Drill rod diamond wear-resistant belt with metal gradient and preparation method of drill rod diamond wear-resistant belt

Abstract

The invention belongs to the technical field of oil and gas drilling engineering and material processing, and particularly relates to a high-wear-resistance and high-bonding-strength composite wear-resistant belt for a drill rod joint. The diamond-metal gradient composite wear-resistant belt comprises a bonding layer, a transition layer and a working layer, and the thickness of each layer is larger than or equal to 0.5 mm. The bonding layer is an iron-based alloy layer with strong carbide forming elements and is adjacent to the drill rod base body; the transition layer and the working layer are iron-based composite layers with diamond particles, binding phase components in the transition layer are gradually transited from iron to nickel, cobalt or copper, and the volume fraction of the diamond particles in the working layer is higher than that of the diamond particles in the transition layer. The diamond is adopted as a hard phase, and by means of the gradient layered structure design of the diamond, strain localization in the deformation process of the diamond is effectively relieved, so that the structural advantage of the material is fully played, effective combination of the drill rod base body and the wear-resistant belt is guaranteed, and the wear resistance of the diamond is fully played.

Description

Technical Field

[0001] This application belongs to the field of oil and gas drilling engineering and materials processing technology, specifically relating to a high wear-resistant and high bonding strength composite wear-resistant belt for drill pipe joints and its preparation method. Background Technology

[0002] Drill pipe joints are critical components of the drill string system. During drilling, they undergo continuous impact and friction with the wellbore (rock formation or casing), resulting in severe wear. To ensure the safe operation of the drill pipe and casing, a wear-resistant strip is typically fabricated on the surface of the drill pipe joint.

[0003] Currently, wear-resistant belts made of iron-based or nickel-based alloys reinforced with tungsten carbide (WC) particles are commonly used. However, such wear-resistant belts have the following inherent defects: (1) WC has limited hardness (about 2400 HV) and will still wear out quickly in highly abrasive formations; (2) WC is easily oxidized and decomposed at high temperatures, forming a brittle phase, which leads to a decrease in wear resistance; (3) The bond between WC and the metal matrix mainly relies on mechanical interlocking, which makes it easy to fall off under strong impact loads.

[0004] Diamond is the hardest material in nature (about 10,000 HV) and has excellent wear resistance. However, applying diamond to wear-resistant belts faces huge challenges: (1) Diamond has extremely poor wettability with the metal matrix and weak interfacial bonding force, making it easy to peel off from the matrix under stress; (2) Diamond reacts with elements such as Fe, Co, and Ni at high temperatures (>700℃) and undergoes graphitization, losing its super-hard properties; (3) The huge difference in thermal expansion coefficients between diamond and the metal matrix leads to huge internal stress during preparation and cooling, causing cracks or even delamination.

[0005] Therefore, there is an urgent need in this field for an innovative technology that can fully utilize the exceptional wear resistance of diamond while solving the problems of weak bonding between diamond and metal matrix and high-temperature damage. Summary of the Invention

[0006] To address the aforementioned problems, this application provides a diamond-metal gradient composite wear-resistant strip, comprising a bonding layer, a transition layer, and a working layer, each with a thickness greater than or equal to 0.5 mm. The bonding layer is an iron-based alloy layer containing a strong carbide-forming element, adjacent to the drill pipe substrate. The transition layer and working layer are iron-based composite layers containing diamond particles, with the binder phase composition in the transition layer gradually transitioning from iron to nickel, cobalt, or copper. The strong carbide-forming element is titanium or chromium, with a particle size of 5 μm-20 μm. The iron-based alloy layer containing the strong carbide-forming element is composed of 95-99% iron and 1-5% titanium or chromium. The transition layer contains 10%-30% diamond particles by volume, and the binder phase in the transition layer consists of 35%-45% iron and 35%-45% nickel, cobalt, or copper, with the composition varying according to a gradient ratio to achieve bonding. The working layer is a nickel-based, cobalt-based, or copper-based composite layer containing diamond particles, and the volume fraction of diamond particles in the working layer is higher than that in the transition layer. The working layer contains 30%-50% diamond particles by volume, and the particle size of the diamond particles is 10μm-30μm. The iron-based, nickel-based, cobalt-based, or copper-based composite layer is made from iron powder, nickel powder, cobalt powder, or copper powder, respectively, with a particle size of 5μm-20μm.

