Advanced Coatings for Wear and Corrosion Protection: Advanced Coatings for Wear and Corrosion Protection I
Program Organizers: Evelina Vogli, Flame Spray Inc.; Fei Tang, DNV
Wednesday 8:00 AM
November 4, 2020
Room: Virtual Meeting Room 30
Location: MS&T Virtual
Session Chair: Evelina Vogli, LM Group Holdings Inc.; Virendra Singh, Schlumberger
8:00 AM
Improved Coating Performance of REACH Compliant Trivalent Chromium Plating Process for Functional Applications: Andrew Moran1; Rajeswaran Radhakrishnan1; Kamyar Ahmadi2; Timothy Hall1; Stephen Snyder1; Tony Oriti3; Mark Feathers4; Michael Johnson4; George Bokisa3; Jennings Taylor1; Maria Inman1; Stanko Brankovic2; Jing Xu1; 1Faraday Technology Inc; 2University of Houston; 3Coventya Inc; 4U.S. Army Aviation and Missile Command
Faraday will discuss recent research on the development of functional REACH compliant trivalent chromium plating process to replace hard hexavalent chromium plating. Hexavalent chromium plating has been used for many years to provide hard, durable coatings with excellent wear and corrosion resistance properties. However, hexavalent chromium baths have come under increasing scrutiny due to the toxic nature of the bath, effects on the environment, and workers’ health. Faraday has demonstrated that the prepared chrome coatings have equivalent functional properties to the coatings produced with a hexavalent chromium bath. In this paper, Faraday will present results from its development program and discuss the similarities between chrome deposits from the REACH compliant and hexavalent chemistries. Specifically, Faraday will discuss the effect of processing conditions on microstructure, in-situ stress development, wear resistance, and performance as well as evaluating its potential for a hexavalent chromium free plating shop.
8:20 AM
The Surface Integrity of Hard Coatings and Surface Treatments on Alloy 17-4PH in Highly Soured Environments: Manuel Marya1; Dean Lauppe1; Virendra Singh1; 1Schlumberger
Alloy 17-4PH is PH martensitic stainless steel with short-comings for Oil & Gas applications, yet it is widely used for well services. In common to other load-bearing alloys, its tribological properties are limited, requiring use of surface hardening processes by diffusion or using adherent hard coatings. This investigation explores 17-4PH in highly soured conditions when nitrided through various processes, solution plated (Ni-11%P, Ni-Co-P), tungsten carbide, or DLC vapor deposited. Though immersion tests of various durations (2-5 weeks in up to 1500psi H2S at 4000psi), the 17-4PH surface is found to be relatively resistant to the environment while many surfaces experience various forms of damage. Mechanisms of weight-loss and/or localized corrosion are explained based on optical, SEM, and EDS analyses, all complementing macroscopic and weight-loss measurements. In turns, this investigation clarifies best practices for stainless steels outside the scope of environmentally assisted cracking, the normal limiting factor for 17-4PH.
8:40 AM
High Performance Amorphous Based Thermal Sprayed Coatings for Molten Salt Environment: Evelina Vogli1; John Kang1; Rick Salas1; 1Lm Group Holdings Inc.
Chloride salts have been identified as one of the promising media for thermal energy storage and heat transfer for achieving higher operating temperatures. However, these molten salts introduce a set of challenges. LM Group Holdings, Inc. has developed and applied proprietary innovative amorphous-based coatings that are able to withstand the severe corrosive environment of molten salt at high temperatures. Amorphous metals are a novel class of materials that have a disordered, non-crystalline, glassy structure. Amorphous Metals are more corrosion resistant compared to conventional metals due to the lack of long-range periodicity, related grain boundaries and crystal defects such as dislocations.This presentation will highlight amorphous thermal sprayed coatings on Haynes 230 which have been tested at ORNL and SRNL and compared to non-coated Haynes230 in terms of corrosion resistance under molten chloride salt at 750 degree C.
9:00 AM
Electrochemical Corrosion Behaviors of Nitrogen-enriched Stainless Steels and High Chromium White Irons: Virendra Singh1; Manuel Marya1; 1Schlumberger
Stainless steels are economic choices of oilfield production equipment for sweet and mild sour environments, even though lacking hardness, abrasive wear properties, and galling resistance. In this short investigation, surface diffusion treatments such as liquid nitrocarburizing and plasma nitriding are applied to different grades of high-chromium alloys, specifically 13Cr (UNS41000), S13Cr (UNS41425), 17-4PH (UNS17400), 316 (UNS31600), as well as ASTM A532 white irons. The alloy corrosion behaviors were successfully established in different environmental chloride-rich conditions. Tribological properties were investigated by microindentation, correlated to (1) microstructural evaluations by SEM, EDS, and XRD, and (2) corrosion properties established by cyclic polarization testing, salt-sprays, and a variety of immersion tests. It is found that the effect of surface modifications predominantly depends on the selected alloys, with consistent reduction in passivation for all alloys.
9:20 AM
Production of Chromium-aluminized Coatings to Protect Against Wear and Corrosion: Borys Sereda1; Dmytro Sereda1; Irina Kruglyak1; 1Dneprovsky State Technical University
Offered promising methods of applying protective wear-resistant coatings - technology for producing powder coatings by in a high-temperature synthesis (SHS). This kind of protection is the most promising and less costly, since it does not require changes in the technology of materials. To increase the corrosion resistance it is necessary to saturate the surface layer with elements that will form passive skin. In our case, when the ionic passivation potential is reached, oxide films are formed, with the following composition - Cr2O3, Al2O3, TiO2, SiO2, which protect the metal from destruction. The high hardness of the resulting alloy coating and the ability to retain lubricant on the surface leads to an increase in the resistance of these parts to wear. Tests on the friction machine MT-5 (friction under conditions of shock-dynamic loading) showed that the best wear resistance is provided by protective coatings doped with Si.