Fouad Y, Merah N, Azeem M A, Gasem Z, Alqutub A, Aleid A A, Osman O, Shaarawi A, Aljohar A
Department of Mechanical Engineering, King Fahd University of Petroleum and Minerals, Dhahran, 31261, Saudi Arabia.
Interdisciplinary Research Center for Advanced Materials, King Fahd University of Petroleum and Minerals, Dhahran, 31261, Saudi Arabia.
Heliyon. 2024 Sep 4;10(17):e37333. doi: 10.1016/j.heliyon.2024.e37333. eCollection 2024 Sep 15.
Casing wear is a persistent issue in oil and gas drilling facilities that call for innovative more wear-resistant materials to mitigate casing failures. The present work examines the tribological performance of a novel composite lining comprised of Kevlar honeycomb in a matrix of epoxy reinforced with Zirconia particles against hardband drillpipe tooljoint (DP-TJ). Three side loads (1000, 1200, and 1400 N) and three DP-TJ speeds (0.43, 0.76, and 1.02 m/s) were considered under dry sliding conditions. The results showed that the specific wear rate (K) increased with speed at all side loads. However, K value was found to reach a maximum, reaching 20.310 MPa at 1200 N before dropping to about 8.510 MPa when the load is increased to 1400 N. This decline in specific wear rate at the load of 1400 N was attributed to the growth of a double transfer layer through the alignment of zirconia particles in the lining. The scanning electron microscope (SEM) images of worn surfaces revealed that higher K values are associated with more adhesion, delamination, and fiber breakage. Energy dispersive spectroscopy (EDS) and X-ray diffraction (XRD) analysis of the worn surface and the debris collected after the wear test reveals minimal wear of DP-TJ. The epoxy/Kevlar-honeycomb composite lining demonstrated appreciable wear resistance even under dry sliding conditions.
套管磨损是石油和天然气钻井设施中一个长期存在的问题，需要创新的更耐磨材料来减少套管故障。本研究考察了一种新型复合衬里的摩擦学性能，该复合衬里由芳纶蜂窝在氧化锆颗粒增强的环氧树脂基体中组成，与硬质合金钻杆接头（DP-TJ）相对。在干滑动条件下考虑了三种侧向载荷（1000、1200和1400 N）和三种DP-TJ速度（0.43、0.76和1.02 m/s）。结果表明，在所有侧向载荷下，比磨损率（K）均随速度增加。然而，发现K值在1200 N时达到最大值，为20.3×10⁻⁶ MPa，当载荷增加到1400 N时降至约8.5×10⁻⁶ MPa。在1400 N载荷下比磨损率的下降归因于通过衬里中氧化锆颗粒的排列形成了双转移层。磨损表面的扫描电子显微镜（SEM）图像显示，较高的K值与更多的粘着、分层和纤维断裂有关。对磨损表面和磨损试验后收集的碎屑进行能谱分析（EDS）和X射线衍射（XRD）分析，结果表明DP-TJ的磨损最小。即使在干滑动条件下，环氧/芳纶蜂窝复合衬里也表现出了可观的耐磨性。
