Self-healing coatings for oil and gas applications

Patent metadata

Field	Value
Publication number	US-2019249308-A1
Application number	US-201916390841-A
Country	US
Kind code	A1
Filing date	Apr 22, 2019
Priority date	Aug 18, 2015
Publication date	Aug 15, 2019
Grant date	—

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.

First claim

What is claimed is:

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 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 comprise an active agent intercalated between layers of a material having a layered structure.

3 . The coated article of claim 2 , 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.

4 . 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.

5 . The coated article of claim 4 , 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.

6 . 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.

7 . The coated article of claim 6 , 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.

8 . The coated article of claim 7 , 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.

9 . 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.

10 . 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.

11 . The coated article of claim 10 , wherein the metallic matrix comprises a nickel-based alloy, Ti-based alloy or Al-based alloy.

12 . 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.

13 . 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.

14 . 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.

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

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

17 . 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 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.

18 . The method of claim 17 , 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.

Assignees

• Chilukuri Anusha
• Murugesan Sankaran
• Monteiro Othon
• Baker Hughes A Ge Co Llc

Inventors

• Chilukuri Anusha
• Murugesan Sankaran
• Monteiro Othon

Classifications

• C09D5/082 Primary

  characterised by the anti-corrosive pigment · CPC title

• C08K9/10

  Encapsulated ingredients · CPC title

• C25D15/00

  Electrolytic or electrophoretic production of coatings containing embedded materials, e.g. particles, whiskers, wires · CPC title

• C23C18/1662

  Use of incorporated material in the solution or dispersion, e.g. particles, whiskers, wires · CPC title

• C09D7/69 Primary

  Particle size larger than 1000 nm · CPC title