Hard and Lubricious Valve Surfaces, Material Compositions and Sequences of Manufacturing

Patent metadata

Field	Value
Publication number	US-2020141509-A1
Application number	US-201816183388-A
Country	US
Kind code	A1
Filing date	Nov 7, 2018
Priority date	Nov 7, 2018
Publication date	May 7, 2020
Grant date	—

Abstract

The disclosure provides for a valve including a surface movably engaged with another surface. A coating is on the surface and is characterized by: 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. The disclosure provides for material constructions including a continuous phase, including a transition metal, and a discontinuous phase, including a solid dry lubricant. The disclosure also provides for a method of depositing a coating that includes depositing a first layer of a coating onto a surface using electroplating, electroless plating, thermal spraying, or cladding, and then depositing a second layer of the coating onto a surface of the first layer using sputtering, ion beam, plasma enhanced chemical vapor deposition, cathodic arc, or chemical vapor deposition.

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 and 20,000 psi;
a surface finish of 63 or less; and
a thickness ranging from 0.5 to 20 mils.

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

3 . The valve of claim 1 , 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.

4 . The valve of claim 3 , 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.

5 . The valve of claim 4 , 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.

6 . The valve of claim 3 , 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.

7 . The valve of claim 3 , 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.

8 . The valve of claim 7 , 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.

9 . 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.

10 . The valve of claim 9 , 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.

11 . The valve of claim 9 , wherein the coating comprises a third layer applied over a surface of the second layer, wherein the third layer includes a solid-lubricant layer.

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

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

14 . 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.

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

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

17 . A method of depositing a coating onto a surface of a valve, the method comprising:
depositing a first layer of a coating onto a surface of a valve, wherein the first layer is deposited using electroplating, electroless plating, thermal spraying, or cladding; and optionally depositing a second layer of the coating onto a surface of the first layer, wherein the second layer is deposited using electroplating, electroless plating, thermal spraying, cladding, sputtering, ion beam, plasma enhanced chemical vapor deposition, cathodic arc, or chemical vapor deposition.

18 . The method of claim 17 , further comprising, after depositing the first layer and before depositing the second layer, preparing the surface of the first layer, wherein preparing the surface of the first layer includes cleaning the surface of the first layer, honing the surface of the first layer, polishing the surface of the first layer, or combinations thereof.

19 . A material construction comprising:
a first layer including 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, each based on a total volume of the first layer; wherein the discontinuous phase comprises a solid dry lubricant, and wherein the continuous phase comprises Ni and Co in an amount ranging from 50 to 70 wt. %, Cr in an amount ranging from 16 wt. % to 30 wt. %, Mo in an amount ranging from 2.5 wt. % to 10 wt. %, W in an amount ranging from 0 wt. % to 4 wt. %, and Fe in an amount ranging from 0 wt. % to 15 wt. %, each based on a total weight of the continuous phase.

20 . The material construction of claim 19 , further comprising:
a second layer applied over a surface of the first layer, wherein the second layer comprises at least 30 wt. % carbon; or 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.

Assignees

• Cameron Int Corp

Inventors

• Marya Manuel
• Manson Ronald
• Meade Christian

Classifications

• F16K25/005 Primary

  Particular materials for seats or closure elements · CPC title

• C10M125/04

  Metals; Alloys · CPC title

• C10M171/06

  Particles of special shape or size · CPC title

• C10M103/04

  Metals; Alloys · CPC title

• C10M2201/087

  Boron oxides, acids or salts · CPC title