Fabrication of erosion resistant WC-Cu-Ni metal matrix composite coatings by cold spraying for use on down-hole drilling tools

该研究项目将开发一种新型的冷喷涂抗腐蚀碳化钨-铜-镍(WC-Cu-Ni)金属基复合材料(MMC)涂层，用于井下钻井泥浆阀门。在石油和天然气开采过程中，钻井泥浆用于深井钻井。泥浆在高摩擦钻井过程中起到了润滑剂和冷却剂的作用。在钻井过程中，泥浆还将作为沙子等固体材料的载体。当充砂泥浆以高速、高流量通过阀门等流动控制装置的孔口时，这些装置的材料侵蚀速率显著增加。虽然用耐磨材料制造部件和工具可以延长它们的寿命，但这一过程的成本将显著增加。沉积一种硬面耐磨的WC基金属基复合涂层，几乎没有脱碳，将是一种可行的解决方案，为所制造的部件和工具提供保护。本研究项目的创新之处在于制备了一种涂层材料加热有限、材料性能变化有限的热喷涂耐蚀涂层，并进行了现场试验。

The proposed research project will develop a novel cold-sprayed erosion resistant tungsten carbide-copper-nickel (WC-Cu-Ni) metal matrix composite (MMC) coating for use on downhole drilling mud valves. Drilling mud is used during the drilling of deep boreholes during oil and gas extraction. The mud acts as a lubricant and coolant during the high-friction drilling process. During the drilling process, the mud will also act as a carrier for solid materials such as sand. As the sand-filled mud passes through the orifices in flow control devices such as valves at high velocities and flow rates, the material erosion rates of these devices increase significantly. While the life of the components and tools may be extended by fabricating them from wear resistant materials, the cost of the process would increase appreciably. The deposition of a hard-faced wear resistant WC-based metal matrix composite coating, nearly devoid of decarburization, will be a viable solution to provide protection to the fabricated components and tools. The novelty of this research project lies in the fabrication and on-site testing of an erosion resistant coating deposited by a thermal spray process in which limited heating and material property change of the coating material occurred.