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.
A thermal spray alloy system is disclosed that is more resistant to corrosion and wear than conventional thermally sprayed coatings. The alloy system utilizes layers of different alloys to provide increased wear and corrosion resistance. The disclosed alloy addresses issues of wear and corrosion by utilizing a copper-based alloy as one thermally sprayed layer and an iron-based alloy as a second thermally sprayed layer via twin wire arc spray application processes, as is known in the art. The first layer may be about 50.0 wt % to about 95.0 wt % of copper. Between 2-10 applications of each layer may be applied to a substrate.
The present disclosure provides a thermal spray alloy system that is more resistant to corrosion than conventional alloy compositions. The disclosed alloy comprises copper as the main component and also potentially nickel, tin, boron, and/or carbon as other principle elements. The alloy composition may utilize a cored wire, and an outer sheath of the cored wire may comprise unalloyed copper. The alloy has superior corrosion resistance to a wide number of corrosive materials, such as hydrogen sulfide, carbon dioxide/carbonic acid, sodium chloride/potassium chloride (salts), bio-fouling, and micro-biologicals. The alloy demonstrates superior thermal conductivity compared to nickel based alloys and stainless steels. The alloy may form an anti-corrosive coating that may be applied to any number of substrates. The disclosed alloy may be applied to a substrate in thick layers, such as between 0.100 inches and 3.0 inches, and may be used to form shapes, such as centralizers.
B23K 35/30 - Emploi de matériaux spécifiés pour le soudage ou le brasage dont le principal constituant fond à moins de 1550 C
B23K 35/02 - Baguettes, électrodes, matériaux ou environnements utilisés pour le brasage, le soudage ou le découpage caractérisés par des propriétés mécaniques, p. ex. par la forme
C22C 9/01 - Alliages à base de cuivre avec l'aluminium comme second constituant majeur
C22C 9/05 - Alliages à base de cuivre avec le manganèse comme second constituant majeur
C22C 9/10 - Alliages à base de cuivre avec le silicium comme second constituant majeur
C22C 9/02 - Alliages à base de cuivre avec l'étain comme second constituant majeur
C22C 9/06 - Alliages à base de cuivre avec le nickel ou le cobalt comme second constituant majeur
C23C 4/073 - Matériaux métalliques contenant des alliages MCrAl ou MCrAlY où M est le nickel, le cobalt ou le fer, avec ou sans éléments non métalliques
The present disclosure provides a method, system, and apparatus that adds one or more reinforcing structures to a thermally sprayed layer of metallic material onto a substrate to reinforce and/or further support the formed substrate coating. The reinforcing structure may be a metallic or non-metallic wire, filament, whisker, mesh, or similar structure and may be coupled to the substrate before or during the thermal spray process, thereby embedding the reinforcing structure(s) into the resulting thermal spray matrix. The type, material, size, shape, and application technique of the reinforcing structure is variable based upon the desired characteristics of the ultimate coating. The durable coating may be formed by a plurality of separate and/or distinct layers. The resultant coating (e.g., the reinforcing structure(s) with the one or more thermal spray layers) provides numerous benefits, including increased strength and resistance to spalling, breaking, cracking, deforming, crack formation, and corrosion.
B05C 3/04 - Appareillages dans lesquels un ouvrage est mis en contact avec une grande quantité de liquide ou autre matériau fluide l'ouvrage étant immergé dans le liquide ou autre matériau fluide avec des dispositions spéciales en vue d'agiter l'ouvrage ou le liquide ou autre matériau fluide
Wear resistant, metal cladding for downhole equipment; Wear resistant, metal cladding for machinery and tools; Wire; Metal alloys for further manufacturing; Metals and metal alloys; Welding wire
Coatings in the nature of thermally sprayed metallic and non-metallic compositions; Coatings in the nature of metallic and non-metallic materials, namely, for the use on machinery, tools, and downhole equipment; Coatings in the nature of wear resistant compositions; Coatings in the nature of corrosion resistant compositions; Coatings in the nature of thermally sprayed downhole equipment; Heat-resistant coatings for industrial applications where elevated temperatures occur
