Performance of Ni-Based Coatings with Various Additives Fabricated by Cold Gas Spraying

Ekaterina Alekseeva,Nikita Shaposhnikov,Pavel Glukhov,Margarita Shishkova,Dmitry Gerashchenkov,Darya Strekalovskaya

doi:10.3390/met12020314

Ekaterina Alekseeva, Nikita Shaposhnikov + Show 4 more

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https://doi.org/10.3390/met12020314

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Journal: Metals	Publication Date: Feb 10, 2022
Citations: 5	License type: CC BY 4.0

Affiliation: Peter the Great St. Petersburg Polytechnic University

Abstract

The complexity of the operating conditions in oil fields requires the development and use of materials with unique properties. This paper presents the study results for nickel-based coatings fabricated by cold gas spraying. In this study, compositions based on Ni, Ni-Cu, Ni-Zn, Ni-Al2O3/TiC coatings applied to low-alloyed steel bases were investigated. Corrosion resistance was studied by means of electrochemical 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. All the studied coating specimens had a sufficiently high adhesion. The Ni-Zn coating exhibited the lowest corrosion resistance and high hydroabrasive resistance. The Ni-Cu coatings exhibited a high degree of corrosion. The Al2O3/TiC additives gave ambiguous results with respect to the studied properties. Thicknesses of 40–60 microns provided acceptable performance for the studied coatings. Thus, varying the chemical composition the thickness of coatings allows optimal qualities to be obtained for Ni-based coatings made by cold gas spraying for use in the oil and gas industry.

Highlights

The aggressive conditions encountered in the oil and gas industry require corrosionresistant materials for service in chloride-containing media saturated with hydrogen sulfide and carbon dioxide aqueous solutions, and which contain abrasive particles [1,2]
The purpose of this work is to study the effect of the chemical composition (Ni, Ni-Cu, Ni-Zn, Ni-Al2O3, Ni-TiC) on the corrosion and wear resistance of nickel coatings obtained by the cold gas dynamic spraying (CS) method to assess their applicability in the oil and gas industry
The samples of the nickel-based Ni-Zn, Ni-Cu, Ni-Al2O3, Ni-TiC, Ni fabricated using cold gas dynamic spraying were assessed to determine their applicability in the oil and gas industry

Summary

Introduction

The aggressive conditions encountered in the oil and gas industry require corrosionresistant materials for service in chloride-containing media saturated with hydrogen sulfide and carbon dioxide aqueous solutions, and which contain abrasive particles [1,2]. Corrosion-resistant steels and alloys are associated with significant capital costs and technical drawbacks; various types of coatings are becoming increasingly crucial for the oil and gas industry [2]. At this moment, nonmetallic polymer epoxy coatings are widely used for oilfield pipelines and tubing, and aluminum, zinc, and nickel coatings are used for tubing and more expensive downhole equipment, as well as for certain components like flanges and bolting [3]. The method of cold gas dynamic spraying, or cold spraying (CS), is based on the formation of a strong metal layer when a two-phase supersonic flow hits a perpendicularly located surface. The cold gas dynamic spraying method has the following advantages:

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