Abstract: A thermal spray alloy system that is more resistant to corrosion and erosion and hard-wear abrasion than conventional alloy compositions, and may be applied to a substrate by conventional welding techniques or thermal spray. The alloy may comprise carbon, nitrogen, and boron, in addition to chromium and other elements. The object to be coated may be any downhole component used in the oil and gas industry, or may be applied to any object or tool that needs an increased wear and/or corrosive protection layer including in diverse fields such as marine, chemical processing, and refining. A thermal spray coating with the alloy composition provides increased strength and resistance to spalling, breaking, cracking, deforming, and crack formation.

Abstract: A thermal spray alloy system is disclosed that is more resistant to corrosion and wear than conventional thermally sprayed coatings. The alloy system utilizes layers of different alloys to provide increased wear and corrosion resistance. The disclosed alloy addresses issues of wear and corrosion by utilizing a copper-based alloy as one thermally sprayed layer and an iron-based alloy as a second thermally sprayed layer via twin wire arc spray application processes, as is known in the art. The first layer may be about 50.0 wt % to about 95.0 wt % of copper. Between 2-10 applications of each layer may be applied to a substrate.

Abstract: The present disclosure provides a method, system, and apparatus that adds one or more reinforcing structures to a thermally sprayed layer of metallic material onto a substrate to reinforce and/or further support the formed substrate coating. The reinforcing structure may be a metallic or non-metallic wire, filament, whisker, mesh, or similar structure and may be coupled to the substrate before or during the thermal spray process, thereby embedding the reinforcing structure(s) into the resulting thermal spray matrix. The type, material, size, shape, and application technique of the reinforcing structure is variable based upon the desired characteristics of the ultimate coating. The durable coating may be formed by a plurality of separate and/or distinct layers. The resultant coating (e.g., the reinforcing structure(s) with the one or more thermal spray layers) provides numerous benefits, including increased strength and resistance to spalling, breaking, cracking, deforming, crack formation, and corrosion.

Abstract: The present disclosure provides a thermal spray alloy system that is more resistant to corrosion than conventional alloy compositions. The disclosed alloy comprises copper as the main component and also potentially nickel, tin, boron, and/or carbon as other principle elements. The alloy composition may utilize a cored wire, and an outer sheath of the cored wire may comprise unalloyed copper. The alloy has superior corrosion resistance to a wide number of corrosive materials, such as hydrogen sulfide, carbon dioxide/carbonic acid, sodium chloride/potassium chloride (salts), bio-fouling, and micro-biologicals. The alloy demonstrates superior thermal conductivity compared to nickel based alloys and stainless steels. The alloy may form an anti-corrosive coating that may be applied to any number of substrates. The disclosed alloy may be applied to a substrate in thick layers, such as between 0.100 inches and 3.0 inches, and may be used to form shapes, such as centralizers.

Abstract: The present disclosure provides a thermal spray alloy system that is more resistant to wear and/or corrosion than conventional alloy compositions. The disclosed alloys minimize or eliminate micro-cracks within the formed coating on the tool. The alloy comprises carbon, boron, and a fluxing agent selected from the group of aluminum, magnesium, or lithium. The alloy may also comprise titanium, silicon, manganese, molybdenum, nickel, and chromium, as well as other elements. The object to be coated may be any downhole component used in the oil and gas industry, or may be applied to any object or tool that needs an increased wear and/or corrosive protection layer including in diverse fields such as marine, chemical processing, and refining. A thermal spray coating with the disclosed alloy composition provides increased strength and resistance to spalling, breaking, cracking, deforming, and crack formation, as well as metallurgical bonding between the coating and the substrate.

Abstract: The present disclosure provides a thermal spray alloy system that is more resistant to corrosion than conventional alloy compositions. The disclosed alloy comprises copper as the main component and also potentially nickel, tin, boron, and/or carbon as other principle elements. The alloy composition may utilize a cored wire, and an outer sheath of the cored wire may comprise unalloyed copper. The alloy has superior corrosion resistance to a wide number of corrosive materials, such as hydrogen sulfide, carbon dioxide/carbonic acid, sodium chloride/potassium chloride (salts), bio-fouling, and micro-biologicals. The alloy demonstrates superior thermal conductivity compared to nickel based alloys and stainless steels. The alloy may form an anti-corrosive coating that may be applied to any number of substrates. The disclosed alloy may be applied to a substrate in thick layers, such as between 0.100 inches and 3.0 inches, and may be used to form shapes, such as centralizers.

Abstract: The present disclosure provides a thermal spray system and method that utilizes an exothermic reaction. The exothermic reaction creates substantial heat and provides increased diffusion and bonding between different components of the wire alloy during coating and solidifying. The disclosed exothermic reaction creates greater diffusion of boron and carbon within the coating, increases bond strength between different components and/or solidified droplets or splats of the coating, and increases bonding strength between the coating and the substrate. The resulting coating provides greater homogeneity of the coating chemistry and fewer micro-cracks. The exothermic reaction may be created by a particular alloy composition (such as powdered elements within a cored wire) that creates and maintains a higher droplet temperature. The exothermic reaction may be created by the use of an oxidizer and a fuel, such as iron oxide and aluminum, as well as other reactive elements causing an exothermic reaction.

Abstract: The present disclosure provides a method, system, and apparatus that adds one or more reinforcing structures to a thermally sprayed layer of metallic material onto a substrate to reinforce and/or further support the formed substrate coating. The reinforcing structure may be a metallic or non-metallic wire, filament, whisker, mesh, or similar structure and may be coupled to the substrate before or during the thermal spray process, thereby embedding the reinforcing structure(s) into the resulting thermal spray matrix. The type, material, size, shape, and application technique of the reinforcing structure is variable based upon the desired characteristics of the ultimate coating. The durable coating may be formed by a plurality of separate and/or distinct layers. The resultant coating (e.g., the reinforcing structure(s) with the one or more thermal spray layers) provides numerous benefits, including increased strength and resistance to spalling, breaking, cracking, deforming, crack formation, and corrosion.