CN112281103A - 一种钻井隔水套管火焰喷涂铝基防护涂层及其制备方法 - Google Patents
一种钻井隔水套管火焰喷涂铝基防护涂层及其制备方法 Download PDFInfo
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- 238000002360 preparation method Methods 0.000 title claims abstract description 9
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- 238000007598 dipping method Methods 0.000 claims description 9
- 238000010438 heat treatment Methods 0.000 claims description 8
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Abstract
本发明属于海洋装备防护涂层领域,具体为一种钻井隔水套管火焰喷涂铝基防护涂层及其制备方法。方法包括如下步骤:称取Al粉末或AlCu粉末或AlMg粉末或AlSi粉末;对待喷涂的隔水套管外壁进行粗化处理;采用火焰喷涂方式在待喷涂隔水套管表面进行喷涂,获得喷涂态Al涂层或AlCu涂层或AlMg涂层或AlSi涂层;对喷涂态铝基涂层采用水溶性Al2O3或水溶性SiO2封孔剂进行封孔处理,获得低孔隙率高耐蚀性的铝基涂层。本发明利用火焰喷涂和封孔复合处理获得低孔隙率铝基防护涂层,制备工艺简单,同时水溶性纳米Al2O3或SiO2封孔剂,具有良好的耐腐蚀能力和极强的附着力,能够有效降低火焰喷涂涂层的孔隙率,抑制腐蚀性介质的渗透,提高涂层耐蚀性能,进而提高了钻井隔水套管的使用寿命。
Description
技术领域
本发明属于海洋装备防护涂层领域,具体涉及一种钻井隔水套管火焰喷涂铝基防护涂层及其制备方法。
背景技术
在海上石油的勘探中,钻井隔水套管是整个钻井系统中重要而又薄弱的环节,是影响海上钻井装备安全的关键因素,因而隔水套管的长周期安全服役性能对于石油、天然气的开采起着重要的作用。海洋钻井隔水套管长期暴露在腐蚀性极强的海水介质中,海水中的氯离子会腐蚀隔水套管表面,造成隔水套管失效。因此,钻井隔水套管亟需低成本、高效的耐腐蚀防护处理技术。
热喷涂技术操作方便、适用范围广,是提高基体材料表面耐腐蚀性能中常用的一种方法。其中,火焰喷涂以燃烧火焰为热源,操作简单、成本低,火焰焰流温度低,适用于铝基涂层的制备。然而,火焰喷涂涂层中孔隙的存在严重威胁涂层的耐腐蚀性能。因此,降低涂层孔隙缺陷便成了提高涂层耐蚀性的关键问题。
为了解决该问题,人们提出了许多降低涂层孔隙率的方法,如激光重熔、封孔处理、热处理等方法。CN201510393588.6发明了一种海洋平台用钢表面电弧喷涂铝涂层的激光重熔方法,该方法通过电弧喷涂工艺在海洋平台用钢基材表面制备一层铝涂层,再通过激光重熔技术将铝涂层与底材表面铁熔化,冷却后形成Fe-Al合金层。目前较常用的降低涂层孔隙率的方法是对涂层进行封孔处理,封孔处理作为一种后处理技术,因其操作简单、成本低廉而得到广泛应用。
