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BESCHICHTUNGEN MIT GERINGER REIBUNG UND VERBESSERTEN ABRIEB- UND VERSCHLEISSEIGENSCHAFTEN SOWIE VERFAHREN ZUR HERSTELLUNG

专利摘要

Provided are low friction coatings with improved abrasion, wear resistance and methods of making such coatings. In one form, the coating includes: i) an under layer selected from the group consisting of CrN, TiN, TiAIN, TiAIVN, TiAlVCN, TiSiN, TiSiCN, TiAISiN and combinations thereof, wherein the under layer ranges in thickness from 0.1 to 100 Ltm, ii) an adhesion promoting layer selected from the group consisting of Cr, Ti, Si, W, CrC, TiC, SiC, WC, and combinations thereof, wherein the adhesion promoting layer ranges in thickness from 0.1 to 50 μη and is contiguous with a surface of the under layer, and iii) a functional layer selected from the group consisting of a fullerene based composite, a diamond based material, diamond-like-carbon and combinations thereof, wherein the functional layer ranges from 0.1 to 50 μη and is contiguous and is contiguous with a surface of the adhesion promoting layer. ......

基本信息

专利类型:
发明专利
申请/专利号:
DE602013048509
申请日期:
2013-11-19
专利申请人:
EXXONMOBIL RESEARCH AND ENGINEERING COMPANY
分类号:
C23C28/04; E21B10/00; E21B17/10; C23C14/02; C25F3/16; C23C14/06; C23C28/00; C23C16/26; C23C16/02; E21B17/00
发明/设计人:
RAJAGOPALAN, SRINIVASAN, EASTON ， HAQUE, TABASSUMUL, DEPTFORD ， ERTAS, MEHMET, DENIZ, BETHLEHEM ， OZEKCIN, ADNAN, BETHLEHEM ， JIN, HYUNWOO, EASTON ， ZHAO, BO, ROCHESTER
权利要求: CLAIMS:1. A multi-layer low friction coating comprising: i) an under layer selected from the group consisting of CrN, TiN, TiAIN, TiAlVN, TiAlVCN, TiSiN, TiSiCN, TiAlSiN and combinations thereof, wherein the under layer ranges in thickness from 0,1 to 100 μιη, ii) an adhesion promoting layer selected from the group consisting of Cr, Ti, Si, W, CrC, TiC, SiC, WC, and combinations thereof, wherein the adhesion promoting layer ranges in thickness from 0.1 to 50 μηι and is contiguous with a surface of the under layer, and iii) a functional layer selected from the group consisting of a fullerene based composite, a diamond based material, diamond-like-carbon (DLC), , , and combinations thereof, wherein the functional layer ranges from 0.1 to 50 μ ι and is contiguous with a surface of the adhesion promoting layer, wherein the adhesion promoting layer is interposed between the under layer and the functional layer, wherein the coefficient of friction of the functional layer of the low friction coating as measured by the block on ring friction test is less than or equal to 0.15, and wherein the abrasion resistance of the low friction coating as measured by the modified ASTM G105 abrasion test yields a wear scar depth of less than or equal to 20 μηι and a weight loss less than or equal to 0.03 grams.2. The coating of claim 1 , wherein the under layer is contiguous with asurface of a substrate.3. The coating of claim 2, wherein the substrate is selected from the group consisting of steel, stainless steel, hardbanding, an iron alloy, an aluminum based alloy, a titanium based alloy, ceramics and a nickel based alloy.4. The coating of claim 3, wherein the hardbanding comprises a cermet based material, a metal matrix composite or a hard metallic alloy.5. The coating of claim 1, wherein the functional layer is a diamond based material.6. The coating of claim 5, wherein the diamond based material is chemical vapor deposited (CVD) diamond or polycrystailine diamond compact (PDC).7. The coating of claim 1, wherein the functional layer is diamond-like- carbon (DLC).8. The coating of claim 7, wherein the diamond-like-carbon (DLC) isselected from the group consisting of ta~C, ta-C:H, DLCIT, PLCH, GLCH, Si-DLC, N-DLC, O-DLC, B-DLC, Me-DLC, F-DLC and combinations thereof.9. The coating of claim 1 , wherein the under layer hardness ranges from 800 to 3500 VHN.10. The coating of claim 1 , wherein the adhesion promoting layer hardness ranges from 200 to 2500 VHN.11. The coating of claim 1, wherein the functional layer hardness ranges from 1000 to 7500 VHN.12. The coating of claim 1, further including a gradient at the interface of the under layer and the adhesion promoting layer ranging from 0.01 to 10 μηι.13. The coating of claim 1 , further including a gradient