Coatings for wear surfaces and related apparatuses, devices, systems, and methods

Abstract

Metal-based ceramic composite coatings and related devices, assemblies, and methods include monocrystalline superhard particles dispersed in a metal matrix disposed on at least one wear surface of a component of an oil and gas well assembly, system, or device.

What is claimed is: 
     
         1 . A method of producing a metal-based ceramic composite coating on at least a portion of a wear surface of a component for use in an oil and gas well system, the method comprising: 
       positioning the at least a portion of the wear surface of the component in a metal plating bath comprising monocrystalline superhard particles in a metallic matrix; 
       coating the at least a portion of the wear surface of the component with a coating comprising the monocrystalline superhard particles and the metallic matrix; 
       removing the component from the metal plating bath; and 
       heat treating the at least a portion of the wear surface of the component. 
     
     
         2 . The method of  claim 1 , further comprising selecting the coating to include one or more layers comprising phosphorus and exhibiting an amorphous structure. 
     
     
         3 . The method of  claim 1 , further comprising polishing the at least a portion of the wear surface of the component by sliding one or more superhard elements over the at least a portion of the wear surface. 
     
     
         4 . The method of  claim 3 , further comprising sliding the one or more superhard elements comprising one or more elements including tungsten carbide, cubic boron nitride (CBN) or other nitrides, and/or silicon carbide, other over the wear surface. 
     
     
         5 . The method of  claim 3 , further comprising reducing a coefficient of friction of the monocrystalline superhard particles in the coating with the sliding of the one or more superhard elements. 
     
     
         6 . The method of  claim 1 , further comprising, after removing the component, recovering at least some of the monocrystalline superhard particles from the metal plating bath. 
     
     
         7 . The method of  claim 6 , further comprising one or more of: 
       enabling the at least some of the monocrystalline superhard particles to settle in the metal plating bath by maintaining a selected pH in the metal plating bath; 
       pressuring the metal plating bath to force a majority of the monocrystalline superhard particles to settle in the metal plating bath; or 
       separating at least a portion of the metallic matrix of the metal plating bath from the least some of the monocrystalline superhard particles through a J tube. 
     
     
         8 . The method of  claim 6 , further comprising, after recovering at least some of the monocrystalline superhard particles from the metal plating bath, reusing the at least some of the monocrystalline superhard particles in a subsequent coating process. 
     
     
         9 . The method of  claim 1 , further comprising: 
       heat treating the at least a portion of the wear surface of the component to produce a first hardness; and 
       heat treating a wear surface of another component for use in the oil and gas well system that interacts with the wear surface of the component to produce a second, differing hardness. 
     
     
         10 . A method of producing a metal-based ceramic composite coating on at least a portion of a wear surface of a component for use in an oil and gas well system, the method comprising: 
       positioning the at least a portion of the wear surface of the component in a metal plating bath comprising monocrystalline superhard particles in a metallic matrix; 
       coating the at least a portion of the wear surface of the component with a coating comprising the monocrystalline superhard particles and the metallic matrix; 
       removing the component from the metal plating bath; and 
       polishing the at least a portion of the wear surface of the component. 
     
     
         11 . The method of  claim 10 , further comprising selecting the coating to include one or more layers comprising phosphorus and exhibiting an amorphous structure. 
     
     
         12 . The method of  claim 10 , further comprising heat treating the at least a portion of the wear surface of the component. 
     
     
         13 . The method of  claim 10 , wherein polishing the at least a portion of the wear surface of the component comprises sliding one or more ceramic elements comprising a superhard material having a blunt polishing surface over or within the at least a portion of the wear surface in more than one type of relative motion. 
     
     
         14 . The method of  claim 10 , wherein the polishing is performed prior to implementation of the component in the oil and gas well system. 
     
     
         15 . The method of  claim 10 , further comprising providing a relatively reduced friction coefficient of the at least a portion of the wear surface with the polishing that is configured to reduce surface roughness of the at least a portion of the wear surface. 
     
     
         16 . The method of  claim 10 , further comprising forming a second metal-based ceramic composite coating on at least a portion of a wear surface of another component. 
     
     
         17 . The method of  claim 16 , further comprising selecting a first metal matrix of the metal-based ceramic composite coating to have a different hardness than a second metal matrix of the second metal-based ceramic composite coating. 
     
     
         18 . The method of  claim 10 , further comprising heat treating the metal-based ceramic composite coating to produce a selected hardness of 1300-2000 HV0.1. 
     
     
         19 . The method of  claim 10 , further comprising selecting the component to comprise a wear part of a pump, a lift system, a wellhead, a valve, a load bearing component, at least one of a barrel of a pump, a plunger of the pump, a rod coupled to a downhole pump, a coupling between one or more components, a sand separator assembly, wear parts of a ESP pump system, wear parts of a plunger lift pump system, wear parts of a jet pump lift system a wellhead, a valve, a diffuser of pump, an impeller of pump, a casing, a thrust bearing of a ESP protector assembly, an ESP motor assembly, a lubricator assembly, plunger pads and/or rings, a plunger assembly, a bottom hole bumper spring assembly, a throat and/or a diffusor of jet lift system, or a jet nozzle. 
     
     
         20 . A method of producing a metal-based ceramic composite coating on at least a portion of a wear surface of a component for use in an oil and gas well system: 
       forming a metal-based ceramic composite plating on at least a portion of a wear surface of an element configured to move relative to and at least partially contact another component of the oil and gas well system; and 
       selecting the metal-based ceramic composite plating to comprising superhard monocrystalline particles dispersed in a metal matrix. 
     
     
         21 . The method of  claim 20 , further comprising selecting the metal-based ceramic composite plating to substantially lack any superhard polycrystalline material. 
     
     
         22 . The method of  claim 20 , further comprising polishing at least a portion of the metal-based ceramic composite plating prior to implementation in the oil and gas well system.