Surface damage mitigation of TC4 alloy via micro arc oxidation for oil and gas exploitation application: Characterizations of microstructure and evaluations on surface performance

Abstract

Because of its excellent corrosion resistance, high specific strength and high tensile strength, TC4 titanium alloys used as petroleum tubes have received wide interest from material engineers after many technical investigations and estimations. However, because of its low surface hardness values, high coefficient of friction and poor wear resistance, the TC4 alloy is seldom adopted in tribological-related engineering components. In this work, micro-arc oxidation (MAO) coatings were fabricated on TC4 alloys in NaAlO2 and (NaPO3)6 electrolytes with and without ultrasonic assistance. The microstructural characterizations of the produced MAO coatings were investigated. Comparative estimations of electrochemical corrosion in CO2-saturated simulated oilfield brine and tribological behaviours on MAO coatings and TC4 alloys were conducted. The results showed that the introduction of ultrasound increased the thickness of the MAO coatings. The thickness increased by 34% and 15% in the NaAlO2 and (NaPO3)6 electrolytes, respectively. There was no significant discrepancy in phase constitutions when the MAO processes were conducted with and without ultrasonic assistance. Both MAO coatings obtained with and without ultrasonic assistance were found to improve the corrosion and wear resistance of the TC4 alloy. MAO treatments made it possible to ensure the working surface of a TC4 alloy with an enhanced surface performance for oil and gas exploitation applications.