Coating Protection for Production Facilities of Offshore Oil Fields

This paper describes coating protection of production facilities of offshore oil fields based on the practice of development of Bohai Offshore Oil Field, with focus laid on the selection of coating systems, surface preparation, coating application, as well as coating inspection for four types of major production facilities.

Smart composite antibacterial coatings with active corrosion protection of magnesium alloys

A new method of the formation of composite coatings with the function of active corrosion protection of magnesium alloys was developed using the plasma electrolytic oxidation(PEO) method. Susceptibility of PEO-layers to pitting formation was evaluated using localized electrochemical methods(SVET/SIET). The morphological features and electrochemical properties of composite coatings were studied using SEM/EDX, XRD, micro-Raman spectroscopy and EIS/PDP measurements, respectively. The effect of surface layers impregnation with corrosion inhibitor on their protective properties in a corrosive environment was established. Additional protection was achieved using controllable coating pore sealing with polymer. It was found that the polymer treatment of the PEO-layer does not reduce the inhibitor’s efficiency. The formed protective composite inhibitor-and-polymer-containing layers decrease the corrosion current density of a magnesium alloy in a 3 wt.% Na Cl solution to three orders of magnitude. This predetermines the prospect of new smart coatings formation that significantly expand the field of application of electrochemically active materials. The mechanism of smart composite coating corrosion degradation was established. The antibacterial activity of the inhibitor-containing coatings against S. aureus methicillin-resistant strain was proved using the in vitro model. These protective layers are promising for reducing the incidence of implant-associated infections.

Preparation and Microstructure of a Si-Mo Fused Slurry Coating on Carbon/Carbon Composites for Oxidation Protection

A coating of composition Si-40Mo (wt pct) was prepared by fused slurry coating method on the two-dimensional carbon/carbon (2D-C/C) composite to improve oxidation resistance. In the procedure of the fabrication, pure St slurry inner layer in the pre-coating was necessary to apply because of infiltration of liquid Si into the substrate during the sintering. The coating consists of Si continuous phase and MoSi2 particles. In addition, the infiltration of Si into the substrate and the SiC reaction layer between the coating and the C/C composite were observed. Oxidation behavior of coated and uncoated C/C composites was studied in cyclic mode. The oxidation resistance and the thermal shock resistance of the Si-Mo fused slurry coating were quite excellent at 1370℃.

Effect of TiO_(2) nanoparticles on the photocatalytic properties of PEO coatings on Mg alloy

A comprehensive study of the properties of coatings formed on a magnesium alloy by plasma electrolytic oxidation(PEO) using the electrolytes with nanosized particles of anatase(titanium dioxide) has been carried out. Formed coatings reduce corrosion current density 2.5-fold and increase hardness by 25% compared to a coating without particles. Confocal micro-Raman spectroscopy revealed the presence of anatase and rutile phases in the composition of PEO coating due to the incorporation of TiO2nanoparticles during plasma electrolytic treatment. The presence of titanium dioxide had a positive effect on the photocatalytic properties of coatings: the constant rate of the methyl orange and methyl blue decomposition is increased in 1.6 and 1.8-fold, respectively, compared to the coating formed in electrolyte without TiO_(2) particles.

Electrochemical synthesis of boron-containing coatings on Mg alloy for thermal neutron shielding

The work provides the results of the one-step formation of boron-containing coatings on an Mg–Mn–Ce alloy by plasma electrolytic oxidation. The results of studies of the composition, structure and morphology of heteroxide coatings are presented. It was established that the boron is contained in the coating mainly in the form of B or B_(2)O_(3). The introduction of B changes the color of coatings, and also helps to increase their porosity. The method of determining the full cross section of the interaction of thermal neutron absorption efficiency by samples material using the installation of neutron-activation analysis based on ^(252)Cf was developed. It was shown that the introduction of boron into the formed coatings allows to increase the macroscopic cross-section of the interaction of samples with thermal neutrons by 3.8 times. This effect opens the potential for the use of synthesized material in the field of nuclear technologies and aerospace industry.