CN201210111032.X涉及一种抗热冲击耐碱蒸汽腐蚀的柔性封孔剂及其使用方法,该发明封孔剂均匀刷涂于铝涂层表面,可以在室温下24-36小时内完全固化,封孔剂能够填补电弧喷涂铝涂层的孔隙,与铝涂层结合良好,且具有优良的耐热冲击及碱蒸汽腐蚀性能,可以显著提高设备运行的寿命和安全性。
CN201210516219.8公开了一种新型热喷涂涂层专用无机封孔剂及其制备方法和用途,该封孔剂处理后的封孔涂层具有非晶态结构,耐腐蚀性能优异,并且具有良好的热稳定性。CN201610910259.9发明了一种消除喷涂涂层孔隙率的方法,该发明在电磁感应加热同时对涂层施加压力,可以消除孔隙率,增加涂层的综合力学性能,从而提高涂层的寿命和工作效率。
以上方法在一定程度上均能降低涂层孔隙率,但工艺成本较高或封孔剂组分复杂,封孔方法易产生污染。
发明内容
本发明的目的在于提供一种钻井隔水套管火焰喷涂铝基防护涂层及其制备方法。
实现本发明目的的技术解决方案为:一种钻井隔水套管火焰喷涂铝基防护涂层的制备方法,包括如下步骤:
步骤(1):称取粒径范围为48~150μm的Al粉末或AlCu粉末或AlMg粉末或AlSi粉末,所述AlCu粉末中Al与Cu的原子比为98.06:1.94,AlMg粉末中Al与Mg的原子比为98.86:1.14,AlSi粉末中Al与Si的原子比为89.36:10.64,然后干燥备用;
步骤(2):对待喷涂的隔水套管外壁进行粗化处理;
步骤(3):采用火焰喷涂方式,在待喷涂隔水套管表面进行喷涂,获得喷涂态Al涂层或AlCu涂层或AlMg涂层或AlSi涂层,即喷涂态铝基涂层;
步骤(4):对喷涂态铝基涂层采用水溶性Al2O3或水溶性SiO2封孔剂进行封孔处理,获得低孔隙率的铝基涂层。
进一步的,所述步骤(1)中的干燥具体为:80±2℃烘箱中干燥1-3h备用。
进一步的,所述步骤(2)中“对待喷涂的隔水套管外壁进行粗化处理”具体为:对待喷涂的隔水套管外壁进行清洗、干燥,采用棕刚玉喷砂粗化处理,粗化处理后的表面粗糙度为Ra 8.0-10.0。
进一步的,所述步骤(3)中火焰喷涂的参数为:所述步骤(3)中火焰喷涂的参数为:乙炔压强为0.04~0.1MPa,氧气压强为0.3~0.6MPa,压缩空气为0.1~0.5MPa,喷涂距离150~250mm,送粉量为10~20g/min。。
进一步的,所述步骤(4)中封孔处理包括如下步骤:
步骤(4-1)涂层预处理:对喷涂态铝基涂层进行预处理;
步骤(4-2)涂层封孔处理:采用浸渍法封孔工艺或超声法封孔工艺或刷涂法封孔工艺进行封孔处理;
步骤(4-3)热处理:对封孔处理后的涂层进行热处理,具体过程为:在烘干箱中80~100℃保温1~3小时。
进一步的,步骤(4-2)所述浸渍法封孔工艺是将铝基涂层浸泡在封孔剂中0.5~2小时;
所述刷涂法封孔工艺是利用刷子蘸取少量封孔剂涂刷在涂层表面,直至封孔剂在涂层表面未出现气泡停止刷涂。
进一步的,步骤(4-2)中所述超声法封孔工艺具体为在温室下,在持续超声搅拌下将铝基涂层浸入密封剂中0.5~2h,结束后再静置0.5~1小时让封孔剂进入到涂层的微小孔隙中。
进一步的,所述步骤(4-3)中进行热处理前先将封孔处理后的涂层在空气中晾干直至去除表面残留水分,防止残留水分在烘箱干燥中使得涂层表面产生皲裂。
一种采用权利要求上述方法制备的铝基涂层,所述涂层的厚度为200~300μm。
一种上述的涂层用于海洋钻井隔水套管耐海水腐蚀的用途。
