Cemented Carbide Binder Composition for Corrosion and Erosion Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional cemented carbides used in oil and gas fluid flow control applications exhibit unsatisfactory rates of failure due to inadequate corrosion and mechanical resistance, particularly in acidic media and under intermittent impacts from large solid particles.
Innovation Solution
A cemented carbide material with a balanced composition of WC as the hard phase and a binder phase comprising Co, Ni, Cr, and Mo, where the wt% of Co is less than the wt% of Ni, providing enhanced hardness, toughness, wear resistance, and corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional cemented carbide compositions are used, then manufacturing simplicity is maintained, but corrosion resistance and mechanical resistance under acidic conditions deteriorate
Solution Approach 1:
The invention changes the compositional parameters of the binder phase by specifying that Co content must be less than Ni content, and by defining specific ranges for Cr (2.0-4.0 wt%), Mo (1.0-3.0 wt%), and Ni (3.0-6.0 wt%). This parameter modification resolves the contradiction by achieving superior corrosion resistance in acidic media while maintaining a relatively simple four-element composition structure.
Solution Approach 2:
The invention creates a composite binder phase combining Co, Ni, Cr, and Mo with WC hard phase, where the specific composition ratio (Co < Ni) provides synergistic effects that enhance both corrosion resistance and mechanical properties. This composite approach resolves the contradiction by integrating multiple functional elements into a unified material system.
2Reliability
If harder cemented carbide grades are used to improve wear resistance, then erosion resistance improves, but toughness deteriorates
Solution Approach 1:
The invention optimizes the binder phase composition parameters to achieve a balance between hardness and toughness. By specifying Co < Ni and defining precise ranges for Cr, Mo, and Ni, the material achieves enhanced wear resistance through improved surface properties while the specific composition prevents excessive brittleness, thereby resolving the contradiction between wear resistance and toughness.
3Duration of action of stationary object
If service lifetime is extended to withstand high-velocity flows and particle impacts, then reliability improves, but material complexity increases
Solution Approach 1:
The invention extends service lifetime by modifying the binder phase composition parameters, specifically requiring Co < Ni and defining optimized ranges for Cr (2.0-4.0 wt%), Mo (1.0-3.0 wt%), and Ni (3.0-6.0 wt%). These parameter changes enhance resistance to high-velocity flows and particle impacts without requiring excessive material complexity, achieving improved durability through controlled compositional optimization.
Data Source
Figure 1
AI summary
A corrosion and erosion resistant cemented carbide for high demand including in particular oil and gas flow applications. A cemented tungsten carbide grade is described based on a hard phase and a binder phase including the following constituents Co, Ni, Cr, Mo and balance WC. In particular, the binder phase content of the cemented carbide is between 5.1 to 7.5 wt%, the cemented carbide comprises in wt% 1.7-3.3 Co; 2.0-3.7 Ni; 0.5-1.1 Cr, 0.05-0.4 Mo and WC included as balance; and wherein wt% Co is always less than wt% Ni.