Hardfacing Solutions for Oil & Gas Applications Sulzer Metco

Manfred Oechsle | March 2013

Contents Sulzer Metco

Oil and Gas Carbide Coating Overview

Thermal Spray Carbide Coatings

Thermal Spray Carbide Coating Applications

PTA Welding

Hardfacing Solutions for Oil & Gas Applications | Manfred Oechsle | slide 2
Oil and Gas Carbide Application Overview Sulzer Metco

1
Down Hole Tools
Drill Collar / Tool joints / Stabilizers
 MIG Welding / Drop-in process
 MIG Welding / Flux Cored Wire
 PTA Welding
 Laser Cladding
 Oxy-Acetylene Welding (stabilizer refurbishment)

2 4
Bottom Hole Assy. and Pipelines
Mud Motor, Mandrels / Pump impellers / Ball
4 and Gate Valves
HVOF Spray
PTA Welding
1 Laser Cladding

3
Drill Bit
2 Tricone Bits / PDC Bits
 Oxy-Acetylene Welding
 MIG Welding
3  PTA Welding
 Laser Cladding
 Infiltration (matrix materials)
Hardfacing Solutions for Oil & Gas Applications | Manfred Oechsle | slide 3
Oil and Gas Carbide Application Overview Sulzer Metco

Ball and Gate Valves, Mud Motor Stabilizers, Tricone Bits,

Rotors, Mandrels, Pump Impellers Drill Collars PDC Bits

A&S Powders S&C Powders Fine Powders Powder Blends Tubular Rods
WOKA 3652 Amdry 5843 WOKA 3660 PlasmaDur WokaDur A
Drilling
WOKA 3655 WOKA 3903 WOKA 3661 MetcoClad WokaDur A+ Pipelines
WOKA 3703 WOKA 3654 FC WokaDur S70
Metco 5163 Pumps
Metco 5164 Composite Rod
Metco 5165 WokaDur SA 100Ni Matrix Materials
WOKA 102
Flux Cored Wire WOKA FTC
WokaJet-410 Water-Cooled HVAF WOKA MTC
WokaStar-610 DiamondJet Uniquecoat M3 WokaDur NiE-TM WOKA CoDS

Laser Cladding
Arc Welding /
HVOF / HVAF / Spray and Fuse / PTA Welding /
Oxy-Acetylene
Oxy-Acetylene

Hardfacing Solutions for Oil & Gas Applications | Manfred Oechsle | slide 4
Carbide Coatings Effective Wear Protection Basics Sulzer Metco

Properties to Consider for

Type of Wear Wear Mechanism
Effective Wear Protection

Hardness of Abrasive and

Abrasion Abrasion
Coating

Hardness Abrasion
Slurry Erosion
Corrosion Resistance Corrosion

Hardness and Size of

Abrasion
Solid Particle Erosion Abrasive
Fatigue
Ductility

Galling Low Friction Coefficient Adhesion

Fretting Hardness Tribooxidation

Impact Ductility Fatigue

Cavitation Ductility Fatigue

Droplet Impingement Hardness Corrosion
Hardfacing Solutions for Oil & Gas Applications | Manfred Oechsle | slide 5
Contents Sulzer Metco

Oil and Gas Carbide Coating Overview

Thermal Spray Carbide Coatings

Thermal Spray Carbide Coating Applications

PTA Welding

Hardfacing Solutions for Oil & Gas Applications | Manfred Oechsle | slide 6
Application Development – HVOF Carbide Coatings Sulzer Metco

Powder Spray Gun Coating Properties

Wear Resistance
Chemical Composition Liquid- or Gas-Fuel
Corrosion Resistance
Spray Gun Choice
Manufacture Method
Phase Composition
Fuel Used
Particle Shape
Coating Roughness
Spray Parameter
Particle Size Distribution
Hardness
Kinetic Energy
Hall Flow
Porosity
Apparent Density Thermal Energy
Deposition Efficency

Hardfacing Solutions for Oil & Gas Applications | Manfred Oechsle | slide 7
Carbide HVOF Powders for Wear Resistant Coatings Sulzer Metco

Powder Composition Gun

WOKA 3552 WC NiCr 85 10 % Liquid Fuel

WOKA 3502 WC Ni 90 10 Liquid Fuel

WOKA 3702 WC CrC Ni 73 20 7 Liquid Fuel

WOKA 3102 WC Co 88 12 Liquid Fuel

WOKA 3202 WC Co 83 17 Liquid Fuel

Amdry 5843 WC CoCr 86 10 4 Liquid Fuel

WOKA 3661 WC CoCr 86 10 4 Gas Fuel

WOKA 3655 WC CoCr 86 10 4 Gas Fuel

WOKA 3652 WC CoCr 86 10 4 Liquid Fuel

WOKA 3652 WC CoCr 86 10 4 Liquid Fuel

WOKA 7102 CrC-NiCr 80 20 Liquid Fuel

WOKA 7505 CrC WC NiCo 45 37 18 Liquid Fuel

Diamalloy 3007 CrC NiCr 80 20 cladded Gas Fuel

WOKA 7302 CrC NiCr 75 25 densified Liquid Fuel

WOKA 7202 CrC NiCr 75 25 Liquid Fuel

Hardfacing Solutions for Oil & Gas Applications | Manfred Oechsle | slide 8
Coating Characterization Sulzer Metco

Sprayability

Microstructure Hardness

Functional
Coating
Corrosion - Salt Fog Roughness

Corrosion - Electrochemical Abrasion

Cavitation
Hardfacing Solutions for Oil & Gas Applications | Manfred Oechsle | slide 9
HVOF Carbide Coatings: Hardness and Abrasion Sulzer Metco

