[특허]Wear resistant layer for downhole well equipment

Wear Sox, L.P.

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내보내기 페이스북 공유 트위터 공유 카카오톡 공유

Wear resistant layer for downhole well equipment

특허상세정보
국가/구분	United States(US) Patent 등록
국제특허분류(IPC7판)	E21B-017/10 E21B-017/00 E21B-041/02 E21B-041/00
미국특허분류(USC)	166/380; 166/242.4; 166/902; 175/325.1; 427/451; 427/456
출원번호	US-0116748 (2005-04-28)
등록번호	US-7487840 (2009-02-10)
발명자 / 주소	Gammage,John Hudson Daemen,Roger A. Scott,Joe Lynn
출원인 / 주소	Wear Sox, L.P.
대리인 / 주소	Locke Lord Bissell & Liddell LLP
인용정보	피인용 횟수 : 23 인용 특허 : 23

초록
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The present disclosure provides a method, system, apparatus, and related alloy to provide a protective wear coating on a downhole component for a well through a synergistic use of a thermal spraying process in combination with a novel iron-based alloy. The thermal spraying process melts the material to be deposited while a pressurized air stream sprays the molten material onto the downhole component. The coating operation takes place at low temperatures without fusion or thermal deterioration to the base material. The wear resistance is increased while providing a lower coefficient of friction by the wear resistant layer relative to a coefficient of friction of the downhole equipment without the wear resistant layer. In at least one embodiment, the disclosed process using the iron-based alloy can apply a much thicker coating than heretofore has been able to be applied without spalling and without necessitating an intermediate buffer layer.