Polymer Coatings for Protection of Wood and Wood-Based Materials

Three major types of protective coating of wood and wood-based materials have been considered. These three types include the coatings based on carboxyl-containing water-soluble polymers which are easily cross-linked by inorganic salts or OH-containing compounds, pH-sensitive coatings and polymer multi-layer structures. First of three mentioned approaches allows affecting permeability and enhancing the prevention the loss of water from the surface of wood to its surrounding. The advantage of the second approach is its ability to vary and purposely adjust the polymer composition and the number and distribution of -COOH groups in the chain which make the originally water-soluble polymers completely insoluble. The strong feature of the third approach which includes broad use of hydrogen-bonded films produced by layer-by-layer self-assembly is the possibility of manipulation of coatings stability after construction.

Microstructure and Oxidation Behaviors of Nano-particles Strengthened NiCoCrAlY Cladded Coatings on Superalloys

Nano-particles which can largely improve the microstructure and oxidation resistance of materials are often used as a strengthening component in metal matrix composites. However, few studies were reported on its application in the bond coat of duplex structure thermal barrier coating（TBC）. Three kinds of NiCoCrAlY coatings strengthened by different nano-particles with the same addition （1%, mass fraction） were prepared by the laser cladding technique on Ni-based superalloy substrates, aiming to study the effects of the nano-particles on microstructure and oxidation resistance of NiCoCrAlY coatings （the bond coat of the duplex structure thermal barrier coatings）. Scanning electron microscope （SEM）, X-ray diffractometer（XRD） and thermogravimetry were employed to investigate their morphologies, phases and cyclic oxidation behaviors in atmosphere at 1 050℃, compared with the coating without nano-particles. With the addition of nano-particles, the growth pattern of the grains at the interface changed from epitaxial growth to non-epitaxial growth or part-epitaxial growth; slender dendrites were broken and cellularized; cracks and pores were restrained; and the oxidation weight-gain and the stripping resistance of the oxide scale were improved as well. Among the three kinds of nano-particles, the SiC nano-particles showed the most improvement on microstructure, while the CeO2 nano-particles were insufficient, but its effects on the oxidation resistance are the same as those of the SiC nano-particles. Based on the discussions of the influence mechanism, it is believed that CeO2 nano-particles would show better improvement than SiC nano-particles if the proper amount is added and the proper preparation technique of micro-nanometer composite powders is adopted, with the synergistic action of nanometer effect and reactive element effect.

Preparation and Characterization of Low-melting Glasses Used as Binder for Protective Coating of Steel Slab

The low-melting phosphate glass was prepared for production of glass binders for protective coating of steel slab. Effects of different O/P ratios on glass structures and properties were analyzed. Differential thermal analysis （DTA） and infrared spectroscopy （IR） techniques were applied for low-melting glass binder. It was found that the glass transition temperature（T） was about 300 ℃ and softening temperature（T1） was about 480 ℃. The choice of O/P ratio was very important to the glass transition and softening temperatures. When more P=O bonds existed in the glass networks, P-O-P bond angle was deformed with decreasing of the ratio of O/E The coatings could adhere to the substrates instantaneously at 800 ℃ when the content of binder exceeded 3wt%. The optimal content of glass binder was 5wt%.

High Temperature Corrosion and Protection of Titanium Alloys and TiAl Intermetallics

High temperature corrsoion and protection of trtanium alloys and TiAl intermetallics are reviewed, andsome suggestions on the development of protective coatings are put forward.

Experimental Study on Wax Protective Coating for Wet Deep Silicon Etching Processes

In order to protect the finished structures on the front side during deep silicon wet etching processes, the wax coating for double-sided etching process on the wafer is studied to separate the aforementioned structures from the strong aqueous bases. By way of heating and vacuumization, the air bubbles are expelled from the coating to extend the protection duration. The air pressure in the sealed chamber is 0.026 7 Pa, and the temperature of the heated wafer is 300℃. Two kinds of the wax are used, and the corresponding photos of the etched wafer and the protection times are given. In 75 ℃ 10 % KOH solution, the protection duration is more than 8 h.