at the interface of the adhesion promoting layer and the functional layer ranging from 0.01 to 10 μηι,14. The coating of claim 1 , further including a second adhesion promoting layer selected from the group consisting of Cr, Ti, Si, W, CrC, TiC, SiC, WC, and combinations thereof, wherein the second adhesion promoting layer ranges in thickness from 0.1 to 50 μπι and is contiguous with a surface of the functional layer, and a second functional layer selected from the group consisting of a fullerene based composite, a diamond based material, diamond-like-carbon (DLC), and combinations thereof, wherein the second functional layer ranges from 0.1 to 50 μτη and is contiguous with a surface of the second adhesion promoting layer.15. The coating of claim 14, further including a second under layerinterposed between the functional layer and the second adhesion promoting layer, wherein the second under layer is selected from the group consisting of CrN, TiN, TiAiN, TiAiVN, TiAiVCN, TiSi , TiSiCN, TiAlSiN and combinations thereof, wherein the second under layer ranges in thickness from 0.1 to 100 μιη.16. The coating of claim 14, wherein the second functional layer is diamondlike-carbon (DLC).17. The coating of claim 16, wherein the diamond-like-carbon (DLC) is selected from the group consisting of ta-C, ta-C:H, DLCH, PLCH, GLCH, Si-DLC, N-DLC, O-DLC, B-DLC, Me-DLC, F-DLC and combinations thereof.The coating of claim 1, further including from 1 to 100 series of incremental coating layers, wherein each series of incremental coating layers includes a combination of an incremental adhesion promoting layer, an incremental functional layer and an optional incremental under layer, wherein the each series of incremental coating layers is configured as follows:(i) wherein the optional incremental under layer is selected from the group consisting of CrN, ΊΪΝ, TiAIN, TiAlVN, TiAlVCN, TiSiN, TiSiCN, TiAlSiN and combinations thereof; ranges in thickness from 0.1 to 100 μιτι; and is contiguous with a surface of the functional layer and the incremental adhesion promoting layer; wherein the optional incremental under layer is interposed between the functional layer and the incremental adhesion promoting layer,(ii) wherein the incremental adhesion promoting layer is selected from the group consisting of Cr, Ti, Si, W, CrC, TiC, SiC, WC, and combinations thereof; ranges in thickness from 0.1 to 50 Lim; and is contiguous with a surface of the functional layer or optional incremental under layer, and the incremental functional layer; wherein the incremental adhesion promoting layer is interposed between the functional layer and the incremental functional layer or between the optional incremental under layer and the incremental functional layer(Hi) wherein the incremental functional layer is selected from the group consisting of a fullerene based composite, a diamond based- material, diamond-like-carbon (DLC), and combinations thereof; ranges from 0.1 to 50 μηι in thickness; and is contiguous with a surface of the incremental adhesion promoting layer.19. The coating of claim 18, wherein the incremental functional layer is diamond-like-carbon (DLC) .20. The coating of claim 19, wherein the diamond-like-carbon (DLC) is selected from the group consisting of ta-C, ta-C:H, DLCH, PLCH, GLCH, Si-DLC, N-DLC, O-Di .C. B-DLC, Me-DLC, F-DLC and combinations thereof.21. The coating of claim 18, wherein the optional incremental under layer hardness ranges from 800 to 3500 V) I S ,22. The coating of claim 18, wherein the incremental adhesion promoting layer hardness ranges from 200 to 2500 VHN.23. The coating of claim 18, wherein the incremental functional layerhardness ranees from 1000 to 7500 VHN,24. The coating of claim 18, further including a gradient at the interface of the optional incremental under layer and the incremental adhesion promoting layer ranging from 0.01 to 10 μηι.25. The coating of claim 18, further including a gradient at the interface of the incremental adhesion promoting layer and the incremental functional layer ranging from 0.01 to 10 μπι.26. The coating of claim 1 , wherein the surface roughness of the func tional layer ranges from 0.01 μηι to 1 .0 μηι Ra.27. The coating of claim 18, wherein the surface roughness of the outermost