[0007] This application also provides a method for preparing the diamond-metal gradient composite wear-resistant tape, comprising the following steps: (1) The area to be clad on the drill pipe joint is treated with degreasing, derusting and sandblasting (Ra 15–30μm); (2) Surface cleaning and activation of diamond particles; (3) The components of the bonding layer, transition layer and working layer are pre-placed onto the surface of the drill pipe joint layer by layer according to the design; (4) Rapid scanning cladding of the pre-placed billet under inert gas protection.

[0008] The bonding layer is formed by chemically depositing a dense Ti or Cr metal layer on its surface.

[0009] The activation method is called the Minhua-activation method, which specifically includes the following steps: adsorbing metal ions (such as Sn) 2+ Pd 2+ This forms catalytically active centers on the surface for subsequent electroless plating. The specific steps are as follows: Sensitization: Immerse diamond in a SnCl / HC solution (e.g., SnCl₂ 10 g / L + HCl 40 mL / L), stir at room temperature for 10-20 minutes to allow Sn to be adsorbed onto the surface. 2+ ; Cleaning: Rinse with deionized water to remove excess Sn. 2+ ; Activation: Drain PdCl / HCl solution (e.g., PdCl2 0.5 g / L + HCl 10 mL / L), stir at room temperature for 5-10 minutes. 2+ They are reduced to Pd atoms, which attach to the surface to form catalytic nuclei; Cleaning and drying: Clean with deionized water and then dry at low temperature.

[0010] The preparation steps of the preforms for the transition layer and working layer include: preparing slurries of metal alloy powders (particle size of 5μm-20μm) and surface-metallized diamond powder in different proportions, and then pre-setting them layer by layer on the surface of the drill pipe joint by spraying or coating to form a preform with a compositional gradient.

[0011] The rapid scanning cladding is performed under inert gas (such as argon) protection using an ultra-high frequency induction heating device with a frequency >1MHz on a pre-placed blank. By precisely controlling the power, scanning speed, and cooling rate, each layer of powder melts sequentially and achieves metallurgical bonding with the matrix. Simultaneously, it ensures that carbide formation occurs at the diamond particle interface, while the bulk temperature is controlled below 700℃ to prevent graphitization. The final result is a diamond-metal gradient composite wear-resistant band. More specifically, the power is 8×10⁻⁶. 8 ~1×10 9 W / m 2 The scanning speed is 50-200 mm / s, and the substrate is actively water-cooled and then cooled by strong nitrogen gas. The speed is 50-200℃ / s.

[0012] In the above technical solutions, the iron-based alloy in the bonding layer has a similar composition to the drill pipe steel matrix and a matching coefficient of thermal expansion. This allows for metallurgical bonding through welding or sintering, preventing delamination caused by thermal stress. Another reason the bonding layer can effectively bond the drill pipe to the wear-resistant band is that Ti / Cr reacts with carbon on or at the diamond surface at high temperatures, generating carbides such as TiC or Cr3C2. These carbides chemically bond to the diamond surface and tightly bind to the metal matrix, forming a strong "diamond-carbide-metal" interface, significantly improving the holding force of the diamond particles. Furthermore, the bonding layer itself does not contain diamond and has good plasticity, which can buffer the thermal and mechanical stresses between the subsequent hard layer and the matrix.

[0013] The Fe content in the transition layer gradually decreases, while the Ni / Co / Cu content gradually increases, achieving a continuous transition from iron-based to nickel / cobalt / copper-based. Since the coefficient of thermal expansion of diamond is much lower than that of Fe / Ni / Co / Cu, the compositional gradient allows for a smooth transition in the coefficient of thermal expansion from the bonding layer to the working layer, avoiding thermal stress cracking or delamination caused by abrupt changes. Furthermore, Fe and Ni / Co / Cu have high miscibility, allowing for the formation of a solid solution alloy through powder metallurgy, ensuring a tight bond within the transition layer. Therefore, the gradual increase in diamond content avoids early interface fragility due to excessive diamond content and lays the foundation for high wear resistance in the working layer.

