s1e overview 11-jan-07 to ptc - wallwork heat treatment

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Sub-One Technology

January 21st, 2008

InnerArmor™ Overview

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Problem

• Internal corrosion, erosion and wear of – surface piping, downhole tubulars, chokes, valves,

pumps, and other subsea and downhole equipment

costly downtime, maintenance, and repair• Existing internal coatings are often ineffective• Exotic high performance alloys are very

expensive and backlogs cause significant delays in ramping production




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InnerArmor™ coatings:§ super hard

§ high performance

§ thin films

on the internal surfaces of products from large diameter industrial piping to small components.

Solution - Sub-One Technology




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Coatings - Adjustable in these key areas:▪ Thickness ▪ Wear Resistance▪ Hardness ▪ Corrosion Resistance▪ Adhesion ▪ Erosion Resistance

InnerArmor™ Technology

InnerArmor™ process deposits high performance coatings:

§Diamond-Like Carbon (DLC)§Titanium Carbide§ANY material that we can ionize – we can make coatings

InnerArmor™ process can:- Customize performance- Create composite coatings




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S Tube Cross Section Video




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Process – Plasma Inside Part




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InnerArmor™ - Machines

CS10(Up to 10 Foot Capacity)

CSL40(Up to 40 Foot Capacity)

* In Assembly

InnerArmor™

Coating Machines




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InnerArmor™ - Typical Composition

• Structure: Mixture of sp3 (diamond) and sp2 (graphitic)

• Deposition Temperature: <200°C

• Coating Finish: Identical to Substrate

• Hardness (Vickers) : 1000-3000 (adjustable) - (carbon steel = 217)

• Modulus: 100-180GPa (adjustable) - (carbon steel = 200GPa)

• Adhesion: > 30N

• Wear: < 5e-07

• Friction Coefficient: <0.08

• Coating Thickness: Adjustable up to 80 µm

• Working Temp: 400°C; 600ºC with doping

• Chemical Resistance: Chemically inert i.e., No reaction with acids or

alkaline

Most InnerArmor coating properties are tunable to meet specific application




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InnerArmor Film StructureCross Sectional SEM40 µm thick Multi-layer Coating on 304SS

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• Silicon adhesion layer for good chemical bond to substrate and to DLC cap

• Inert, amorphous, dense, pinhole free, dense coating – high corrosion resistance

• Layered structures possible– Stress reduction– toughness & ductility

– Surface property enhancement

• Electrically insulating• Structure can be designed

for end application

Surface

SteelSilicon

Silicon Carbide

Silicon Carbide

Diamond-like Carbon




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InnerArmor™ - Coatings

1. InnerArmor™ Super Hard

Optimum wear resistance (dry or in oil) including applications such as reciprocating pistons.

2. InnerArmor™ Hard

Superior for mud or water wear applications, including reciprocating pumps.

3. InnerArmor™ Erosion

Thick coating for applications requiring maximum abrasion and erosion resistance, such as down-hole tools with high velocity sand particle flow.

4. InnerArmor™ CorrosionPatented multi-layer defect free structure protects the component against corrosive and aggressive media including acids, salts, hydrogen sulphide (H2S).




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Today– Interiors of conductive substrates (carbon steel, stainless

steel, nickel, aluminum, titanium, etc.)

– 0.375 in - 24 in ID

– 8 -12 ft long

– Aspect ratio (length:diameter) up to 50:1

– 5 to 80 μm thick

– Multiple entry points and shapes

Future– Length: 40 ft long

– ID: Several feet

What We Can Do Today vs Future

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Corrosion Performance

Substrate: 1020CSAdhesion: >30NHardness: 12 GpaThickness: 65 um

Post Exposure Holiday Test: PASS

Test Conditions

• Temperature = 300°F• Pressure = 5000 psi• Duration = 3 days

• Aqueous Phase: 5% NaCl Brine• Hydrocarbon Phase: 100% Xylene• Gas Phase: 1% H2S + 85% CO2 + 14% CH4

Gas phase

Hydrocarbon Phase

Aqueous Phase

Indent AFTER Autoclave Test

Sour Autoclave (NACE MR-175)




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Corrosion Performance

Test Conditions:§ Concentration: 18% HCl§ Temperature: 200F§ Duration: 8 hours

Substrate: CS1020Hardness: 10GPaAdhesion: >30NThickness: 65um

No Damage

InnerArmor™ Protected

Substrate : Coated CS1020

Substrate : Uncoated CS1020

Hole thru the pipe wall

Hot HCl - CS1020




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Instrument – Tribometer

• ASTM G133-02, Linearly Reciprocating Ball-on-Flat Sliding Wear

•COF = resistive force/normal perpendicularforce

200X

Sample of wear track using crude oil Bare steel

Sliding Wear Test




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InnerArmorTM Wear Performance

10X Improvement




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• Substrate: 13Cr• Corrosion Resistance:

Excellent• Hardness:15 GPa• Thickness:23 µm

No abrasion damage on surface

Test conditions:• Abrasive: Al203• Abrasive Discharge: 2 gm/min• Velocity: 30m/Sec• Angle of impingement: 90 deg

• Duration: 10 minutes

• Substrate: 316SS• Corrosion Resistance:

Excellent• Hardness:12 GPa• Thickness:70 µm

No abrasion damage on surface

Test

Coating Performance: Erosion




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Impact Resistance

Impact Test :§ 34 micron thick coating§ Substrate – Stainless steel§ 30mm stainless steel ball dropped on coated specimen§ Impact with one joule of kinetic energy

Viewed at– 200x magnification No cracks or de-lamination observed

Viewed at– 10x magnification No cracks or de-lamination observed

Impact Crater




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Test condition:• Substrate placed in mechanical vise and compressed to open substrate to almost a flat condition.

• Properties of coating:

• Substrate – SS316

• Hardness= 14 GPa (HV1400)

• Modulus= 104 GPa

• Coating Thickness = 12µm

• Adhesion = 20N

Sample size = 2.5” x 2.5”

Can a super-hard coating have ductility?Bend Testing




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InnerArmorTM Flex-DLC

Impact crater

Flex-DLC Performance:§ Hardness = 20 GPa§ Thickness = 12µm§ Wear rate = 3.9E-07 mm³/Nm with 25N load§ COF = .01 with 25N load

Bend-ability of InnerArmorTM Flex-DLC on stainless steel foil




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EndUser

Business Model

Global Provider Network

NEED

SERVICES

SOLUTION




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Summary

• Developed a proprietary PECVD coating process for interior surface coating– Hollow cathode plasma processing enables thick (70µm) barrier type

DLC films on internal surfaces– High deposition rate and low stress films– Other coating materials and multilayer coatings possible

• Imparts array of ‘tunable’ surface properties– Excellent wear and COF– Corrosion resistant– High hardness– Toughness

• Simple and automated commercial coating systems– Safe and environmentally benign chemistry

• Qualifying applications for oil/gas industry– Applicable to a variety of markets

• Size scale up and joining remain as challenges




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Thank YouContact: Dr. Mark J Gore

Sub-One Europe Ltd1 Berry StreetAberdeen AB25 1HF ScotlandO: +44 (0)1224 841314F: +44 (0)1224 841301M: +44 (0)7769 [email protected]


mailto:[email protected]

http://www.sub-one.com



s1e overview 11-jan-07 to ptc - wallwork heat treatment

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