Formation Conditions of TiN Coatings by Reactive Magnetron Sputtering and Its Characteristics

The TiN coatings on the surfaces of various cemented carbides were performed by use of reactive magnetron sputtering. The highest microhardness which was obtained in our experiment was 49 GPa. The order of effects of deposition parameters is resulted from the L16 experiments according to orthogonal design. The pole density analysis indicated that there were a few of the textureless samples. The crystal orientation of TiN exhibited clear regularity and affected microhardness and other properties of films remarkably. A concept relating to structure factor was proposed. A layer-like structure was found. SAES showed that a transition layer exists between substrate and coating and its thickness is of a micron. The formation mechanism of film was discussed.

PLASMA POLYMERIZED ORGANOSILANES AS A PROTECTIVE COATING ON METAL

Polymer-metal oxane bonds (M-O-Si) can be created in the form of tight networks by silane plasma polymerization directly on the metal (e.g. copper) substrates. In this paper the structure and properties of the plasma-deposited organosilane polymers, the corrosion performance of such coating system on copper substrates were investigated.

Corrosion behavior of NiCrBSi coatings deposited by HVOF spraying

The corrosion resistance of NiCrBSi coating deposited on steel substrate by HVOF was examined using electrochemical tests and immersion tests so as to offer an experimental basis to expand a promising applied field of HVOF in aqueous medium, comparing with those of coatings deposited by oxyacetylene flame spraying and flame cladding. The results show that the general corrosion rate of HVOF sprayed coatings is quite bigger than that of clad coatings, but it is less sensitive to local corrosion. There is less and smaller porosity in the coatings deposited by HVOF than that in flame sprayed coatings. The effects of porosity on the corrosion current density was indistinctive, but the existence of large amount of defects in the coatings damaged the cohesion of the coatings, causing the metallic particles drop off from the coatings under the influence of corrosive medium. Improving the quality and reducing the porosity of coatings is the key to get the coatings with high corrosion resistance.

Study of Thermal Radiation Properties of Pyrolytic Carbon Protective Coatings for Monocrystalline Silicon Furnace

The thermal radiation properties of pyrolytic carbon(PyC)protective coatings for monocrystalline silicon furnace prepared by different processes were tested.The changes of normal emissivity of carbon materials caused by PyC protective coatings were discussed,and the influence of phase structure and surface appearance on the thermal radiation properties was investigated.The results show that the thermal radiation properties of PyC protective coatings with the wave band of 5-25μm are better than C/C substrate,further,normal spectral emissivity of CVD PyC coating remains basically at 0.85-0.90,and the normal total emissivity can reach0.89,which shows high thermal radiation performance.For resin PyC coating and CVD PyC coating,the degree of graphitization are 44.53%and 16.28%respectively,and the R value of Raman spectrum are 0.964and 1.384 respectively.Relatively disorder graphite structure of the latter causes various vibration modes,and the spectral emissivity is better,so the thermal radiation property of CVD PyC coating is excellent.A lot of spherical particles exists on the surface of the CVD PyC coating,and the more interface and spacing of particles reduce the number of particles per unit volume.Therefore,the scattering of thermal radiation is strongly strengthened,and the spectral emissivity is higher.

Influence of a Protective Coating Slurry on Enhancing the Descaling Ability and Oxidation Resistance of 9% Nickel Steel

A kind of ceramic slurry was prepared and sprayed onto the surface of 9Ni steel at room temperature. The coating layer will not only reduce the depth of the formed Ni-enriched entanglement at high temperature but also have an excellent ability to resist oxidation of the 9Ni steel. Compared to bare specimen, the depths of the entanglement of the coated 9Ni specimen could be successfully reduced by 74.1% and the oxidation loss be decreased by 62.3% by heating at 1 250 ℃ for 60 min. In addition, the coated specimen indicates no trace of oxide pegs. It proves that the coating has outstanding improvement to internal oxidation resistance. Some characterization methods such as metalloscopy, XRD, XPS, SEM and EDX have been used to reveal a possible protective mechanism. The result shows that the coating layer reacts with the iron oxide to form Mg Fe2O4 on the surface of the coated specimen, which could provide a smaller diffusion coefficient rate of Fe ion. The coating with a low cost and easy implementation is promisingly applicable in the slab-reheating process of the 9Ni steel.

