Corrosion and wear are critical issues that threaten the operations of the petroleum and petrochemical industries. According to industry reports, direct economic losses caused by these problems in China's oil and gas sector amount to hundreds of millions of yuan annually. As oil and gas fields develop and equipment ages, corrosion and wear in pipelines, storage tanks, and well casings have become increasingly severe. In the petrochemical industry, the refining of high-sulfur crude oil has further intensified equipment corrosion. These challenges significantly impact the safe and stable operation of industrial facilities, making it essential to enhance the wear and corrosion resistance of equipment used in oil and gas production.
Studies on part failures due to wear and corrosion show that most damage occurs on the surface of materials. Surface engineering technologies offer a solution by modifying material surfaces to improve their properties, thereby extending the service life of components. This makes surface engineering a crucial field within the petroleum and petrochemical industries.
Thermal spraying is one of the most widely used surface treatment techniques in surface engineering. It involves applying a coating with superior properties onto the surface of a component while maintaining the original material’s performance. This technique can enhance wear resistance, corrosion resistance, high-temperature stability, oxidation resistance, and fatigue resistance. One of its main advantages is the ability to create thin functional layers—only a fraction of the structural size—but with enhanced performance. Even when using rare or expensive materials, the cost increase remains minimal. Additionally, thermal spraying allows for localized repair, strengthening, and pre-protection of valuable components, effectively extending their lifespan or restoring their value. As a result, thermal spraying offers significant economic and social benefits.
Thermal spraying technology works by heating wire or powder materials using a heat source such as flame, arc, or plasma, then accelerating the molten particles toward the substrate to form a coating. Compared to other coating methods, thermal spraying offers several advantages:
1. **Versatile methods**: Over a dozen different thermal spraying techniques are available, providing flexibility in coating application.
2. **Wide material compatibility**: It can be applied to almost all solid surfaces, including metals, ceramics, and plastics.
3. **Diverse material options**: Almost all metals, alloys, ceramics, and polymers can be used as spray materials.
4. **Flexible application**: It can be used on large structures or small parts, regardless of size or shape.
5. **Enhanced surface properties**: Thermal spraying can give ordinary materials special characteristics such as wear resistance, corrosion resistance, and heat insulation.
6. **Adjustable coating thickness**: Coatings can range from micrometers to millimeters, offering precise control.
7. **Cost-effective**: The process is economical and provides substantial returns on investment.
These features make thermal spraying a highly adaptable and economically viable option in surface engineering. Commonly used methods include flame spraying, plasma spraying, and arc spraying.
In the petroleum and petrochemical industry, thermal spraying is widely applied for repairing machinery, improving wear resistance, and protecting equipment. For instance, it is used to restore worn crankshafts, pump plungers, and drill bits, significantly reducing costs and extending service life. Ball valves, sucker rods, and turbine blades also benefit from thermal spraying, enhancing their durability under harsh conditions. Additionally, it is used for anti-corrosion protection of tanks, pipelines, and towers, ensuring long-term reliability in challenging environments. Overall, thermal spraying plays a vital role in maintaining the efficiency and safety of critical infrastructure in the oil and gas sector.
Huaian Yige New Material Co., Ltd. , http://www.cnygplastic.com