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Ni-based coatings for oil and gas industry made by cold gas spraying

This paper presents the results of the study of nickel-based coatings fabricated by cold gas spraying. In this study compositions based on Ni, Ni-Cu, Ni-Zn, Ni-Al2O3/TiC coatings applied to low alloyed steel bases were investigated. The composition, type of powder (mechanical mix or mechanically alloying), and thickness varied to choose the optimal characteristics for recovery, repair procedures, and other applications in the oil and gas industry. The second phase was added to Ni-base coatings to increase corrosion and wear resistance. Pure nickel coatings were also studied as a benchmark. Corrosion resistance was studied by means of electrochemical testing, salt spray tests, autoclave testing in simulated oilfield conditions. Hydroabrasive resistance was studied using the unique testing bench. Scanning electron microscopy mappings, microhardness testing, and adhesion testing were used to correlate the results of the tests with the structure, continuity, and porosity of the studied coatings. It was shown that applying mechanical alloying of the powder did not lead to an effective increase of corrosion and hydroabrasive resistance. All the studied coating specimens have a sufficiently high adhesion. Ni-Zn coating has the lowest corrosion resistance and high hydroabrasive resistance. Ni-Cu coatings have high corrosion and the lowest hydroabrasive resistance. Al2O3/TiC additives give ambiguous results in the studied properties. The thickness of 40 – 60 microns provides sufficient performance of the studied coatings. Thus, varying chemical composition, a thickness of coatings allow obtaining optimal properties of Ni-based coatings made by cold gas spraying for use in the oil and gas industry.