High speed laser cladding as a new approach to prepare ultra-high temperature ceramic coatings

Ultra-high temperature ceramic(UHTC)coatings are used to protect the hot-end components of hypervelocity aerocrafts from thermal ablation.This study provides a new approach to fabricate UHTC coatings with high speed laser cladding(HSLC)technology,and places more emphasis on investigating the formation mechanism,phase compositions,and mechanical properties of HSLC-UHTC coatings.Results show that a well-bonded interface between the coating and the tantalum alloy substrate can be formed.The coating is mainly composed of(Zr,Ta)C ceramic solid solution phase with a content of higher than 90% by volume and Ta(W)metal solid solution phase.At a relatively high powder feeding rate,the ZrC ceramic phase appears in the coating while a dense ZrC UHTC top layer with a thickness of up to~50μm is successfully fabricated.As for the mechanical properties of the HSLC coatings,the fracture toughness of the coating decreases with the increase of powder feeding rate.The increase of carbide solid solution phase can significantly improve the high temperature microhardness(552.7±1.8 HV0.5@1000℃).The innovative design of HSLC ZrC-based coatings on refractory alloys accomplishes continuous transitions on microstructure and properties from the substrate to the UHTC top layer,which is a very promising candidate scheme for thermal protection coating.

In-situ chemical conversion film for stabilizing zinc metal anodes

Zinc metal anodes face several challenges,including the uncontrolled formation of dendrites,hydrogen evolution,and corrosion,which seriously hinder their application in practice.To address the above problems such as dendrite formation and corrosion,we present a simple and applicable immersion method that enables in situ formation of a zinc phytate(PAZ)coating on the surface of commercial Zn flakes via a substitution reaction.This protective coating mitigates corrosion of zinc flakes by the electrolyte,reduces the interfacial impedance,and accelerates the migration kinetics of zinc ions.Besides,this method can preferentially expose the(002)crystal plane with strong atomic bonding,which not only improves the corrosion resistance of the zinc flake,but can also guide the parallel deposition of zinc ions along the(002)crystal plane and reduce the formation of dendrites.Benefiting from the above advantages,the PAZ@Zn‖Cu half-cell has shown over 900 cycles with average coulombic efficiency(CE)of99.81%at 4 mA cm^(-2).Besides,the PAZ@Zn‖PAZ@Zn symmetric cell operate stably for>1000 h at5 mA cm^(-2)and>340 h at 10 mA cm^(-2).Furthermore,we demonstrated that this in situ chemical treatment enables the formation of a robust,well-bound protective coating.This method provides insights for advancing the commercialization of zinc anodes and other metal anodes.

Influence of ZrO_(2)/SiO_(2) nanomaterial incorporation on the properties of PEO layers on Mg-Mn-Ce alloy

The properties of coatings formed on the MA8 magnesium alloy by the plasma electrolytic oxidation in electrolytes containing mechanical mixture of zirconia and silica nanoparticles in concentrations of 2,4 and 6 g/l have been investigated.It has been established by SEM,EDS,and XPS that ZrO_(2)/SiO_(2)nanoparticles successfully were incorporated into the coatings.Micro-Raman spectroscopy showed the presence of ZrO_(2)in tetragonal and monoclinic forms in the PEO-coating composition as well as Mg_(2)SiO_(4) in tetrahedral configuration uniformly distributed in the outer part of coatings.Obtained coatings significantly reduce corrosion current density in comparison with bare Mg alloy and base PEOlayer(from 2.4×10^(–7)A/cm^(2) for base PEO layer to 0.7×10^(–7)A/cm^(2) for coatings with nanoparticles).It has been found that the presence of solid nanoparticles in the composition of coating has a positive effect on their hardness(this parameter was increased from 2.1±0.3 GPa to 3.1±0.4 GPa)and wearproof(the wear was reduced from(4.3±0.4)×10^(–5)mm^(3)/(N×m)to(3.5±0.2)×10^(–5)mm^(3)/(N×m)).