本发明与现有技术相比,其显著优点在于:
(1)本发明中封孔剂为水溶性Al2O3或水溶性SiO2封孔剂,不含甲醛、苯、重金属等有害物质,干燥后变为透明光亮膜层,具有良好的耐腐蚀能力和极强的附着力,且来源广泛,成本低廉。
(2)本发明所涉及的火焰喷涂和封孔方法工艺简单,制备的低孔隙率铝基涂层可以有效隔绝海水介质与钻井隔水套管,有效提高钻井隔水套管耐腐蚀性能,大大延长钻井隔水套管服役寿命。
附图说明
图1为Al涂层采用Al2O3封孔剂封孔前后涂层的动极化曲线图;
图2为AlCu涂层采用Al2O3封孔剂封孔前后涂层的动极化曲线图;
图3为AlMg涂层采用Al2O3封孔剂封孔前后涂层的动极化曲线图。
具体实施方式
下面结合附图对本发明作进一步详细描述。
实施例1:
1.称取一定质量的粒径范围为48~150μm的Al粉末,然后放于80℃烘箱中干燥2h备用;
2.对待喷涂不锈钢基体表面进行清洗、干燥,采用棕刚玉喷砂粗化处理,粗化处理后的表面粗糙度为Ra 8.0-10.0。
3.采用火焰喷涂方式,在待喷涂基体表面进行喷涂Al粉末,获得Al涂层。具体火焰喷涂的参数为:乙炔压强为0.07MPa,氧气压强为0.4MPa,压缩空气为0.1MPa,喷涂距离200mm,送粉量为15g/min。
4.对喷涂态铝基涂层采用水溶性Al2O3封孔剂,并通过浸渍法、超声法及刷涂法进行封孔处理,获得低孔隙率高耐蚀性的铝涂层。
5.采用电化学工作站对三种封孔处理后Al涂层进行电化学实验,测试涂层的耐腐蚀性能。结果表明,封孔前涂层表现出较高的腐蚀电流密度,封孔后涂层表现出更低的腐蚀电流密度,表明经过封孔处理后隔水套管火焰喷涂涂层的耐蚀性大大提高。其中,刷涂封孔在提高涂层耐腐蚀性能方面效果最好,如图1所示。
实施例2:
1.称取一定质量的粒径范围为48~150μm的AlCu粉末,然后放于80℃烘箱中干燥2h备用;
2.对待喷涂不锈钢基体表面进行清洗、干燥,采用棕刚玉喷砂粗化处理,粗化处理后的表面粗糙度为Ra 8.0-10.0。
3.采用火焰喷涂方式,在待喷涂基体表面进行喷涂AlCu粉末,获得AlCu涂层。具体火焰喷涂的参数为:乙炔压强为0.07MPa,氧气压强为0.4MPa,压缩空气为0.1MPa,喷涂距离200mm,送粉量为15g/min。
4.对喷涂态铝基涂层采用水溶性Al2O3封孔剂,并通过浸渍法、超声法及刷涂法进行封孔处理,获得低孔隙率高耐蚀性的铝铜涂层。
5.采用电化学工作站对封孔后AlCu涂层进行电化学实验,测试涂层的耐腐蚀性能。结果表明,封孔前涂层表现出较低的腐蚀电位和较高的腐蚀电流密度,封孔后涂层表现出更低的腐蚀电流密度,表明经过封孔处理后,隔水套管火焰喷涂涂层的耐蚀性较封孔前涂层有明显提高。其中,刷涂封孔在提高涂层耐腐蚀性能方面效果最好,如图2所示。
实施例3:
1.称取一定质量的粒径范围为48~150μm的AlMg粉末,然后放于80℃烘箱中干燥2h备用;
2.对待喷涂不锈钢基体表面进行清洗、干燥,采用棕刚玉喷砂粗化处理,粗化处理后的表面粗糙度为Ra 8.0-10.0。
3.采用火焰喷涂方式,在待喷涂基体表面进行喷涂AlMg粉末,获得AlMg涂层。具体火焰喷涂的参数为:乙炔压强为0.07MPa,氧气压强为0.4MPa,压缩空气为0.1MPa,喷涂距离200mm,送粉量为15g/min。
