques.


In general, the disclosed alloy/coating may be used on any tool (and is not limited to downhole equipment). As one example, as shown in FIG. 5, it may be hardband welded to a downhole rotor 501 in a repair weld 503. As another example, as shown in FIG. 6, it may be applied to drill pipe, or other downhole equipment, drill bands, stabilizer blades, etc. As another example, it may be applied to marine equipment. The present alloy can be used in components for drilling oil and gas wells, such as for hardbanding the tool joints on drill pipe and various down hole tools. One of skill in the art will realize that the disclosed alloy is not limited to oil and gas components.


While an embodiment of the disclosure is directed to drill pipe or other downhole components used in the oil and gas industry, a thermally sprayed layer of the disclosed novel alloy can be used in a variety of applications and industries. As one example, the disclosed alloy may be used to form relatively thick coatings (greater than 0.100″), which can be used to form shapes on tools, such as centralizers. For example, the disclosed corrosion resistant thermally sprayed layer may be used for many other downhole components in the oil and gas industry, such as but not limited to drill pipes, drill pipe tool joints, heavy weight pipes, stabilizers, cross-overs, jars, MWDs, LWDs, drill bit shanks, etc. In one embodiment, the relevant components are downhole oil well production components such as electrically submersible pumps, sucker rods, and related components and other artificial lift equipment. The corrosion layer may also be used on banding to rigidly attach separate components, such as around drill pipe tool joints.


EXAMPLES AND TESTS

Various corrosive tests show that a coating formed of the disclosed alloy composition provides superior benefits as compared to prior art alloys.



FIGS. 2A-2C illustrate cross sectional views of a weld using the disclosed stainless steel alloy. FIG. 2A illustrates two layers of a weld on a downhole tool component, shown at a magnification of 200X. First layer 201 is the original weld on the downhole tool, while second layer 202 is a repair weld on the tool using the disclosed alloy composition. FIG. 2B illustrates an SEM image of the disclosed stainless steel alloy 211 on a downhole tool component at a magnification of 10,000X, which shows some elemental compositions of the alloy by different shades. FIG. 2C illustrates an SEM image of the same component from FIG. 2B at a magnification of 10,000X, showing other alloying elements and their dispersion with differed shades.



FIG. 3 illustrates a cross-sectional view of a thermally sprayed layer 301 of the disclosed iron-based alloy composition, according to one embodiment of the present disclosure. FIG. 3 illustrates a magnification of 650x. FIG. 3 shows the distribution throughout the matrix of carbon, nitrogen, and boron. These elements behave synergistically to provide resistance to abrasive wear, high velocity erosion, and corrosion.



FIGS. 4A-4C illustrate cross-sectional views of thermally sprayed layers of different alloys, according to one embodiment of the present disclosure. FIG. 4A shows a prior art alloy thermally sprayed deposit 401 (which is an alloy as disclosed from U.S. Pat. No. 9,920,412) at a magnification of 277X. After testing, cracks 403 develop throughout the layer. FIG. 4B illustrates a thermally sprayed deposit of a stainless steel alloy 411 as disclosed in the present application, which shows no cracks formed in the thermally sprayed layer. Droplet morphology is smaller and intersplat boundaries are much more tortuous, creating more difficult crack formation. FIG. 4C illustrates a thermally sprayed deposit of a stainless steel alloy 421 as disclosed in the present application using carbon, nitrogen, and boron to create a hard wear resistant coating, which shows no cracks formed in the thermally sprayed layer.



FIG. 5 illustrates a downhole rotor 501, wherein a repair weld 503 was made with GTAW process using the disclosed stainless steel alloy. The repaired rotor was deployed in the field and field tested. After 100 hours of drilling, the rotor was removed and analyzed, and no loss of thickness was observed. As disclosed by the test, the abrasive wear resistance is equivalent or superior to premium hard-banding techniques.



