Pipes used in oil and gas operations are constantly exposed to harsh conditions like corrosion, high temperatures, and heavy wear. Existing solutions—like coatings, corrosion inhibitors, or expensive alloy pipes—either wear off easily, aren’t effective in all conditions, or are far too costly for widespread use. Most pipes can only meet one or two performance needs at a time, creating safety and cost issues for operators.
Innovative Solution
This invention introduces a specialized arc-spraying process and a uniquely designed spraying device that applies a durable alloy layer to both the inside and outside of ordinary carbon steel pipes. It uses high-purity aluminum, copper, or a copper-aluminum mix to form a metallurgically bonded alloy coating that becomes part of the pipe’s surface—making it significantly more wear-resistant, corrosion-proof, and heat-tolerant.
What’s New
Unlike traditional methods that can’t spray inside pipe walls and produce weak, easily damaged layers, this invention includes a precision-engineered inner wall spray gun and rotary system that ensures uniform coating thickness (30–600 μm) inside and out. The alloy layer bonds directly to the steel and stays intact—even under heavy wear—while resisting corrosion from aggressive chemicals and high heat up to 800°C.
Benefits
- Strong, durable surface that doesn’t crack or peel
- Withstands high temperatures and corrosive environments
- More affordable than using full alloy pipes
- Works even for small-diameter pipes (as narrow as 50mm)
- Extends pipe life, reducing replacement and maintenance costs
Broader Impact
This innovation makes oil and gas operations safer, more cost-effective, and environmentally friendlier by reducing failures and the need for frequent pipe replacement. It also helps meet global demands for more resilient infrastructure in energy and industrial sectors.