Self-healing coatings for oil and gas applications

• US 10,316,413 B2
• Filed: 08/18/2015
• Issued: 06/11/2019
• Est. Priority Date: 08/18/2015
• Status: Active Grant

• Current Assignee: Baker Hughes Holdings LLC (Baker Hughes Company)
• Original Assignee: Baker Hughes, a GE Company, LLC (Baker Hughes Company)
• Inventors: Chilukuri, Anusha, Murugesan, Sankaran, Monteiro, Othon
• Primary Examiner(s): Huang, Cheng Yuan
• Application Number:
  US14/829,529
• Publication Number:
  US 20170051156A1
• Time in Patent Office: 1,393 Days
• CPC Class Codes: C08K 9/10 Encapsulated ingredients
• CPC Class Codes: C09D 5/082 characterised by the anti-corrosive pigment
• CPC Class Codes: C09D 7/67 Particle size smaller than 100 nm
• CPC Class Codes: C09D 7/69 Particle size larger than 1000 nm
• CPC Class Codes: C23C 18/1662 Use of incorporated material in the solution or dispersion, e.g. particles, whiskers, wires
• CPC Class Codes: C23C 4/06 Metallic material
• CPC Class Codes: C25D 15/00 Electrolytic or electrophoretic production of coatings containing embedded materials, e.g. particles, whiskers, wires

Abstract

A coated article comprises a substrate and a self-healing coating disposed on a surface of the substrate, the self-healing coating comprising a metallic matrix; and a plurality of micro- or nano-sized particles dispersed in the metallic matrix; the micro- or nano-sized particles comprising an active agent disposed in a carrier comprising a micro- or nano-sized metallic container, a layered structure, a porous structure, or a combination comprising at least one of the foregoing.

Claims

1. A coated article comprising:

a substrate; and

a self-healing coating disposed on a surface of the substrate;

the self-healing coating comprising

a continuous metallic matrix formed from Ni, Cu, Ag, Au, Sn, Fe, In, W, Ti, Co, Al, Mg, Cr, Mo, or an alloy thereof, or a combination thereof; and

a plurality of micro- or nano-sized particles dispersed in the continuous metallic matrix;

the micro- or nano-sized particles having a core-shell structure comprising an active agent encapsulated in a micro- and nano-sized metallic container shell,

wherein the micro- or nano-sized metallic container and the continuous metallic matrix have at least one common metal; and

the micro- or nano-sized particles have a number average particle size of about 100 nm to about 100 microns; and

the micro- or nano-sized metallic container shell has a thickness of about 10 nanometers to about 50 nanometers.

2. The coated article of claim 1, wherein the micro- or nano-sized metallic container comprises Fe, Zn, Ni, Cu, Ag, Au, W, Ti, Co, Al, Mg, Cr, Mo, alloys thereof, or a combination comprising at least one of the foregoing.

3. The coated article of claim 1, wherein the active agent comprises a corrosion inhibitor, a scale inhibitor, or a combination comprising at least one of the foregoing.

4. The coated article of claim 3, wherein the active agent comprises an inorganic corrosion inhibitor, an organic corrosion inhibitor comprising at least one of S, N, O, P, or a combination comprising at least one of the foregoing corrosion inhibitors.

5. The coated article of claim 3, wherein the corrosion inhibitor comprises an amine, an imidazoline, a quaternary compound, an amide, a phosphate, a sulfur-containing compound, a vanadate, a molybdate, a tungstate, a chromate, a lanthanide, a niobate, a cerate, a borate, a polymeric corrosion inhibitor, or a combination comprising at least one of the foregoing.

6. The coated article of claim 1, wherein the active agent is released from the micro- or nano-sized particles in response to a mechanical damage to the coating, a change of pH, temperature, pressure, radiation, or a combination comprising at least one of the foregoing.

7. The coated article of claim 1, wherein the continuous metallic matrix comprises a nickel-based alloy or Ti-based alloy.

8. The coated article of claim 1, wherein the self-healing coating further comprises carbon, boron, a carbide, a nitride, an oxide, a boride or a solid lubricant, or a combination comprising at least one of the foregoing.

