Self-healing coatings for oil and gas applications
A coated article comprises a substrate and a self-healing coating disposed on a surface of the substrate, the self-healing coating comprising a metallic matrix; and a plurality of micro- or nano-sized particles dispersed in the metallic matrix; the micro- or nano-sized particles comprising an active agent disposed in a carrier comprising a micro- or nano-sized metallic container, a layered structure, a porous structure, or a combination comprising at least one of the foregoing.
1. A coated article comprising:
a substrate; and
a self-healing coating disposed on a surface of the substrate;
the self-healing coating comprising
a metallic matrix; and
a plurality of micro- or nano-sized particles dispersed in the metallic matrix;
wherein the plurality of micro- or nano-sized particles comprise an active agent intercalated between layers of a material having a layered structure; and
the active agent comprises a corrosion inhibitor, a scale inhibitor, or a combination comprising at least one of the foregoing,
wherein the material having a layered structure is an oxide layered material comprising spinels, pervoskites, pyrochlore, or a combination thereof.
2. The coated article of claim 1 , wherein the active agent comprises an inorganic corrosion inhibitor, an organic corrosion inhibitor comprising at least one of S, N, O, P, or a combination comprising at least one of the foregoing corrosion inhibitors.
3. The coated article of claim 2 , wherein the corrosion inhibitor comprises an amine, an imidazoline, a quaternary compound, an amide, a phosphate, a sulfur-containing compound, a vanadate, a molybdate, a tungstate, a chromate, a lanthanide, a niobate, a cerate, a borate, a polymeric corrosion inhibitor, or a combination comprising at least one of the foregoing.
4. The coated article of claim 1 , wherein the active agent is released from the plurality of micro- or nano-sized particles in response to a mechanical damage to the coating, a change of pH, temperature, pressure, radiation, or a combination comprising at least one of the foregoing.
5. The coated article of claim 1 , wherein the metallic matrix comprises Ni, Cu, Ag, Au, Zn, Sn, Fe, In, W, Ti, Co, Al, Mg, Cr, Mo, or an alloy thereof, or a combination comprising at least one of the aforementioned materials.
6. The coated article of claim 5 , wherein the metallic matrix comprises a nickel-based alloy, Ti-based alloy or Al-based alloy.
7. The coated article of claim 1 , wherein the self-healing coating further comprises carbon, boron, a carbide, a nitride, an oxide, a boride or a solid lubricant, or a combination comprising at least one of the foregoing.
8. The coated article of claim 1 , wherein the plurality of micro- or nano-sized particles are present in an amount of about 0.5 volume percent to about 40 volume percent based on the total volume of the self-healing coating.
9. The coated article of claim 1 , wherein the substrate comprises iron, magnesium, aluminum, titanium, manganese, cobalt, nickel, copper, molybdenum, tungsten, palladium, chromium, ruthenium, gold, silver, zinc, zirconium, vanadium, silicon, an alloy thereof, or a combination comprising at least one of the foregoing.
10. The coated article of claim 1 , wherein the self-healing coating has a thickness of about 0.1 micron to 10 mm.
11. The coated article of claim 1 , wherein the coated article is a downhole element.
12. A method of manufacturing a coated article, the method comprising:
depositing on a surface of the substrate the self-healing coating of claim 1 ,
wherein the depositing comprises electroplating, electrolessly depositing, thermal spraying, or a combination comprising at least one of the foregoing.
13. The method of claim 12 , wherein the metallic matrix comprises a nickel-based alloy, a Ti-based alloy, or an Al-based alloy; and the active agent comprises a corrosion inhibitor, a scale inhibitor, or a combination comprising at least one of the foregoing.