Hardfacing Solutions for Oil & Gas Applications | Manfred Oechsle | slide 10
HVOF Carbide Coatings:
Hardness and Open Circut Potential Sulzer Metco

Noble
More Noble
More

Hardfacing Solutions for Oil & Gas Applications | Manfred Oechsle | slide 11
HVOF Carbide Coatings: Abrasion and Cavitation Sulzer Metco

WC 10Co 4Cr

Hardfacing Solutions for Oil & Gas Applications | Manfred Oechsle | slide 12
HVOF Carbide Coatings: Friction – Abrasion Sulzer Metco

WC 10Co 4Cr

Hardfacing Solutions for Oil & Gas Applications | Manfred Oechsle | slide 13
HVOF Carbide Coatings:
Surface Roughness and Abrasion Sulzer Metco

Fine Carbides
PSD -20 +5 µm

Hardfacing Solutions for Oil & Gas Applications | Manfred Oechsle | slide 14
Contents Sulzer Metco

Oil and Gas Carbide Coating Overview

Thermal Spray Carbide Coatings

Thermal Spray Carbide Coating Applications

PTA Welding

Hardfacing Solutions for Oil & Gas Applications | Manfred Oechsle | slide 15
HVOF Carbide Coating Applications Sulzer Metco

Application Requirements Solution

Ball Valves
 Anti galling properties WokaJet-410
after periods of non use
 Corrosion resistance WOKA 3652
 Gas tight coating WOKA 3903
(> 10,000 psi)
 Smooth surface texture WOKA 3660

Gate Valves
 Anti galling properties WokaJet-410
after periods of non use
 Corrosion resistance WOKA 3903
 Gas tight coating Amdry 5843
(> 15,000 psi)
 Smooth surface texture WOKA 7202 (seat)

Hardfacing Solutions for Oil & Gas Applications | Manfred Oechsle | slide 16
HVOF Carbide Coating Applications Sulzer Metco

Application Requirements Solution

Mandrels WokaJet-410
 Anti galling properties
after periods of non use
WOKA 3652

 Corrosion resistance WOKA 3903

 Abrasion / erosion
WOKA 3660
resistance
WOKA 3552

Pump Impellers
WokaJet-410
 Abrasion / erosion
resistance WOKA 3652
 Corrosion resistance
Amdry 5843
 Cavitation resistance
WOKA 7505

Hardfacing Solutions for Oil & Gas Applications | Manfred Oechsle | slide 17
HVOF Carbide Coating Applications Sulzer Metco

Application Requirements Solution

Hydraulic Rods Water-Cooled

DiamondJet (propane)
 Abrasion resistance
 Corrosion resistance WOKA 7103

 Sealing friendly WOKA 7203

WOKA 7503

Mud Motor Rotors  Abrasion resistant

against mud
WokaJet-410

 Corrosion resistance in WOKA 3652

acidic and alkaline
environments WOKA 3703
 Smooth as-sprayed
Metco 5163
surface texture

Hardfacing Solutions for Oil & Gas Applications | Manfred Oechsle | slide 18
Contents Sulzer Metco

Oil and Gas Carbide Coating Overview

Thermal Spray Carbide Coatings

Thermal Spray Carbide Coating Applications

PTA Welding

Hardfacing Solutions for Oil & Gas Applications | Manfred Oechsle | slide 19
PTA Welding Sulzer Metco

Hardfacing Solutions for Oil & Gas Applications | Manfred Oechsle | slide 20
Surface Mining: Oil Sands Sulzer Metco

1 2 3 4

Source: Imperial Oil of Canada

Hardfacing Solutions for Oil & Gas Applications | Manfred Oechsle | slide 21
Surface Mining: Material Selection Sulzer Metco

100

80

SILT SAND GRAVEL SEM micrograph of the wear scar

60 produced on a WC-NiCrBSi (60
% Finer

HRC) overlay deposit when

40 abraded by 50/70 grade sand.
Magnification X500.
20

0
0.002 0.006 0.02 0.06 0.2 0.6 2 6 10 60
Particle Size [mm]

Abrasion / Erosion Impact / Erosion

Fine Abrasives Coarse Abrasives

Silt / Sand Gravel / Stones /
Primary carbide
Coarse Sand
PlasmaDur 51227 Large precipitate
in matrix alloy
PlasmaDur 51122 PlasmaDur 51322
PlasmaDur 51027 PlasmaDur 51142

Hardfacing Solutions for Oil & Gas Applications | Manfred Oechsle | slide 22
Crusher Station – Mining Picks Sulzer Metco

Hardfacing Solutions for Oil & Gas Applications | Manfred Oechsle | slide 23
PTA Carbide Powders for Surface Mining Sulzer Metco

Material Product Requirement

PlasmaDur 51937
Blends of Per Customer Specification
Tailored for on-site
NiCrBSi
Premium +
Tungsten Carbide Blend of conditions
Spherical Cast Special Applications
Various Carbides Monocrystalline
Pellets

High impact and

PlasmaDur 51322
Blends of abrasion resistance
Specification NiCrBSi + MTC
PlasmaDur 51142
Oil sands
PlasmaDur 51122
Thick overlays

Abrasion resistant
Blends of
PlasmaDur 51027 Cost effective
Value NiBSi + FTC
PlasmaDur 51227 solution
NiCrBSi + FTC
Lignite Mining

Hardfacing Solutions for Oil & Gas Applications | Manfred Oechsle | slide 24
Contact Us Sulzer Metco

To take control of your surface engineering challenges,

contact:

Your local Sulzer Metco Sales Office

Visit our web site at www.sulzer.com

E-mail us at info@sulzermetco.com

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Hardfacing Solutions for Oil & Gas Applications | Manfred Oechsle | slide 25