incremental functional layer ranges from 0,01 μηι to 1.0 μηι Ra.28. The coating of claim 1, wherein the counterface wear scar depth asmeasured by the block on ring friction test is less than or equal to 500 μηι,29. The coating of claim 1, wherein the abrasion resistance of the low friction coating as measured by the modified ASTM G105 abrasion test yields a wear scar depth and a weight loss at least 5 times lower than a single layer coating of the same functional layer.30. The coating of claims 1 or 18, wherein the coating is applied to a portion of the surface of a device selected from the group consisting of a drill bit for subterraneous rotary drilling, a drill stem assembly for subterraneous rotary drilling, a casing, a tubing, couplings, a work string, a coiled tubing, a pipe, a riser, a plunger, centralizers, a completion string, a production string, and a petrochemical and chemical production device.31. A method of making a multi-layer low friction coating comprising: i) providing a substrate for coating, ii) depositing on a surface of the substrate an under layer selected from the group consisting of CrN, TiN, TiAlN, TiAlVN, TiAlVCN, TiSiN, TiSiCN, TiAlSiN and combinations thereof, wherein the under layer ranges in thickness from 0.1 to 100 μηι, iii) depositing on the surface of the under layer an adhesion promoting layer selected from the group consisting of Cr, Ti, Si, W, CrC, TiC, SiC, WC, and combinations thereof, wherein the adhesion promoting layer ranges in thickness from 0. 1 to 50 μπι and is contiguous with a surface of the under layer, and iv) depositing on the surface of the adhesion promoting layer a functional layer selected from the group consisting of a fullerene based composite, a diamond based material, diamond-like-carbon (DLC), and combinations thereof, wherein the functional layer ranges from 0.1 to 50 ,Ltm and is contiguous with a surface of the adhesion promoting layer, wherein the coefficient of friction of the functional laver of the low friction coating as measured by the block on ring friction test is less than or equal to 0.15, and wherein the abrasion resistance of the low friction coating as measured by the modified ASTM G 105 abrasion test yields a wear scar depth of less than or equal to 20 μηι and a weight loss less than or equal to 0.03 grams.32. The method of claim 31 , further including depositing from 1 to 100series of incremental coating layers, wherein each series of incremental coating layers includes a combination of an incremental adhesion promoting layer, an incremental functional layer and an optional incremental under layer, wherein the each series of incremental coating layers is configured as follows:(i) wherein the optional incremental under layer is selected from the group consisting of CrN, TiN, TiAIN, TiAlVN, TiAlVCN, TiSiN, TiSiCN, TiAlSiN and combinations thereof; ranges in thickness from 0.1 to 100 μπι; and is contiguous with a surface of the functional layer and the incremental adhesion promoting layer; wherein the optional incremental under layer is interposed between the functional layer and the incremental adhesion promoting layer, (ii) wherein the incremental adhesion promoting layer is selected from the group consisting of Cr, Ti, Si, W, CrC, TiC, 8iC, WC, and combinations thereof; ranges in thickness from 0.1 to 50 μπι; and is contiguous with a surface of the functional layer or optional incremental under layer, and the incremental functional layer; wherein the incremental adhesion promoting layer is interposed betwee the functional layer and the incremental functional layer or between the optional incremental under layer and the incremental functional layer(iii) wherein the incremental functional layer is selected from thegroup consisting of a fullerene based composite, a diamond based material, diamond-like-carbon (DLC), and combinations thereof; ranges from 0.1 to 50 μηι in thickness; and is contiguous with a surface of the incremental adhesion promoting layer.33. The method of claim 31 , wherein the substrate is selected from the group consisting of steel, stainless steel, hardbanding, an iron alloy, an aluminum based alloy, a titanium based alloy, ceramics and a nickel based alloy.34. The method of claim 33, wherein the hardbanding comprises