Abstract: A bore seal for connecting and sealing oil and gas tubular members is disclosed which has a metal core manufactured from a high yield strength ferrous material and a protective overlay of corrosion and abrasion resistant stainless steel and/or nickel based alloy. The protective overlay is applied to the entire outer surface of the bore seal by a metal thermal spray process, such as plasma thermal spraying. In a preferred embodiment of the invention, the bore seal has a fishtail profile which facilitates the use of resilient seals to provide resistance to external pressures in addition to the traditional metal-to-metal seal between the bore seal and the tubular members. In an alternative embodiment, a pressure relief valve is disposed within the bore seal to verify the integrity of the metal-to-metal seal with respect to internal bore pressure.

Abstract: A bore seal for connecting and sealing oil and gas tubular members is disclosed which has a metal core manufactured from a high yield strength ferrous material and a protective overlay of corrosion and abrasion resistant stainless steel and/or nickel based alloy. The protective overlay is applied to the entire outer surface of the bore seal by a metal thermal spray process, such as plasma thermal spraying. In a preferred embodiment of the invention, the bore seal has a fishtail profile which facilitates the use of resilient seals to provide resistance to external pressures in addition to the traditional metal-to-metal seal between the bore seal and the tubular members. In an alternative embodiment, a pressure relief valve is disposed within the bore seal to verify the integrity of the metal-to-metal seal with respect to internal bore pressure.