S1E overview 11-JAN-07 to PTC - Wallwork Heat Treatment
Transcript of S1E overview 11-JAN-07 to PTC - Wallwork Heat Treatment
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Sub-One Technology
January 21st, 2008
InnerArmor™ Overview
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Problem
• Internal corrosion, erosion and wear of – surface piping, downhole tubulars, chokes, valves,
pumps, and other subsea and downhole equipment
costly downtime, maintenance, and repair• Existing internal coatings are often ineffective• Exotic high performance alloys are very
expensive and backlogs cause significant delays in ramping production
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InnerArmor™ coatings:§ super hard
§ high performance
§ thin films
on the internal surfaces of products from large diameter industrial piping to small components.
Solution - Sub-One Technology
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Coatings - Adjustable in these key areas:▪ Thickness ▪ Wear Resistance▪ Hardness ▪ Corrosion Resistance▪ Adhesion ▪ Erosion Resistance
InnerArmor™ Technology
InnerArmor™ process deposits high performance coatings:
§Diamond-Like Carbon (DLC)§Titanium Carbide§ANY material that we can ionize – we can make coatings
InnerArmor™ process can:- Customize performance- Create composite coatings
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S Tube Cross Section Video
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Process – Plasma Inside Part
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InnerArmor™ - Machines
CS10(Up to 10 Foot Capacity)
CSL40(Up to 40 Foot Capacity)
* In Assembly
InnerArmor™
Coating Machines
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InnerArmor™ - Typical Composition
• Structure: Mixture of sp3 (diamond) and sp2 (graphitic)
• Deposition Temperature: <200°C
• Coating Finish: Identical to Substrate
• Hardness (Vickers) : 1000-3000 (adjustable) - (carbon steel = 217)
• Modulus: 100-180GPa (adjustable) - (carbon steel = 200GPa)
• Adhesion: > 30N
• Wear: < 5e-07
• Friction Coefficient: <0.08
• Coating Thickness: Adjustable up to 80 µm
• Working Temp: 400°C; 600ºC with doping
• Chemical Resistance: Chemically inert i.e., No reaction with acids or
alkaline
Most InnerArmor coating properties are tunable to meet specific application
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InnerArmor Film StructureCross Sectional SEM40 µm thick Multi-layer Coating on 304SS
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• Silicon adhesion layer for good chemical bond to substrate and to DLC cap
• Inert, amorphous, dense, pinhole free, dense coating – high corrosion resistance
• Layered structures possible– Stress reduction– toughness & ductility
– Surface property enhancement
• Electrically insulating• Structure can be designed
for end application
Surface
SteelSilicon
Silicon Carbide
Silicon Carbide
Diamond-like Carbon
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InnerArmor™ - Coatings
1. InnerArmor™ Super Hard
Optimum wear resistance (dry or in oil) including applications such as reciprocating pistons.
2. InnerArmor™ Hard
Superior for mud or water wear applications, including reciprocating pumps.
3. InnerArmor™ Erosion
Thick coating for applications requiring maximum abrasion and erosion resistance, such as down-hole tools with high velocity sand particle flow.
4. InnerArmor™ CorrosionPatented multi-layer defect free structure protects the component against corrosive and aggressive media including acids, salts, hydrogen sulphide (H2S).
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Today– Interiors of conductive substrates (carbon steel, stainless
steel, nickel, aluminum, titanium, etc.)
– 0.375 in - 24 in ID
– 8 -12 ft long
– Aspect ratio (length:diameter) up to 50:1
– 5 to 80 μm thick
– Multiple entry points and shapes
Future– Length: 40 ft long
– ID: Several feet
What We Can Do Today vs Future
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Corrosion Performance
Substrate: 1020CSAdhesion: >30NHardness: 12 GpaThickness: 65 um
Post Exposure Holiday Test: PASS
Test Conditions
• Temperature = 300°F• Pressure = 5000 psi• Duration = 3 days
• Aqueous Phase: 5% NaCl Brine• Hydrocarbon Phase: 100% Xylene• Gas Phase: 1% H2S + 85% CO2 + 14% CH4
Gas phase
Hydrocarbon Phase
Aqueous Phase
Indent AFTER Autoclave Test
Sour Autoclave (NACE MR-175)
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Corrosion Performance
Test Conditions:§ Concentration: 18% HCl§ Temperature: 200F§ Duration: 8 hours
Substrate: CS1020Hardness: 10GPaAdhesion: >30NThickness: 65um
No Damage
InnerArmor™ Protected
Substrate : Coated CS1020
Substrate : Uncoated CS1020
Hole thru the pipe wall
Hot HCl - CS1020
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Instrument – Tribometer
• ASTM G133-02, Linearly Reciprocating Ball-on-Flat Sliding Wear
•COF = resistive force/normal perpendicularforce
200X
Sample of wear track using crude oil Bare steel
Sliding Wear Test
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InnerArmorTM Wear Performance
10X Improvement
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• Substrate: 13Cr• Corrosion Resistance:
Excellent• Hardness:15 GPa• Thickness:23 µm
No abrasion damage on surface
Test conditions:• Abrasive: Al203• Abrasive Discharge: 2 gm/min• Velocity: 30m/Sec• Angle of impingement: 90 deg
• Duration: 10 minutes
• Substrate: 316SS• Corrosion Resistance:
Excellent• Hardness:12 GPa• Thickness:70 µm
No abrasion damage on surface
Test
Coating Performance: Erosion
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Impact Resistance
Impact Test :§ 34 micron thick coating§ Substrate – Stainless steel§ 30mm stainless steel ball dropped on coated specimen§ Impact with one joule of kinetic energy
Viewed at– 200x magnification No cracks or de-lamination observed
Viewed at– 10x magnification No cracks or de-lamination observed
Impact Crater
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Test condition:• Substrate placed in mechanical vise and compressed to open substrate to almost a flat condition.
• Properties of coating:
• Substrate – SS316
• Hardness= 14 GPa (HV1400)
• Modulus= 104 GPa
• Coating Thickness = 12µm
• Adhesion = 20N
Sample size = 2.5” x 2.5”
Can a super-hard coating have ductility?Bend Testing
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InnerArmorTM Flex-DLC
Impact crater
Flex-DLC Performance:§ Hardness = 20 GPa§ Thickness = 12µm§ Wear rate = 3.9E-07 mm³/Nm with 25N load§ COF = .01 with 25N load
Bend-ability of InnerArmorTM Flex-DLC on stainless steel foil
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EndUser
Business Model
Global Provider Network
NEED
SERVICES
SOLUTION
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Summary
• Developed a proprietary PECVD coating process for interior surface coating– Hollow cathode plasma processing enables thick (70µm) barrier type
DLC films on internal surfaces– High deposition rate and low stress films– Other coating materials and multilayer coatings possible
• Imparts array of ‘tunable’ surface properties– Excellent wear and COF– Corrosion resistant– High hardness– Toughness
• Simple and automated commercial coating systems– Safe and environmentally benign chemistry
• Qualifying applications for oil/gas industry– Applicable to a variety of markets
• Size scale up and joining remain as challenges
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Thank YouContact: Dr. Mark J Gore
Sub-One Europe Ltd1 Berry StreetAberdeen AB25 1HF ScotlandO: +44 (0)1224 841314F: +44 (0)1224 841301M: +44 (0)7769 [email protected]
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