FIG. 6 illustrates a section of drill pipe 601 with a plurality of bands 603 of the disclosed iron based alloy thermally sprayed onto the drill pipe, after downhole testing. In particular, a 3″ band and a 6″ band of the disclosed alloy were thermally sprayed onto the drill pipe. The drill pipe also contained four 3″ bands of conventional thermally sprayed layers. After being placed downhole and subject to testing, the bands of the disclosed iron based alloy did not show any signs of cracking, spalling, or other damage, while the bands of the conventional thermally sprayed alloy were gone. In one embodiment, the band of the disclosed alloy has a hardness range from HRc 60-65. In one embodiment, abrasive wear resistance has been demonstrated in the ASTM G-65 dry stand rubber wheel test to be about 0.355 grams weight loss in six thousand revolutions. The drill pipe hardbands of the disclosed alloy were subjected to repeated testing blows by a sledge hammer for comparison purposes to conventional alloys. In one such tests, the disclosed alloy was subject to 80 hammer blows before visual cracks or any failure of the banding, whereas a conventional layered thermal spray alloy was subject to only 62 hammer blows before visual cracks became apparent.


All of the methods disclosed and claimed herein can be made and executed without undue experimentation in light of the present disclosure. While the apparatus and methods of this invention have been described in terms of preferred embodiments, it will be apparent to those of skill in the art that variations may be applied to the methods and in the steps or in the sequence of steps of the method described herein without departing from the concept, spirit and scope of the invention. In addition, modifications may be made to the disclosed apparatus and components may be eliminated or substituted for the components described herein where the same or similar results would be achieved. All such similar substitutes and modifications apparent to those skilled in the art are deemed to be within the spirit, scope, and concept of the invention.


Many other variations in the system are within the scope of the invention. For example, the alloy may comprise varying amounts of carbon, nitrogen, and boron. In some applications, the amount of boron may be greater than the amount of carbon and nitrogen, while in other embodiments the amount of boron might be less than either carbon or nitrogen. The alloy may or may not include tin, manganese, zirconium, and/or titanium. The alloy may or may not include chromium, nickel, and/or copper. The tool to be coated may be a downhole component or other tool used in the oil and gas industry, or may be applied to any object or tool that needs an increased corrosive protection layer and/or thermally dissipative layer, such as in the aviation, refining, chemical, processing, and marine industries, as well as dredge pups, cable sheaves, and helicopter landing runners, among others. The alloy may have other desirable properties besides corrosion resistance, such as being a conductor of heat (for heat dissipation purposes) or crack resistant or wear resistant or electrical conductivity. In one embodiment, the substrate may be a metallic or non-metallic material, such as drill pipe or fiberglass. It is emphasized that the foregoing embodiments are only examples of the very many different structural and material configurations that are possible within the scope of the present invention.


Although the invention(s) is/are described herein with reference to specific embodiments, various modifications and changes can be made without departing from the scope of the present invention(s), as presently set forth in the claims below. Accordingly, the specification and figures are to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of the present invention(s). Any benefits, advantages, or solutions to problems that are described herein with regard to specific embodiments are not intended to be construed as a critical, required, or essential feature or element of any or all the claims.


Unless stated otherwise, terms such as “first” and “second” are used to arbitrarily distinguish between the elements such terms describe. Thus, these terms are not necessarily intended to indicate temporal or other prioritization of such elements. The terms “coupled” or “operably coupled” are defined as connected, although not necessarily directly, and not necessarily mechanically. The terms “a” and “an” are defined as one or more unless stated otherwise. The terms “comprise” (and any form of comprise, such as “comprises” and “comprising”), “have” (and any form of have, such as “has” and “having”), “include” (and any form of include, such as “includes” and “including”) and “contain” (and any form of contain, such as “contains” and “containing”) are open-ended linking verbs. As a result, a system, device, or apparatus that “comprises,” “has,” “includes” or “contains” one or more elements possesses those one or more elements but is not limited to possessing only those one or more elements. Similarly, a method or process that “comprises,” “has,” “includes” or “contains” one or more operations possesses those one or more operations but is not limited to possessing only those one or more operations.

