Electrically Smart Multi-Layered Coating for Condition-Base Monitoring

Patent metadata

Field	Value
Publication number	US-2020141890-A1
Application number	US-201816183324-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 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, the multilayer coating including at least three layers, wherein at least two of the layers are electrically conductive layers.

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

3 . The apparatus of claim 2 , wherein each electrically non-conductive layers comprises ceramic, polymer, ceramic-polymer composite, or ceramic-metal composite; wherein each electrically conductive layer comprises metal; or combinations thereof.

4 . The apparatus of claim 1 , wherein the 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 voltmeter electrically coupled with the at least two of the electrically conductive layers, wherein the multilayer coating includes at least one electrically non-conductive layer positioned between the at least two electrically conductive layers; an ammeter and a source of electrical potential electrically coupled with the at least two of the 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 across 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 across 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, the multilayer coating including at least three layers, wherein at least two of the layers are electrically conductive layers.

10 . The method of claim 9 , wherein applying the multilayer coating includes applying at least one electrically non-conductive layer sandwiched between the at least two electrically conductive layers.

11 . The method of claim 10 , wherein the electrically non-conductive layers are applied via spraying, a sol-gel process, chemical vapor deposition, or physical vapor deposition.

12 . The method of claim 9 , wherein the electrically conductive layers are applied via electroplating, electroless plating, chemical vapor deposition, physical vapor deposition, or thermal spray processes.

13 . The method of claim 9 , further comprising electrically coupling the multilayer coating with a voltmeter; an ammeter and a source of electrical potential; or combinations thereof.

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 includes at least three layers, including at least two electrically conductive layers; measuring an electrical response 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 two electrically conductive layers and measuring a voltage across the multilayer coating; electrically coupling an ammeter and a source of electrical potential with the two electrically conductive layers, generating a current across the multilayer coating, and measuring the current across 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 voltage, 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 voltage, 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

• 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

• E21B47/00

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

• C09D5/24

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

• G01N27/205 Primary

  in insulating materials · CPC title