Electrically smart multi-layered coating for condition-base monitoring

Patent metadata

Field	Value
Publication number	US-11002701-B2
Application number	US-201816183324-A
Country	US
Kind code	B2
Filing date	Nov 7, 2018
Priority date	Nov 7, 2018
Publication date	May 11, 2021
Grant date	May 11, 2021

Abstract

The disclosure provides for apparatus, including coated parts, where a base material of the part is coated with a multilayer coating. The multilayer coating includes at least three layers, including at least two electrically conductive layers. Also provided is a method for making apparatus, which includes providing a part and applying a multilayer coating to the base material of the part. Further provided is a method of monitoring and diagnosing a condition of a coated part. The method includes providing a coated part having a multilayer coating on a base material, measuring an electrical response of the multilayer coating, and correlating the electrical response with a condition of the multilayer coating.

First claim

What is claimed is:

1. An apparatus comprising:
a part including a base material; and
a multilayer coating on the base material, wherein the multilayer coating comprises at least three layers including first and second electrically conductive layers, wherein the first electrically conductive layer is an outermost layer on the part, wherein the multilayer coating is electrically responsive to a condition of the multilayer coating for condition-based monitoring of the coating and the part.

2. The apparatus of claim 1 , wherein the multilayer coating includes at least one electrically non-conductive layer positioned between the first and second electrically conductive layers.

3. The apparatus of claim 2 , wherein the second electrically conductive layer is disposed at a greater depth than the first electrically conductive layer, wherein a first thickness of the first electrically conductive layer is less than a second thickness of the second electrically conductive layer.

4. The apparatus of claim 1 , wherein each of the first and second electrically conductive layers exhibit a hardness ranging from 450 to 1500 HVN, exhibit corrosion resistance, or combinations thereof.

5. The apparatus of claim 1 , further comprising a condition-based monitoring system, comprising:
a voltmeter electrically coupled between the first and second electrically conductive layers, wherein the multilayer coating includes at least one electrically non-conductive layer positioned between the first and second electrically conductive layers;
an ammeter and a source of electrical potential electrically coupled between the first and second electrically conductive layers, wherein each layer of the multilayer coating is an electrically conductive layer; or
combinations thereof.

6. The apparatus of claim 5 , wherein:
the multilayer coating is responsive to voltage such that voltage between the first and second electrically conductive layers of the multilayer coating varies in response to the presence of a defect in the multilayer coating;
the multilayer coating is responsive to current such that current between the first and second electrically conductive layers of the multilayer coating varies in response to the presence of a defect in the multilayer coating; or
combinations thereof.

7. The apparatus of claim 1 , wherein the part is a valve, a drill bit, or a pump.

8. The apparatus of claim 1 , wherein the part is a ball, a seat, a stem, or a bearing of a valve.

9. A method for making an apparatus comprising:
providing a part, the part including a base material; and
applying a multilayer coating to at least a portion of the base material, wherein the multilayer coating comprises at least three layers including first and second electrically conductive layers, wherein the first and second electrically conductive layers extend continuously in two-dimensions along the portion, wherein the multilayer coating is electrically responsive to a condition of the multilayer coating for condition-based monitoring of the coating and the part.

10. The method of claim 9 , wherein applying the multilayer coating includes applying at least one electrically non-conductive layer sandwiched between the first and second electrically conductive layers, wherein the second electrically conductive layer is disposed at a greater depth than the first electrically conductive layer, wherein a first thickness of the first electrically conductive layer is less than a second thickness of the second electrically conductive layer.

11. The method of claim 9 , wherein the first electrically conductive layer is an outermost layer on the part.

12. The method of claim 9 , wherein the second electrically conductive layer is disposed at a greater depth than the first electrically conductive layer, wherein a first electrical conductivity of the first electrically conductive layer is greater than a second electrical conductivity of the second electrically conductive layer.

13. The method of claim 9 , further comprising electrically coupling the multilayer coating with a condition-based monitoring system comprising: a voltmeter; an ammeter and a source of electrical potential; or combinations thereof, wherein the condition-based monitoring system is disposed electrically between the first and second electrically conductive layers.

14. A method of monitoring and diagnosing a condition of a coated part, the method comprising:
providing a coated part, the coated part including a base material having a multilayer coating thereon, wherein the multilayer coating comprises at least three layers including first and second electrically conductive layers;
measuring an electrical response between the first and second electrically conductive layers of the multilayer coating; and
correlating the electrical response with a condition of the multilayer coating.

15. The method of claim 14 , wherein measuring the electrical response includes:
electrically coupling a voltmeter with the first and second electrically conductive layers and measuring a voltage between the first and second electrically conductive layers of the multilayer coating;
electrically coupling an ammeter and a source of electrical potential with the first and second electrically conductive layers, generating a current across the multilayer coating, and measuring the current between the first and second electrically conductive layers of the multilayer coating; or
combinations thereof.

16. The method of claim 15 , wherein the measured voltage varies in response to the presence of a defect in the multilayer coating, wherein the measured current varies in response to the presence of a defect in the multilayer coating, or combinations thereof.

17. The apparatus of claim 16 , wherein the defect is a scratch, a pit, a crevice, a crack, abrasive wear, erosion, fretting, or debonding.

18. The method of claim 15 , further comprising continually or continuously varying voltage across the multilayer coating, continually or continuously varying current across the multilayer coating, or combinations thereof.

19. The method of claim 15 , wherein:
if the measured voltage is below a threshold voltage, determining that the coated part has a surface that is suitable for deployment and service in an operational environment;
if the measured voltage is above the threshold voltage, maintaining the coated part, replacing the coated part, inspecting the coated part, or combinations thereof;
if the measured current is above a threshold current, determining that the coated part has a surface that is suitable for deployment and service in an operational environment; or
if the measured current is below the threshold current, maintaining the coated part, replacing the coated part, inspecting the coated part, or combinations thereof.

20. The method of claim 14 , further comprising, based upon the electrical response: determining whether a defect is forming in the multilayer coating; determining whether a defect is present in the multilayer coating; determining a degree of penetration of a defect into the multilayer coating; determining whether to pause or cease operations of the part; determining whether to recoat the part with an additional multilayer coating; determining whether to perform maintenance on the part; determining whether to replace the part; or combinations thereof.

Assignees

• Cameron Int Corp

Inventors

• Marya Manuel
• Manson Ronald
• Meade Christian

Classifications

• E21B47/00

  Survey of boreholes or wells (monitoring pressure or flow of drilling fluid E21B21/08) · CPC title

• G01N27/205 Primary

  in insulating materials · CPC title

• C09D5/24

  Electrically-conducting paints {(conductive materials H01B1/00)} · CPC title

• G01N27/20 Primary

  Investigating the presence of flaws · CPC title

• E21B41/00

  Equipment or details not covered by groups E21B15/00 - E21B40/00 · CPC title