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用于井下钻井泥浆阀的新型冷喷涂耐磨蚀碳化钨-铜-镍（WC-Cu-Ni）金属基复合材料（MMC）涂层。钻井泥浆在石油和天然气开采期间的深钻孔的钻探期间使用。在高摩擦钻井过程中，泥浆起到润滑剂和冷却剂的作用。在钻井过程中，泥浆还将作为固体材料（如沙子）的载体。当填砂泥浆以高速度和流速通过流量控制装置（例如阀门）中的孔口时，这些装置的材料侵蚀速率显著增加。虽然部件和工具的寿命可以通过由耐磨材料制造而延长，但该过程的成本将明显增加。几乎没有脱碳的硬面耐磨WC基金属基复合材料涂层的沉积将是为制造的部件和工具提供保护的可行解决方案。该研究项目的新奇在于通过热喷涂工艺沉积的耐腐蚀涂层的制造和现场测试，其中发生涂层材料的有限加热和材料性能变化。

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.