a cermet- based material, a metal matrix composite or a hard metallic alloy.35. The method of claim 31, wherein the functional layer is a diamond based material.36. The method of claim 35, wherein the diamond based material ischemical vapor deposited (CVD) diamond or polvcrystalline diamond37. The method of claim 31 , wherein the functional layer is diamond-like- carbon (DLC),38. The method of claim 37, wherein the diamond-like-carbon (DLC) is selected from the group consisting of ta-C, ta-C:H, DLCH, PLCH, GLCH, Si-DLC, N-DLC, O-DLC, 1 4 )1 . . Me-DLC, F-DLC and combinations thereof.39. The method of claim 31 , wherein the under layer hardness ranges from 800 to 3500 VHN.40. The method of claim 31 , wherein the adhesion promoting layerhardness ranges from 200 to 2500 VHN.41. The method of claim 31 , wherein the functional layer hardness ranges from 1000 to 7500 VHN.42. The method of claim 31 , further including a gradient at the interface of the under layer and the adhesion promoting layer ranging from. 0.01 to 10 μ ι.43. The method of claim 31 , further including a gradient at the interface of the adhesion promoting layer and the functional layer ranging from 0.01 to 10 μηι.44. The method of claim 32, wherein the incremental functional layer is diamond-like-carbon (DLC).45. The method of claim 44, wherein the diamond-like-carbon (DLC) is selected from the group consisting of ta-C, ta-C:H, DLCH, PLCH, GLCH, Si-DLC, N-DLC, O-DLC, B-DLC, Me-DLC, F-DLC and combinations thereof. 46, The method of claim 32, wherein the optional incremental under layer hardness ranges from 800 to 3500 VHN,47. The method of claim 32, wherein the incremental adhesion promoting layer hardness ranges from 200 to 2500 VHN.48. The method of claim 32, wherein the incremental functional layer hardness ranges from 1000 to 7500 VHN.49. The method of claim 32, further including a gradient at the interface of the optional incremental under layer and the incremental adhesion promoting layer ranging from 0.01 to 10 μηι.50. The method of claim 32, further including a gradient at the interface of the incremental adhesion promoting layer and the incremental functional layer ranging from 0.01 to 10 μπι.51. The method of claim 31 , wherein the surface roughness of thefunctional layer ranges from 0.01 μηι to 1.0 μηι Ra.52. The method of claim 32, wherein the surface roughness of theoutermost incremental functional layer ranges from 0.01 μηι to 1 ,0 μηι Ra.53. The method of claim 31, wherein the counterface wear scar depth as measured by the block on ring friction test is less than or equal to 500 μπι.54. The method of claim 31 , wherei the abrasion resistance of the low friction coating as measured bv the modified ASTM G 105 abrasion test yields a wear scar depth and a weight loss at least 5 times lower than a single layer coating of the same functional layer.55. The method of claims 3 1 or 32, wherein the substrate is a portion of the surface of a device selected from the group consisting of a drill bit for subterraneous rotary drilling, a drill stem assembly forsubterraneous rotary drilling, a casing, a tubing, couplings, a work string, a coiled tubing, a pipe, a riser, a plunger, centralizers, a completion string, a production string, and a petrochemical and chemical production device,56. The method of claim 31, wherein the steps of depositing the under layer, depositing the adhesion promoting layer or depositing the functional layer are selected from the group consisting of physical vapor deposition, plasma assisted chemical vapor deposition, and chemical vapor deposition.57. The method of claim 56, wherein the physical vapor depositioncoating method is selected from the group consisting of magnetron sputtering, ion beam assisted deposition, cathodic arc deposition and pulsed laser deposition.58. The method of claim 31 , further including a post-processing step on the functional layer to achieve a surface roughness between 0.01 to1.0 Lim a.59. The method of claim 58, wherein the post-processing step is selected from the group consisting of mechanical polishing, chemical polishing, depositing of smoothening layers, an ultra-finesuperpolishing process, a tribochemical polishing process, an electrochemical polishing process, and combinations thereof.