Air plasma-sprayed high-entropy (Y_(0.2)Yb_(0.2)Lu_(0.2)Eu_(0.2)Er_(0.2))_(3)Al_(5)O_(12) coating with high thermal protection performance

High-entropy rare-earth aluminate(Y_(0.2)Yb_(0.2)Lu_(0.2)Eu_(0.2)Er_(0.2))_(3)Al_(5)O_(12)(HE-RE_(3)Al_(5)O_(12))has been considered as a promising thermal protection coating(TPC)material based on its low thermal conductivity and close thermal expansion coefficient to that of Al2O3.However,such a coating has not been experimentally prepared,and its thermal protection performance has not been evaluated.To prove the feasibility of utilizing HE-RE_(3)Al_(5)O_(12) as a TPC,HE-RE_(3)Al_(5)O_(12) coating was deposited on a nickelbased superalloy for the first time using the atmospheric plasma spraying technique.The stability,surface,and cross-sectional morphologies,as well as the fracture surface of the HE-RE_(3)Al_(5)O_(12) coating were investigated,and the thermal shock resistance was evaluated using the oxyacetylene flame test.The results show that the HE-RE_(3)Al_(5)O_(12) coating can remain intact after 50 cycles at 1200℃ for 200 s,while the edge peeling phenomenon occurs after 10 cycles at 1400℃ for 200 s.This study clearly demonstrates that HE-RE_(3)Al_(5)O_(12) coating is effective for protecting the nickel-based superalloy,and the atmospheric plasma spraying is a suitable method for preparing this kind of coatings.

Role of Calcium Magnesium Aluminate in Carbon-containing Bricks for Steel Ladle

Calcium magnesium aluminate,with the commercial name of MagArmour,is a synthetic material consisting of 70 mass%Al_(2)O_(3),20 mass%MgO and 10 mass%CaO,approximately.It is characterized by porous microstructure,intergranular aluminates phases and micro-crystalline spinel.Since globally launched in 2017,MagArmour has been successfully applied to various carbon-containing refractories serving for steel refining process.Lots of cases have demonstrated the role of MagArmour in enhancing the service life of carbon containing bricks for ladle lining.The benefits embody in formation of protective coating on hot surface,relief of drilling corrosion in joint positions,and elimination of grooves or cracks caused by mechanical stress concentration.In addition,MagArmour is effective in protecting graphite from deep oxidization so as to be capable of replacing the metallic or carbide anti-oxidants in carbon-containing bricks entirely.By means of chemical analysis and microstructural dissection,postmortem investigations on the used MgO-C bricks from both metal and slag zones of 120t steel refining ladle were conducted to clarify the working mechanism of MagArmour.The formation of protective coating on hot face is attributed to the dissolution of micro-crystalline spinel into contacting slag,which changes the slag chemistry so as to enhance viscosity.The improvement in corrosion/erosion resistance is highly related to the porous microstructure and dispersive aluminates.As well known,evaporation of Mg,Al and SiO,and/or internal migration,occurs in MgO-C bricks at elevated temperatures.The gaseous phases are absorbed by MagArmour particles due to the high surface area of porous microstructure and condense as corresponding oxides.These oxides react with the intergranular calcium aluminates forming liquid phase.With increasing temperature,the liquid phase seeps into the matrix under capillary force.The increased liquid amount improves the flexibility of the matrix and thus releases the internal stresses concentration resulting from mechanical stress and temperature gradient.Meanwhile,densification of the matrix microstructure occurs under the static pressure generated by liquid steel and molten slag,which blocks the channels of oxygen infiltration.