[0014] In the working layer, Ni / Co / Cu serves as the bonding phase, transitioning completely to a non-ferrous base. High-volume-fraction diamond acts as the hard phase, directly bearing wear and impact, providing extremely high hardness and wear resistance. Ni / Co possesses good toughness, high-temperature strength, and wettability for diamond, helping to prevent diamond from detaching under impact loads; its good thermal conductivity facilitates heat dissipation and reduces thermal damage, while also possessing a certain degree of plastic deformation capacity to buffer localized stress. Through the gradient transition of the transition layer, the working layer, bonding layer, and drill pipe matrix are firmly bonded, preventing spalling caused by abrupt performance changes.

[0015] In the above implementation scheme, the bonding layer is composed of 95-99% iron and 1-5% titanium or chromium, adjacent to the drill pipe matrix, and has a particle size of 5μm to 20μm. The particle size refers to the portion cut from a 500-mesh to 2500-mesh sieve. This ensures sufficient reactivity without excessive embrittlement. The transition layer has a metal gradient transition (iron → nickel / cobalt / copper) and the diamond content increases towards the working layer, which alleviates the difference in thermal expansion coefficients. The diamond particle size is 10μm to 30μm, and the large / small particles take into account both cutting efficiency and surface finish, while ensuring sintering density without generating excessive shrinkage stress.

[0016] In summary, this application has achieved the following beneficial effects through the above technical solutions. (1) Diamond with a hardness far exceeding WC is used as the hard phase, and its gradient layered structure is used to effectively alleviate the strain localization during the deformation process, so that the advantages of the material structure can be fully utilized. This ensures the effective combination of the drill pipe matrix and the wear-resistant band, and also allows the wear resistance of diamond to be fully utilized. (2) By metallizing the diamond surface and generating a carbide interface layer, a high-strength chemical metallurgical bond between diamond and the metal matrix is ​​achieved, solving the problem of easy particle detachment. (3) The gradient structure design effectively alleviates the internal stress caused by the mismatch of thermal expansion coefficients and avoids the generation of macroscopic cracks; the tough metal bonding phase can absorb impact energy and give the wear-resistant belt good impact resistance. Attached Figure Description

[0017] Figure 1 This is an overall diagram showing the bonding of diamond-metal gradient composite wear-resistant band A with the drill pipe matrix.

[0018] Figure 2 This is an enlarged view of diamond-metal gradient composite wear-resistant belt A.

[0019] In the diagram, 1 represents the bonding layer, 2 the transition layer, 3 the working layer, and 4 the drill pipe joint. Detailed Implementation

[0020] In order to clearly and concisely illustrate the implementation scheme of this application, the operation using the prior art is not described in excessive detail. Based on this, the embodiments of this application are only for illustrating the technical solution and do not represent all the work of this application. Example

[0021] The layer thickness is designed as follows: 0.7mm for the bonding layer, 0.7mm for the transition layer, and 0.6mm for the working layer.

[0022] Example 1.11 The diamond-metal gradient composite wear-resistant strip has the following thickness direction: In the bonding layer, the volume fraction of diamond particles is 0%, the volume fraction of iron powder is 95%, and the volume fraction of titanium is 5%, and the bonding layer is adjacent to the drill pipe joint layer; In the transition layer, the volume fraction of diamond particles is 30%, the volume fraction of iron powder is 35%, and the volume fraction of nickel is 35%; In the working layer, the volume fraction of diamond particles is 50%, and the volume fraction of nickel is 50%. The preparation method of the diamond-metal gradient composite wear-resistant tape includes the following steps: (1) The drill pipe joint is made of high-quality alloy steel, such as 42CrMo. The area of ​​the drill pipe joint to be clad is treated with degreasing, derusting and sandblasting (Ra 15–30μm). (2) The diamond particles (particle size 10μm-30μm) are surface cleaned and activated; the activation is a conventional technique in the field, namely the sensory activation method, which involves adsorbing metal ions (such as Sn). 2+ Pd 2+ This forms catalytically active centers on the surface for subsequent electroless plating. The specific steps are as follows: Sensitization: Immerse diamond in a SnCl / HC solution (e.g., SnCl₂ 10 g / L + HCl 40 mL / L), stir at room temperature for 10-20 minutes to allow Sn to be adsorbed onto the surface. 2+ ; Cleaning: Rinse with deionized water to remove excess Sn. 2+ ; Activation: Drain PdCl / HCl solution (e.g., PdCl2 0.5 g / L + HCl 10 mL / L), stir at room temperature for 5-10 minutes. 2+They are reduced to Pd atoms, which attach to the surface to form catalytic nuclei; Cleaning and drying: Clean with deionized water and then dry at low temperature.