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The invention claimed is: 1. A process for applying a wear resistant layer to a downhole component for inserting into a well, comprising: thermal spraying the wear resistant layer onto at least a portion of an external surface of the downhole component, the wear resistant layer being formed of an iron-containing material having a composition prior to thermal spraying consisting essentially of: C: from about 0.40 to about 2.5 weight percent; Cr: from about 4.0 to about 35 weight percent; B: from about 3.5 to about 10.0 weight percent; Ni: from about 0.0 to about 2.0 weight percent; Nb: from about 0.0 to about 2.5 weight percent; Mn: from about 1.0 to about 3.5 weight percent; Si: from about 0.0 to about 2.5 weight percent; Ti: from about 0.0 to about 2.0 weight percent; V: from about 1.15 to about 2.0 weight percent; and W: from about 0.0 to about 2.5 weight percent; with iron (Fe) being a principal remaining element of the composition. 2. The process of claim 1, wherein thermal spraying comprises using a twin wire thermal spraying process. 3. The process of claim 2, wherein the twin wire thermal spraying process uses a first wire and a second wire comprising the same material. 4. The process of claim 2, wherein one wire comprises a first material having a first portion of the material from claim 1 and a second wire comprises a second material complementary to the first material that when thermal sprayed together with the first material produces the wear resistant layer. 5. The process of claim 1, wherein the iron-containing material prior to thermal spraying comprises: C: from about 0.6 to about 0.7 weight percent; Cr: from about 5.0 to about 6.0 weight percent; B: from about 4.3 to about 5.0 weight percent; Ni: from about 1.65 to about 1.85 weight percent; Nb: from about 0.10 to about 0.25 weight percent; Mn: from about 2.0 to about 2.5 weight percent; Si: from about 0.4 to about 0.6 weight percent; Ti: from about 1.0 to about 1.35 weight percent; V: from about 1.15 to about 1.35 weight percent; and W: from about 0.10 to about 1.0 weight percent. 6. The process of claim 1, wherein the iron-containing material prior to thermal spraying comprises: C: from about 1.5 to about 2.5 weight percent; Cr: from about 20.0 to about 25.0 weight percent; B: from about 5.0 to about 8.5 weight percent; Ni: from about 0.0 to about 2.0 weight percent; Nb: from about 0.0 to about 1.0 weight percent; Mn: from about 1.0 to about 1.5 weight percent; Si: from about 0.85 to about 2.5 weight percent; Ti: from about 0.0 to about 1.0 weight percent; V: from about 1.15 to about 1.35 weight percent; and W: from about 0.0 to about 2.0 weight percent. 7. The process of claim 1, further comprising increasing a wear resistance of the downhole component with the wear resistant layer relative to a wear resistance of the downhole component without the wear resistant layer. 8. The process of claim 7, wherein the wear resistance is increased while providing a lower coefficient of friction of the wear resistant layer relative to a coefficient of friction of the downhole component without the wear resistant layer. 9. The process of claim 8, further comprising causing a lower driving force from a rig moving the downhole component in the well from the wear resistant layer relative to a driving force caused without the wear resistant layer. 10. The process of claim 1, wherein the thermal spraying applies the wear resistant layer independent of metallurgical changes to the downhole component. 11. The process of claim 1, further comprising thermal spraying a plurality of downhole components to form at least a portion of a drill string. 12. The process of claim 1, further comprising thermal spraying the wear resistant layer at least 0.10 inches (2.5 millimeters) thick onto the downhole component while maintaining bonding with a base material of the downhole component. 13. A thermal spray system used to apply the wear resistant layer of claim 1, the thermal spray system having a thermal spray material with the composition of the iron-containing material of claim 1. 14. The process of claim 1, wherein the thermal spraying comprises spraying with a twin wire thermal spray system the wear resistant layer without causing metallurgical changes to a base material of the downhole component. 15. The process of claim 1, wherein the downhole component comprises a component designed to rotate in operation in a downhole location. 16. A process for applying a wear resistant layer to a downhole component for a well, comprising: a. obtaining a downhole component adapted to be inserted into the well; b. thermal spraying a wear resistant layer of a principally iron-based material onto at least a portion of an external surface of the downhole component independent of metallurgical changes to a base material of the downhole component to cause deposition of the wear resistant layer having a thickness of at least 0.10 inches (2.5 millimeters) and the layer being adapted by the thermal spraying to maintain bonding with the base material of the downhole component when used downhole. 17. The process of claim 16, wherein the wear resistant layer is formed of an iron-containing material having a composition prior to thermal spraying comprising: C: from about 0.40 to about 2.5 weight percent; Cr: from about 4.0 to about 35 weight percent; B: from about 3.5 to about 10.0 weight percent; Ni: from about 0.0 to about 2.0 weight percent; Nb: from about 0.0 to about 2.5 weight percent; Mn: from about 1.0 to about 3.5 weight percent; Si: from about 0.0 to about 2.5 weight percent; Ti: from about 0.0 to about 2.0 weight percent; V: from about 0.0 to about 2.0 weight percent; and W: from about 0.0 to about 2.5 weight percent. 18. The process of claim 16, wherein the wear resistant layer is formed of an iron-containing material having a composition prior to thermal spraying comprising: C: from about 0.6 to about 0.7 weight percent; Cr: from about 5.0 to about 6.0 weight percent; B: from about 4.3 to about 5.0 weight percent; Ni: from about 1.65 to about 1.85 weight percent; Nb: from about 0.10 to about 0.25 weight percent; Mn: from about 2.0 to about 2.5 weight percent; Si: from about 0.4 to about 0.6 weight percent; Ti: from about 1.0 to about 1.35 weight percent; V: from about 1.15 to about 1.35 weight percent; and W: from about 0.10 to about 1.0 weight percent. 19. The process of claim 16, wherein the wear resistant layer is formed of an iron-containing material having a composition prior to thermal spraying comprising: C: from about 1.5 to about 2.5 weight percent; Cr: from about 20.0 to about 25.0 weight percent; B: from about 5.0 to about 8.5 weight percent; Ni: from about 0.0 to about 2.0 weight percent; Nb: from about 0.0 to about 1.0 weight percent; Mn: from about 1.0 to about 1.5 weight percent; Si: from about 0.85 to about 2.5 weight percent; Ti: from about 0.0 to about 1.0 weight percent; V: from about 0.0 to about 1.0 weight percent; and W: from about 0.0 to about 2.0 weight percent. 