4.对喷涂态铝基涂层采用水溶性Al2O3封孔剂,并通过浸渍法、超声法及刷涂法进行封孔处理,获得高耐蚀性的铝镁涂层。
5.采用电化学工作站对封孔后AlMg涂层进行电化学实验,测试涂层的耐腐蚀性能。结果表明,封孔前涂层表现出较低的腐蚀电位和较高的腐蚀电流密度,封孔后涂层表现出更低的腐蚀电流密度,表明三种封孔处理方式均可提高隔水套管火焰喷涂涂层的耐蚀性。同上述结果一致,刷涂封孔对提高涂层的耐腐蚀性能效果最明显,如图3所示。
Claims (10)
1.一种钻井隔水套管火焰喷涂铝基防护涂层的制备方法,其特征在于,包括如下步骤:
步骤(1):称取粒径范围为48~150μm的Al粉末或AlCu粉末或AlMg粉末或AlSi粉末,所述AlCu粉末中Al与Cu的原子比为98.06:1.94,AlMg粉末中Al与Mg的原子比为98.86:1.14,AlSi粉末中Al与Si的原子比为89.36:10.64,然后干燥备用;
步骤(2):对待喷涂的隔水套管外壁进行粗化处理;
步骤(3):采用火焰喷涂方式,在待喷涂隔水套管表面进行喷涂,获得喷涂态Al涂层或AlCu涂层或AlMg涂层或AlSi涂层,即喷涂态铝基涂层;
步骤(4):对喷涂态铝基涂层采用水溶性Al2O3或水溶性SiO2封孔剂进行封孔处理,获得低孔隙率的铝基涂层。
2.根据权利要求1所述的方法,其特征在于,所述步骤(1)中的干燥具体为:80±2℃烘箱中干燥1-3h备用。
3.根据权利要求1所述的方法,其特征在于,所述步骤(2)中“对待喷涂的隔水套管外壁进行粗化处理”具体为:对待喷涂的隔水套管外壁进行清洗、干燥,采用棕刚玉喷砂粗化处理,粗化处理后的表面粗糙度为Ra 8.0-10.0。
4.根据权利要求1所述的方法,其特征在于,所述步骤(3)中火焰喷涂的参数为:乙炔压强为0.04~0.1MPa,氧气压强为0.3~0.6MPa,压缩空气为0.1~0.5MPa,喷涂距离150~250mm,送粉量为10~20g/min。
5.根据权利要求1所述的方法,其特征在于,所述步骤(4)中封孔处理包括如下步骤:
步骤(4-1)涂层预处理:对喷涂态铝基涂层进行预处理;
步骤(4-2)涂层封孔处理:采用浸渍法封孔工艺或超声法封孔工艺或刷涂法封孔工艺进行封孔处理;
步骤(4-3)热处理:对封孔处理后的涂层进行热处理,具体过程为:在烘干箱中80~100℃保温1~3小时。
6.根据权利要求5所述的方法,其特征在于,步骤(4-2)所述浸渍法封孔工艺是将铝基涂层浸泡在封孔剂中0.5~2小时;
所述刷涂法封孔工艺是利用刷子蘸取少量封孔剂涂刷在涂层表面,直至封孔剂在涂层表面未出现气泡停止刷涂。
7.根据权利要求6所述的方法,其特征在于,步骤(4-2)中所述超声法封孔工艺具体为在温室下,在持续超声搅拌下将铝基涂层浸入密封剂中0.5~2h,结束后再静置0.5~1小时让封孔剂进入到涂层的微小孔隙中。
8.根据权利要求5所述的方法,其特征在于,所述步骤(4-3)中进行热处理前先将封孔处理后的涂层在空气中晾干直至去除表面残留水分,防止残留水分在烘箱干燥中使得涂层表面产生皲裂。
9.一种采用权利要求1-8所述的方法制备的铝基涂层,其特征在于,所述涂层的厚度为200~300μm。
10.一种权利要求9所述的涂层用于海洋钻井隔水套管耐海水腐蚀的用途。
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