Claims
  • 1. An iron-based alloy, the composition comprising the following components: about 0.2 wt % to about 2.0 wt % of carbon;about 0.2 wt % to about 2.0 wt % of nitrogen;about 0.4 wt % to about 7.0 wt % of boron;about 0.0 wt % to about 5.0 wt % of manganese;about 0.0 wt % to about 7.0 wt % of chromium;about 0.0 wt % to about 5.0 wt % of titanium;about 0.0 wt % to about 2.5 wt % of aluminum; andabout 0.0 wt % to about 2.0 wt % of zirconium,with iron being a principal remaining element of the composition.
  • 2. The composition of claim 1, wherein the composition comprises about 0.3 wt % to 1.5 wt % of carbon and 0.3 wt % to 1.5% nitrogen.
  • 3. The composition of claim 1, wherein the composition comprises about 0.3 wt % to 1.15 wt % of carbon and 0.3 wt % to 1.15% nitrogen.
  • 4. The composition of claim 1, wherein the composition comprises about 1.0 wt % carbon and about 1.0 wt % nitrogen.
  • 5. The composition of claim 1, wherein the composition of carbon and nitrogen is approximately the same.
  • 6. The composition of claim 1, wherein the composition comprises about 1.5 wt % to about 6.0 wt % of boron.
  • 7. The composition of claim 1, wherein the composition comprises at least 2.0 wt % of boron.
  • 8. The composition of claim 1, wherein the composition comprises at least 5.0 wt % of boron.
  • 9. The composition of claim 1, wherein the composition comprises about 0.5 wt % to about 2.0 wt % of manganese.
  • 10. The composition of claim 1, wherein the composition comprises about 0.5 wt % to about 2.0 wt % of chromium.
  • 11. The composition of claim 1, wherein the composition comprises about 0.3 wt % to about 3.0 wt % of titanium.
  • 12. The composition of claim 1, wherein the composition comprises about 0.3 wt % to about 1.0 wt % of aluminum.
  • 13. The composition of claim 1, wherein the composition comprises about 0.3 wt % to about 1.0 wt % of zirconium.
  • 14. The composition of claim 1, wherein the composition is contained within a cored wire.
  • 15. The composition of claim 1, wherein the amount of boron is configured to provide hardness to the alloy.
  • 16. The composition of claim 1, wherein the amount of carbon and nitrogen is configured to keep carbon in solution to the alloy.
  • 17. The composition of claim 1, wherein the composition is effective to prevent micro-cracks from forming in the alloy.
  • 18. The composition of claim 1, wherein the composition is configured for being thermally sprayed on a substrate.
  • 19. The composition of claim 1, wherein the composition is configured for being welded on a substrate.
  • 20. A stainless steel alloy, the composition comprising the following components: about 0.2 wt % to about 1.5 wt % of carbon;about 0.2 wt % to about 1.5 wt % of nitrogen;about 10.0 wt % to about 35.0 wt % of chromium;about 0.0 wt % to about 35.0 wt % of nickel;about 0.0 wt % to about 3.0 wt % of silicon;about 0.0 wt % to about 7.5 wt % of molybdenum;about 0.0 wt % to about 8.0 wt % of copper; andabout 0.1 wt % to about 2.0 wt % of boron,with iron being a principal remaining element of the composition.
  • 21. The composition of claim 20, wherein the composition comprises about 0.4 wt % to 1.15 wt % of carbon and 0.3 wt % to 1.15% nitrogen.
  • 22. The composition of claim 20, wherein the composition comprises about 2.0 wt % to about 25.0 wt % of nickel.
  • 23. The composition of claim 20, wherein the composition comprises at least 0.5 wt % of boron.
  • 24. A thermally sprayed coating on a substrate, comprising: a coating of thermally sprayed metallic material on a substrate,wherein the coating is formed by one or more layers of metallic material
  • 25. The coating of claim 24, wherein the metallic material comprises the following composition: about 0.3 wt % to 1.15 wt % of carbon;about 0.3 wt % to 1.15% nitrogen; andat least 0.5 wt % of boron.
  • 26. The coating of claim 24, wherein the substrate is a downhole component.
  • 27. The coating of claim 24, wherein the substrate is a band on a tubular.
  • 28. The coating of claim 24, wherein the substrate is a downhole rotor.
  • 29. A method for applying a coating to a substrate, comprising: thermally spraying metallic material on an external surface of a substrate to form a thermal spray layer on the substrate, wherein the material, at least prior to being sprayed, comprises the following components:about 0.2 wt % to about 2.0 wt % of carbon;about 0.2 wt % to about 2.0 wt % of nitrogen; andabout 0.1 wt % to about 7.0 wt % of boron,with iron being a principal remaining element of the composition.
  • 30. The method of claim 29, wherein the substrate is a downhole component.
  • 31. The method of claim 29, wherein the substrate is a band on a tubular.
  • 32. The method of claim 29, wherein the substrate is a downhole component.
Provisional Applications (2)
Number Date Country
63489475 Mar 2023 US
63518746 Aug 2023 US