Artificial Lift Pump Coupling Surface Treatments
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Solution Overview
Problem
Current hydrocarbon pumping systems face issues with corrosion, wear, and fatigue, leading to reduced lifespan, particularly in sucker rod systems, where coupling failures are common, and existing advanced coatings like diamond-like carbon (DLC) are costly and difficult to implement effectively.
Innovation Solution
A two-layer surface treatment and coating process involving nitrocarburizing or boronizing followed by a diamond-like carbon coating, which enriches the substrate with carbon, nitrogen, or boron, providing low friction and wear resistance without significant dimensional changes, and is more cost-effective than conventional multi-layer DLC coatings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If conventional multi-layer DLC coatings are applied to increase wear resistance and friction reduction, then component life span is extended, but manufacturing cost and process complexity increase significantly
Solution Approach 1:
The coating process is segmented into two distinct stages: a preliminary surface treatment stage (nitrocarburizing or boronizing) that modifies the substrate chemistry, and a subsequent DLC coating stage that applies the low-friction layer. This segmentation allows each stage to be optimized independently, reducing overall process complexity while maintaining performance benefits.
Solution Approach 2:
The patent applies a preliminary surface treatment (nitrocarburizing or boronizing) before applying the DLC coating. This preliminary action modifies the substrate surface chemistry to enhance adhesion and wear resistance, creating an optimal foundation for the subsequent DLC coating and reducing the need for complex multi-layer structures.
2Duration of action of stationary object
If thick DLC coatings are applied to increase wear resistance, then component life span is extended, but coating adhesion and internal stress control become difficult
Solution Approach 1:
The patent applies a preliminary surface treatment (nitrocarburizing or boronizing) before applying the DLC coating. This preliminary action modifies the substrate surface chemistry to enhance adhesion and wear resistance, creating an optimal foundation for the subsequent DLC coating and reducing the need for complex multi-layer structures.
Solution Approach 2:
The patent changes the surface chemistry parameters of the substrate by introducing carbon, nitrogen, or boron through nitrocarburizing or boronizing. This parameter change creates a chemically active surface that enhances DLC coating adhesion and reduces internal stresses, allowing for thicker coatings without compromising reliability.
3Productivity
If advanced coatings like DLC are used to reduce friction and wear, then pump efficiency improves, but manufacturing cost increases
Solution Approach 1:
The coating process is segmented into two distinct stages: a preliminary surface treatment stage (nitrocarburizing or boronizing) that modifies the substrate chemistry, and a subsequent DLC coating stage that applies the low-friction layer. This segmentation allows each stage to be optimized independently, reducing overall process complexity while maintaining performance benefits.
Solution Approach 2:
The patent creates a composite structure combining the treated substrate (enriched with carbon, nitrogen, or boron) and the DLC coating. This composite material approach leverages the benefits of both the modified substrate and the low-friction coating, achieving high pump efficiency at a more manageable manufacturing cost compared to thick multi-layer DLC coatings.
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 solution significantly extends the lifespan of hydrocarbon pumping system components by reducing friction and wear, improving fatigue resistance, and offering a cost-competitive alternative to high-end coatings, while maintaining performance and reliability.
Implementation Method 1
performing a nitrocarburizing or boronizing process to produce a case hardening on the item
Implementation Method 2
performing a nitrocarburizing or boronizing process to produce a case hardening on the item
Implementation Method 3
The diamond like carbon coating surface is advantageously ultra hard, thus wear resistant, but by also offering ultra-low friction can reduce steel casing wear
Data Source
AI summary
Artificial lift pump components such as couplings are disclosed, all having a body formed from a selected material, the body having an inner diameter and an outer diameter, a first surface treatment introducing carbon, nitrogen, boron into the material to form a first and hard layer, and a second layer defined as an deposited coating to the first layer that is also made of a carbon, nitrogen, or boron and is further characterized as being ceramic like (hard) and having a low-friction.