SELF-HEALING COATINGS FOR OIL AND GAS APPLICATIONS

• US 20170051156A1
• Filed: 08/18/2015
• Published: 02/23/2017
• Est. Priority Date: 08/18/2015
• Status: Active Grant

• Current Assignee: Baker Hughes Holdings LLC (Baker Hughes Company)
• Original Assignee: Baker Hughes Incorporated (Baker Hughes Company)
• Inventors: Chilukuri, Anusha, Murugesan, Sankaran, Monteiro, Othon
• Granted Patent: US 10,316,413 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• 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 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.

2. The coated article of claim 1, wherein the micro- or nano-sized particles have a core-shell structure comprising an active agent encapsulated in a micro- or nano-sized metallic container.

3. The coated article of claim 2, wherein the 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.

4. The coated article of claim 1, wherein the micro- or nano-sized particles comprise an active agent intercalated between layers of a material having a layered structure.

5. The coated article of claim 4, wherein the material having a layered structure comprises a hydrotalcite, nanoclay, zeolite, metal organic frameworks (MOF), an oxide layered material, or a combination comprising at least one of the foregoing.

6. The coated article of claim 1, wherein the micro- or nano-sized particles comprise an active agent adsorbed or absorbed in a material having a porous structure.

7. The coated article of claim 6, wherein the material having a porous structure comprises nanoclay, a zeolite, a molecular sieve, a metal organic framework (MOF), or a combination comprising at least one of the foregoing.

8. 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.

9. The coated article of claim 8, 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.

10. The coated article of claim 8, 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.

11. 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.

12. The coated article of claim 1, wherein the metallic matrix comprises Ni, Cu, Ag, Au, Zn, Sn, Fe, In, W, Ti, Co, Al, Mg, Cr, Mo, or an alloy thereof, or a combination comprising at least one of the aforementioned materials.

13. The coated article of claim 12, wherein the metallic matrix comprises a nickel-based alloy, Ti-based alloy or Al-based alloy.

14. The coated article of claim 1, wherein the 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.

15. 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 coating.

16. 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.

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

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

19. A method of manufacturing a coated article, the method comprising:

depositing on a surface of a substrate a 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 container, a layered structure, a porous structure, or a combination comprising at least one of the foregoing,

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

20. The method of claim 19, wherein the 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.