9. The coated article of claim 1, wherein the micro- or nano-sized particles are present in an amount of about 0.5 volume percent to about 40 volume percent based on the total volume of the self-healing coating.

10. The coated article of claim 1, wherein the substrate comprises iron, magnesium, aluminum, titanium, manganese, cobalt, nickel, copper, molybdenum, tungsten, palladium, chromium, ruthenium, gold, silver, zinc, zirconium, vanadium, silicon, an alloy thereof, or a combination comprising at least one of the foregoing.

11. The coated article of claim 1, wherein the self-healing coating has a thickness of about 0.1 micron to 10 mm.

12. The coated article of claim 1, wherein the coated article is a downhole element.

13. The coated article of claim 1, wherein the continuous metallic matrix comprises a Ni—

P alloy, a Ni—

B alloy, or a Ni—

W alloy.

14. The coated article of claim 1, wherein the active agent is an imidazoline corrosion inhibitor.

15. The coated article of claim 1, wherein the self-healing coating is configured to provide temperature shielding or thermal conductance to carry heat away from the substrate so that the substrate does not experience a temperature near its thermal decomposition temperature.

16. The coated article of claim 1, wherein the micro- or nano-sized particles are homogeneously dispersed in the continuous metallic matrix.

17. The coated article of claim 1, wherein the micro- or nano-sized metallic container comprises Fe, Zn, Cu, Ag, Au, W, Ti, Co, Mg, Mo, alloys thereof, or a combination comprising at least one of the foregoing.

21. A method of manufacturing the coated article of claim 1, the method comprising:

depositing on the surface of the substrate the self-healing coating comprising the continuous metallic matrix formed from Ni, Cu, Ag, Au, Sn, Fe, In, W, Ti, Co, Al, Mg, Cr, Mo, or an alloy thereof, or a combination thereof; and

the plurality of micro- or nano-sized particles dispersed in the continuous metallic matrix;

the micro- or nano-sized particles having the core-shell structure comprising the encapsulated in the micro- or nano-sized metallic container shell, the micro- or nano-sized metallic container and the continuous metallic matrix having at least one common metal;

the micro- or nano-sized particles having a number average particle size of about 100 nm to about 100 microns; and

the micro- or nano-sized metallic container shell having a thickness of about 10 nanometers to about 50 nanometers,

wherein the depositing comprises electroplating, electrolessly depositing, thermal spraying, or a combination comprising at least one of the foregoing.

22. The method of claim 21, wherein the continuous metallic matrix comprises a nickel-based alloy, a Ti-based alloy, or an Al-based alloy;

and the active agent comprises a corrosion inhibitor, a scale inhibitor, or a combination comprising at least one of the foregoing.

18. A coated article comprising:

a substrate comprising a metal or an alloy; and

a self-healing coating having a thickness of about 10 nm to about 5 mm disposed on a surface of the substrate;

the self-healing coating comprising

a continuous metallic matrix comprising a nickel-based alloy, a Ti-based alloy, or an Al-based alloy;

about 5% to about 30% by volume of the coating a plurality of micro- or nano-sized particles dispersed in the continuous metallic matrix;

the micro- or nano-sized particles having a core-shell structure comprising an active agent encapsulated in a micro- or nano-sized metallic container shell, the micro- or nano-sized particles having a number average particle size of about 100 nm to about 100 microns, the active agent comprising a corrosion inhibitor, a scale inhibitor, or a combination comprising at least one of the foregoing, and the metallic container shell having a thickness of about 10 nanometers to about 50 nanometers,

wherein the micro- or nano-sized metallic container and the continuous metallic matrix have at least one common metal.

19. The coated article of claim 18, wherein the corrosion inhibitor comprises an amine, an imidazoline, a quaternary compound, an amide, a phosphate, a sulfur-containing compound, a vanadate, a molybdate, a tungstate, a chromate, a lanthanide, a niobate, a cerate, a borate, a polymeric corrosion inhibitor, or a combination comprising at least one of the foregoing.

20. The coated article of claim 18, wherein the continuous metallic matrix comprises a Ni—

P alloy, a Ni—

B alloy, or a Ni—

W alloy.