[0023] (3) According to the composition design of the bonding layer, transition layer and working layer, the bonding layer is deposited with a dense Ti or Cr metal layer on its surface by chemical plating; metal alloy powders with different ratios (particle size of 5μm-20μm) and surface metallized diamond powder are respectively prepared into slurries, and then pre-placed on the surface of the drill pipe joint layer by spraying or coating in sequence to form a transition layer and working layer pre-form with composition gradient; (4) Under the protection of an inert gas (such as argon), a high-frequency induction heating device with a frequency >1MHz is used to rapidly scan and clad the pre-formed blank; by precisely controlling the power, scanning speed and cooling rate, each layer of powder is melted sequentially and metallurgically bonded to the matrix, while ensuring that the diamond particle interface reacts to form carbides, but the body temperature is controlled below 700℃ to avoid graphitization; finally, a diamond-metal gradient composite wear-resistant belt is obtained. More specifically, the power is 8×10 8 ~1×10 9 W / m 2 The scanning speed is 50-200 mm / s, and the substrate is actively water-cooled and then cooled by strong nitrogen gas. The speed is 50-200℃ / s.

[0024] Example 1.12 The difference from Example 1.11 is that the volume fraction of diamond particles in the working layer is 50%, and the volume fraction of cobalt is 50%.

[0025] Example 1.13: The difference from Example 1.11 is that the volume fraction of diamond particles in the working layer is 50%, and the volume fraction of copper powder is 50%.

[0026] Example 1.21 The difference from Example 1.11 is that the volume fraction of diamond particles in the transition layer is 30%, the volume fraction of iron powder is 35%, and the volume fraction of cobalt is 35%.

[0027] Example 1.22 The difference from Example 1.11 is that the volume fraction of diamond particles in the transition layer is 30%, the volume fraction of iron powder is 35%, and the volume fraction of copper is 35%.

[0028] Example 1.3 Unlike Example 1.11, the bonding layer has a volume fraction of 0% diamond particles, a volume fraction of 95% iron powder, and a volume fraction of 5% chromium. Example

[0029] Example 2.11 Each layer is designed with a thickness of 0.5mm for the bonding layer, 0.6mm for the transition layer, and 0.7mm for the working layer.

[0030] The specific preparation method is the same as in Example 1.11, but the composition design is different: the diamond-metal gradient composite wear-resistant band has the following composition along the thickness direction: the volume fraction of diamond particles in the working layer is 45%, and the volume fraction of nickel is 55%; the volume fraction of diamond particles in the transition layer is 25%, the volume fraction of iron powder is 40%, and the volume fraction of nickel is 35%; the volume fraction of diamond particles in the bonding layer is 0%, the volume fraction of iron powder is 96%, and the volume fraction of titanium or chromium is 4%, and the bonding layer is adjacent to the drill pipe joint layer; Example 2.12 Unlike Example 2.11, the volume fraction of diamond particles in the working layer is 45%, and the volume fraction of cobalt is 55%.

[0031] Example 2.13 Unlike Example 2.11, the volume fraction of diamond particles in the working layer is 45%, and the volume fraction of copper is 55%.

[0032] Example 2.21 Unlike Example 2.11, the volume fraction of diamond particles in the transition layer is 25%, the volume fraction of iron powder is 40%, and the volume fraction of cobalt is 35%.

[0033] Example 2.22 Unlike Example 2.11, the volume fraction of diamond particles in the transition layer is 25%, the volume fraction of iron powder is 40%, and the volume fraction of copper is 35%.

[0034] Example 2.3 Unlike Example 2.11, the volume fraction of diamond particles in the bonding layer is 0%, the volume fraction of iron powder is 96%, and the volume fraction of chromium is 4%. Example

[0035] The layer thickness is designed as follows: 0.6mm for the bonding layer, 0.5mm for the transition layer, and 0.7mm for the working layer.