20. The process of claim 16, further comprising using a twin wire thermal spraying process, wherein one wire comprises a first material and a second wire comprises a second material complementary to the first material that when thermal sprayed together with the first material produces the wear resistant layer. 21. The process of claim 16, further comprising thermal spraying a wear band proximate to the middle of a drill pipe joint. 22. The process of claim 16, wherein thermal spraying applies the wear resistant layer to the downhole component independent of metallurgical changes to the downhole component. 23. The process of claim 16, further comprising increasing a wear resistance of the downhole component with the wear resistant layer relative to a wear resistance of the downhole component without the wear resistant layer, while providing a lower coefficient of friction of the wear resistant layer relative to a coefficient of friction of the downhole component without the wear resistant layer. 24. A modified downhole component, comprising: a. a downhole component adapted to be inserted into the well; b. a wear resistant layer of a principally iron-based material that is thermal sprayed on at least a portion of an external surface of the downhole component independent of metallurgical changes to a base material of the downhole component to cause deposition of the wear resistant layer having a thickness of at least 0.10 inches (2.5 millimeters) and the layer being adapted by the thermal spraying to maintain bonding with the base material of the downhole component when used downhole. 25. The downhole component of claim 24, wherein the wear resistant layer is formed by a twin wire thermal spray process, wherein one wire comprises a first material and a second wire comprises a second material complementary to the first material that when thermal sprayed together with the first material produces the wear resistant layer. 26. The downhole component of claim 24, wherein the wear resistant layer is coupled to the external surface of the downhole component independent of metallurgical changes to the downhole component. 27. The downhole component of claim 24, wherein the wear resistant layer has greater wear resistance than the downhole component without the wear resistant layer, and has a lower coefficient of friction than a coefficient of friction of the downhole component without the wear resistant layer. 28. The downhole component of claim 27, wherein the wear resistant layer causes a lower driving force from a rig moving the downhole component in the well relative to a driving force caused without the wear resistant layer. 29. The downhole component of claim 24, wherein the wear resistant layer is formed of an iron-containing material having a composition prior to thermal spraying comprising: C: from about 0.40 to about 2.5 weight percent; Cr: from about 4.0 to about 35 weight percent; B: from about 3.5 to about 10.0 weight percent; Ni: from about 0.0 to about 2.0 weight percent; Nb: from about 0.0 to about 2.5 weight percent; Mn: from about 1.0 to about 3.5 weight percent; Si: from about 0.0 to about 2.5 weight percent; Ti: from about 0.0 to about 2.0 weight percent; V: from about 0.0 to about 2.0 weight percent; and W: from about 0.0 to about 2.5 weight percent. 30. The downhole component of claim 29, wherein the wear resistant layer is formed by a twin wire thermal spray process, wherein one wire comprises a first material and a second wire comprises a second material complementary to the first material that when thermal sprayed together with the first material produces the wear resistant layer. 31. A wear resistant layer formed by thermal spraying on a component, the wear resistant layer being formed of an iron-containing material having a composition prior to thermal spraying consisting essentially of: C: from about 0.40 to about 2.5 weight percent; Cr: from about 4.0 to about 35 weight percent; B: from about 3.5 to about 10.0 weight percent; Ni: from about 0.0 to about 2.0 weight percent; Nb: from about 0.0 to about 2.5 weight percent; Mn: from about 1.0 to about 3.5 weight percent; Si: from about 0.0 to about 2.5 weight percent; Ti: from about 0.0 to about 2.0 weight percent; V: from about 1.15 to about 2.0 weight percent; and W: from about 0.0 to about 2.5 weight percent; with iron (Fe) being a principal remaining element of the composition. 32. The wear resistant layer of claim 31, wherein the layer is formed from a twin wire thermal spraying process. 33. The wear resistant layer of claim 31, wherein the wear resistant layer is deposited on the component independent of metallurgical changes to the component. 34. The wear resistant layer of claim 33, wherein the wear resistant layer comprises a thickness at least 0.10 inches (2.5 millimeters) on the component. 35. The wear resistant layer of claim 31, wherein the wear resistant layer has greater wear resistance than a component without the wear resistant layer, and has a lower coefficient of friction than a coefficient of friction of a component without the wear resistant layer. 36. A thermal spray system used to apply the wear resistant layer of claim 31, the thermal spray system having a thermal spray material with the composition of the iron-containing material of claim 31. 37. The wear resistant layer of claim 31, wherein the iron-containing material prior to thermal spraying comprises: C: from about 0.6 to about 0.7 weight percent; Cr: from about 5.0 to about 6.0 weight percent; B: from about 4.3 to about 5.0 weight percent; Ni: from about 1.65 to about 1.85 weight percent; Nb: from about 0.10 to about 0.25 weight percent; Mn: from about 2.0 to about 2.5 weight percent; Si: from about 0.4 to about 0.6 weight percent; Ti: from about 1.0 to about 1.35 weight percent; V: from about 1.15 to about 1.35 weight percent; and W: from about 0.10 to about 1.0 weight percent. 38. The wear resistant layer of claim 31, wherein the iron-containing material prior to thermal spraying comprises: C: from about 1.5 to about 2.5 weight percent; Cr: from about 20.0 to about 25.0 weight percent; B: from about 5.0 to about 8.5 weight percent; Ni: from about 0.0 to about 2.0 weight percent; Nb: from about 0.0 to about 1.0 weight percent; Mn: from about 1.0 to about 1.5 weight percent; Si: from about 0.85 to about 2.5 weight percent; Ti: from about 0.0 to about 1.0 weight percent; V: from about 1.15 to about 1.35 weight percent; and W: from about 0.0 to about 2.0 weight percent.

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