Abstract
This paper presents the results of the study of nickel-based coatings fabricated by cold gas spraying. In this study, compositions based on Ni, Ni–Cu, Ni–Zn, and Ni–Al2O3/TiC coatings applied to low-alloyed steel bases were investigated. The composition, type of powder (mechanical mix or mechanically alloying), and thickness varied to choose the optimal characteristics for recovery, repair procedures, and specific applications in the oil and gas industry media. The second phase was added to Ni-based coatings to increase corrosion and wear resistance. Pure nickel coatings were also studied as a benchmark. Corrosion resistance was studied by means of electrochemical testing and autoclave testing in simulated oilfield conditions. Hydroabrasive resistance was studied using a unique testing bench. Scanning electron microscopy mappings, microhardness testing, and adhesion testing were used to correlate the results of the tests with the structure, continuity, and porosity of the studied coatings. It was shown that applying mechanical alloying of the powder did not lead to an effective increase of corrosion and hydroabrasive resistance. All the studied coating specimens have a sufficiently high adhesion. Ni–Zn coating has the lowest corrosion resistance and high hydroabrasive resistance. Ni–Cu coatings have high corrosion and the lowest hydroabrasive resistance. Al2O3/TiC additives give ambiguous results in the studied properties. A thickness of 40–60 microns provides sufficient performance of the studied coatings. Thus, varying chemical composition and thickness of coatings allows for obtaining the optimal qualities of Ni-based coatings made by cold gas spraying for use in the oil and gas industry.
Highlights
The use of corrosion-resistant steels and alloys is associated with significant capital costs and technical drawbacks; the use of various types of coatings is becoming increasingly important for the oil and gas industry [3]
As is shown in the image, the coatings have an even distribution of zinc in the nickel matrix, there are some micro-discontinuities, and no cracks in the structures
This can be seen in the shades of the spectrum, as well as by size and shape
Summary
The aggressive conditions of the oil and gas industry require the use of corrosion-resistant materials for service in chloride-containing media, saturated with hydrogen sulfide and carbon dioxide aqueous solutions containing abrasive particles [1,2]. The use of corrosion-resistant steels and alloys is associated with significant capital costs and technical drawbacks; the use of various types of coatings is becoming increasingly important for the oil and gas industry [3]. Non-metallic polymer epoxy coatings are widely used for oilfield pipelines, as well as tubing, aluminum, zinc metallization, nickel coatings used for tubing and for more expensive downhole equipment, etc. Aggressive operating conditions require the use of nickel coatings, since nickel provides corrosion resistance in wide range of conditions, wear resistance, and heat resistance [4]. Nickel-based coatings of various compositions can be applied by various methods: the widespread methods of electrochemical and chemical deposition [5,6], cladding [7,8], thermal spray methods [9,10,11], chemical vapor deposition [12], and physical vapor deposition [13] methods
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