[0036] The specific preparation method of Example 3.11 is basically the same as that of Example 1.11, except that: The diamond-metal gradient composite wear-resistant band has the following thickness direction: the working layer has a volume fraction of 40% diamond particles and 60% nickel; the transition layer has a volume fraction of 20% diamond particles, 45% iron powder, and 35% nickel; the bonding layer has a volume fraction of 0% diamond particles, 97% iron powder, and 3% titanium, and the bonding layer is adjacent to the drill pipe joint layer. Example 3.12 Unlike Example 3.11, the volume fraction of diamond particles in the working layer is 40%, and the volume fraction of cobalt is 60%.

[0037] Example 3.13 Unlike Example 3.11, the volume fraction of diamond particles in the working layer is 40%, and the volume fraction of copper is 60%.

[0038] Examples 3.21-3.22 Example 3.21 Unlike Example 3.11, the volume fraction of diamond particles in the transition layer is 20%, the volume fraction of iron powder is 45%, and the volume fraction of cobalt is 35%.

[0039] Example 3.22 Unlike Example 2.11, the volume fraction of diamond particles in the transition layer is 20%, the volume fraction of iron powder is 45%, and the volume fraction of copper is 35%.

[0040] Example 3.3 Unlike Example 2.11, the volume fraction of diamond particles in the bonding layer is 0%, the volume fraction of iron powder is 97%, and the volume fraction of chromium is 3%. Example

[0041] Each layer is designed with a thickness of 0.5mm for the bonding layer, 0.5mm for the transition layer, and 0.6mm for the working layer.

[0042] Example 4.11 The preparation method is basically the same as that in Example 1.11, except that the diamond-metal gradient composite wear-resistant belt has the following structure along the thickness direction: the volume fraction of diamond particles in the working layer is 35%, and the volume fraction of nickel is 65%; the volume fraction of diamond particles in the transition layer is 15%, the volume fraction of iron powder is 45%, and the volume fraction of nickel is 40%; the volume fraction of diamond particles in the bonding layer is 0%, the volume fraction of iron powder is 98%, and the volume fraction of titanium is 2%, and the bonding layer is adjacent to the drill pipe joint layer. Example 4.12 Unlike Example 4.11, the volume fraction of diamond particles in the working layer is 35%, and the volume fraction of cobalt is 65%.

[0043] Example 4.13 Unlike Example 4.11, the volume fraction of diamond particles in the working layer is 35%, and the volume fraction of copper is 65%.

[0044] Example 4.21 Unlike Example 4.11, the volume fraction of diamond particles in the transition layer is 15%, the volume fraction of iron powder is 45%, and the volume fraction of cobalt is 40%.

[0045] Example 4.22 Unlike Example 4.11, the volume fraction of diamond particles in the transition layer is 15%, the volume fraction of iron powder is 45%, and the volume fraction of copper is 40%.

[0046] Example 4.3 Unlike Example 4.11, the volume fraction of diamond particles in the bonding layer is 0%, the volume fraction of iron powder is 98%, and the volume fraction of chromium is 2%. Example

[0047] Each layer is designed with a thickness of 0.5mm for the bonding layer, 0.5mm for the transition layer, and 0.5mm for the working layer.

[0048] Example 5.11 The preparation method is basically the same as that in Example 1.11, except that the diamond-metal gradient composite wear-resistant belt has the following structure along the thickness direction: the volume fraction of diamond particles in the working layer is 30%, and the volume fraction of nickel is 70%; the volume fraction of diamond particles in the transition layer is 10%, the volume fraction of iron powder is 45%, and the volume fraction of nickel is 45%; the volume fraction of diamond particles in the bonding layer is 0%, the volume fraction of iron powder is 99%, and the volume fraction of titanium is 1%, and the bonding layer is adjacent to the drill pipe joint layer. Example 5.12 Unlike Example 5.11, the volume fraction of diamond particles in the working layer is 30%, and the volume fraction of cobalt is 70%.

[0049] Example 5.13 Unlike Example 5.11, the volume fraction of diamond particles in the working layer is 30%, and the volume fraction of copper is 70%.

