Multilayer Thread Coating for Corrosion and Galling Resistance

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Solution Overview

Problem

Existing surface treatments fail to effectively reduce friction, corrosion, and galling damage in interlocking devices, particularly in corrosive environments like those encountered in oil field and offshore drilling applications.

Innovation Solution

A multilayered coating comprising a base adhesive layer of titanium or chrome, an intermediary insulation layer of hafnium oxide, an interstitial adhesive layer of chrome, and a lubricating gold layer, applied in an ultra-high vacuum chamber using electron-beam ion mill assisted deposition, to prevent wear and corrosion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If existing surface treatments are applied to interlocking devices, then the basic protective function is provided, but friction reduction and prevention of galling damage are insufficient

Engineering Contradiction:

Improveprevention of galling damageVSAvoidfriction and wear

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies a multilayered coating system comprising multiple distinct materials (adhesive layer, insulation layer, and lubricating layer) deposited sequentially on the threaded surface. This composite structure combines the adhesion properties of titanium/chrome, the insulation properties of hafnium oxide, and the low-friction properties of gold, achieving superior protection against galling and wear that single-material coatings cannot provide.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The intermediary insulation layer of hafnium oxide serves as a mediator between the base adhesive layer and the top lubricating layer of gold. This intermediate layer prevents direct chemical interaction between the adhesive and lubricating materials while ensuring proper adhesion and maintaining the functional properties of both layers, thereby optimizing the overall performance of the coating system.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If a lubrication layer is added to reduce friction, then galling prevention improves, but coating complexity increases

Engineering Contradiction:

ImprovefrictionVSAvoidcoating structure

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The coating is segmented into three distinct functional layers: an adhesive layer for bonding, an insulation layer for chemical isolation, and a lubricating layer for friction reduction. This segmentation allows each layer to be optimized for its specific function while working together as an integrated system, achieving low friction without compromising adhesion or chemical stability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Each layer of the coating is designed with specific local properties tailored to its function: the adhesive layer uses titanium or chrome for strong bonding, the insulation layer uses hafnium oxide for chemical stability, and the lubricating layer uses gold for low friction. This local optimization of material properties at different depths of the coating enables superior overall performance.

Inventive Principle:

Principle #3Local quality

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The multilayered coating significantly reduces friction and prevents galling and corrosion, enhancing the durability and performance of threaded connectors by minimizing wear and environmental damage.

Implementation Method 1

deposited using electron e-beam ion mill assisted deposition

Methodology Applied

Scientific EffectElectron beam: Electron Beam

Implementation Method 2

applied in an ultra-high vacuum chamber and deposited using electron e-beam ion mill assisted deposition

Methodology Applied

Scientific EffectPhysical vapor deposition: Physical Vapour Deposition

Data Source

PatentUS11248289B2Multilayered corrosion and anti-galling coating for threads and wearable materials

Publication Date: 2022.02.15 DALLAS THIN FILMS

AI summary

A multilayered corrosion and anti-galling coating for threads and wearable materials is a liner that can be superimposed onto the surface of a device in order to protect the surface from environmental hazards. To accomplish this, the coating has a base adhesive layer, an intermediary insulation layer, an interstitial adhesive layer, and a lubricating material layer. The base adhesive layer adheres to the device's surface thus enabling the coating to form a sealing liner. The intermediary insulation layer is positioned in between the base adhesive layer and the interstitial adhesive layer. As a result, the intermediary insulation layer prevents negative chemical interactions between the base adhesive layer and the interstitial adhesive layer. The lubricating material layer is super imposed onto the interstitial adhesive layer to provide a friction-reducing coating for the device's surface.