Hard and lubricious valve surfaces, material compositions and sequences of manufacturing

Patent metadata

Field	Value
Publication number	US-10995871-B2
Application number	US-201816183388-A
Country	US
Kind code	B2
Filing date	Nov 7, 2018
Priority date	Nov 7, 2018
Publication date	May 4, 2021
Grant date	May 4, 2021

Abstract

A valve including a surface movably engaged with another surface. A coating is on the surface. The surface can have a CoF of less than 0.1; a hardness in excess of 1,200 HVN; impermeability to liquids at pressures ranging from 15 and 20,000 psi; a surface finish of 63 or less; and a thickness ranging from 0.5 to 20 mils.

First claim

What is claimed is:

1. A valve for exploration, drilling, or production flow-control, the valve comprising:
a first surface movably engaged with a second surface; and
a coating on the first surface, the coating comprising at least a first layer, wherein the coating is characterized by:
a coefficient of friction of less than 0.15;
a hardness in excess of 1,200 HVN;
impermeability to liquids at pressures ranging from 15 to 20,000 psi;
a surface finish of 63 or less; and
a thickness ranging from 0.5 to 20 mils, and wherein the first layer includes at least two immiscible phases, including from 70 to 99 volume percent of a continuous phase and from 1 to 30 volume percent of a discontinuous phase dispersed within the continuous phase, wherein the continuous phase includes a transition-metal and the discontinuous phase includes a solid dry lubricant.

2. The valve of claim 1 , wherein the coating is further characterized by at least one of:
inertness and corrosion resistance; and
a bond strength to the first surface of equal to or greater than 10 ksi.

3. The valve of claim 1 , wherein the continuous phase has a face-centered cubic structure; wherein the continuous phase comprises Ni, Co, Cr, Mo, W, Fe, or combinations thereof; or combinations thereof.

4. The valve of claim 3 , wherein the continuous phase comprises Ni and Co in an amount ranging from 50 to 70 wt. %, based on a total weight of the continuous phase; Cr in an amount ranging from 16 wt. % to 30 wt. %, based on the total weight of continuous phase; Mo in an amount ranging from 2.5 wt. % to 10 wt. %, based on the total weight of continuous phase; W in an amount ranging from 0 wt. % to 4 wt. %, based on the total weight of continuous phase; and Fe in an amount ranging from 0 wt. % to 15 wt. %, based on the total weight of continuous phase, and wherein the composition of the continuous phase satisfies the following pitting resistance equivalent number value rule: 1 wt. % Cr+3.3% Mo+0.5% W+16N≥30.

5. The valve of claim 1 , wherein particles of the discontinuous phase have a particle size ranging from 0.5 to 150 μm and an aspect ratio of from 1 to 100.

6. The valve of claim 1 , wherein the solid dry lubricant comprises a soft metal; a transition metal dichalcogenide; a binary oxide; a ternary oxide; an alkaline-earth fluoride; boron nitride; a MAX phase; or carbon or a carbon-based material.

7. The valve of claim 6 , wherein the solid dry lubricant comprises Ag, Pb, Au, In, Cu, MoS 2 , WS 2 , MoSe 2 , PBO, MoO 3 , WO 3 , CuO, V 2 O 5 , Re 2 O 7 , B 2 O 3 , Al 2 O 3 , ZrO 2 , Fe 2 O 3 , FeO, MgO, Ag 2 MoO 4 , Ag 2 WO 4 , Ag 3 VO 4 , CaF 2 , BaF 2 , hexagonal boron nitride, Ti 3 SiC 2 , Ti 2 SnC, diamond, diamond like carbon, ultra-nanocrystalline diamond, carbon nanotubes, fluorenes, graphene, graphene oxide, graphite, graphite composite, or tetrahedral amorphous carbon.

8. The valve of claim 1 , wherein the coating further comprises a second layer applied over a surface of the first layer, wherein the second layer comprises at least 30 wt. % carbon.

9. The valve of claim 8 , wherein the second layer has a thickness of from 2 to 40 μm; wherein the second layer comprises diamond like carbon, a transition-metal carbide compound, or a silicon carbide; or combinations thereof.

10. The valve of claim 8 , wherein the coating comprises a third layer applied over a surface of the second layer, wherein the third layer includes a solid-lubricant layer.

11. The valve of claim 10 , wherein the third layer comprises a sulfide.

12. The valve of claim 11 , wherein the third layer comprises MOS 2 , TiC x S y , TiCS/Se/Te, or WS 2 .

13. The valve of claim 1 , wherein the valve is a ball valve, a gate valve, a flow control valve, a safety valve, a formation isolation valve, or a subsea lubricator valve.

14. The valve of claim 1 , wherein the first surface of the valve comprises carbon steel, low-alloy-steel, stainless steel, or a superalloy.

15. The valve of claim 1 , further comprising a second coating on the second surface, wherein the second coating is the same as the coating.

16. A valve for exploration, drilling, or production flow-control, the valve comprising:
a first surface movably engaged with a second surface; and
a coating on the first surface, the coating comprising:
a first layer, wherein the coating is characterized by:
a coefficient of friction of less than 0.15;
a hardness in excess of 1,200 HVN;
impermeability to liquids at pressures ranging from 15 to 20,000 psi;
a surface finish of 63 or less; and
a thickness ranging from 0.5 to 20 mils and

a second layer applied over a surface of the first layer, wherein the second layer comprises at least 30 wt. % carbon; and
a third layer applied over a surface of the second layer, wherein the third layer includes a solid-lubricant layer, wherein the third layer comprises a sulfide.

17. The valve of claim 16 , wherein the third layer comprises MOS 2 , TiC x S y , TiCS/Se/Te, or WS 2 .

18. The valve of claim 16 , wherein the valve is a ball valve, a gate valve, a flow control valve, a safety valve, a formation isolation valve, or a subsea lubricator valve.

19. The valve of claim 16 , wherein the first layer includes at least two immiscible phases, including from 70 to 99 volume percent of a continuous phase and from 1 to 30 volume percent of a discontinuous phase dispersed within the continuous phase, wherein the continuous phase includes a transition-metal and the discontinuous phase includes a solid dry lubricant.

Assignees

• Cameron Int Corp

Inventors

• Marya Manuel
• Manson Ronald
• Meade Christian

Classifications

• Y10T428/12007

  Component of composite having metal continuous phase interengaged with nonmetal continuous phase · CPC title

• C23C28/347

  with layers adapted for cutting tools or wear applications · CPC title

• C10N2040/06

  Instruments or other precision apparatus, e.g. damping fluids · CPC title

• C10M125/22

  Compounds containing sulfur, selenium or tellurium · CPC title

• C10M125/02

  Carbon; Graphite · CPC title