[0050] Example 5.21 Unlike Example 5.11, the volume fraction of diamond particles in the transition layer is 10%, the volume fraction of iron powder is 45%, and the volume fraction of cobalt is 45%.

[0051] Example 5.22 Unlike Example 5.11, the volume fraction of diamond particles in the transition layer is 10%, the volume fraction of iron powder is 45%, and the volume fraction of copper is 45%.

[0052] Example 5.3 Unlike Example 5.11, the volume fraction of diamond particles in the bonding layer is 0%, the volume fraction of iron powder is 99%, and the volume fraction of chromium is 1%.

[0053] This specific embodiment is merely an explanation of this application and is not intended to limit it. After reading this specification, those skilled in the art can make modifications to this embodiment without contributing any inventive step, but such modifications are protected by patent law as long as they fall within the scope of the claims of this application.

Claims

1. A diamond-metal gradient composite wear-resistant belt, characterized in that, The composite wear-resistant belt includes a bonding layer, a transition layer, and a working layer, each with a thickness of ≥0.5mm. The bonding layer is an iron-based alloy layer with strong carbide-forming elements, which is adjacent to the drill pipe substrate. The transition layer and the working layer are iron-based composite layers with diamond particles. The binder phase composition in the transition layer gradually transitions from iron to nickel, cobalt, or copper, and the volume fraction of diamond particles in the working layer is higher than that in the transition layer.

2. The diamond-metal gradient composite wear-resistant belt according to claim 1, characterized in that, The strong carbide forming element is titanium or chromium, with a particle size of 5μm-20μm. The iron-based alloy layer of the strong carbide forming element consists of 95-99% iron and 1-5% titanium or chromium.

3. The diamond-metal gradient composite wear-resistant tape according to claim 1, characterized in that, The transition layer contains 10%-30% diamond particles by volume, and the binder phase in the transition layer contains 35%-45% iron, 35%-45% nickel, cobalt or copper, and the bonding is achieved by varying the gradient ratio. The gradient ratio is that the diamond increases layer by layer from the bonding layer to the working layer, while the other metals decrease layer by layer.

4. The diamond-metal gradient composite wear-resistant tape according to claim 1, characterized in that, The working layer is a nickel-based, cobalt-based, or copper-based composite layer containing diamond particles.

5. The diamond-metal gradient composite wear-resistant belt according to claim 4, characterized in that, The working layer contains 30%-50% diamond particles by volume, and the diamond particles have a particle size of 10μm-30μm. The iron-based, nickel-based, cobalt-based, or copper-based composite layers are made of iron powder, nickel powder, cobalt powder, or copper powder, respectively, and have a particle size of 5μm-20μm.

6. The diamond-metal gradient composite wear-resistant belt according to claim 1, characterized in that, The total thickness of the bonding layer, transition layer, and working layer is less than or equal to 2 mm, and the length covering the drill pipe joint is 3 inches.

7. A method for preparing the diamond-metal gradient composite wear-resistant tape according to claim 1, characterized in that, The preparation method includes the following steps: degreasing, derusting and sandblasting roughening (Ra 15–30μm) of the area to be clad in the drill pipe joint; surface cleaning and activation of diamond particles; and pre-setting each layer of the bonding layer, transition layer and working layer onto the surface of the drill pipe joint according to the composition design to obtain the pre-formed blanks of each layer. Rapid scanning cladding is performed on the pre-placed billet under inert gas protection.

8. The method for preparing diamond-metal gradient composite wear-resistant tape according to claim 7, characterized in that, The rapid scanning cladding process involves using an ultra-high frequency induction heating device with a frequency >1MHz to rapidly scan and clad the pre-formed blank under the protection of an inert gas (such as argon). By precisely controlling the power, scanning speed, and cooling rate, each layer of powder is melted sequentially and metallurgically bonded to the matrix. At the same time, it ensures that the diamond particle interface reacts to form carbides, but the body temperature is controlled below 700℃ to prevent graphitization.

9. The method for preparing diamond-metal gradient composite wear-resistant tape according to claim 8, characterized in that, The power in the precise control of power, scanning speed, and cooling rate is 8 × 10 8 ~1×10 9 W / m 2 The scanning speed is 50-200 mm / s, and the cooling rate is 50-200 ℃ / s.

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