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Surface treatment plays a crucial role in improving the corrosion resistance, wear resistance, and overall service life of oil casing pipes. Below are the common surface treatment methods of oil casing pipe widely used in the industry.
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1. Coating Treatments (Mainstream Process)
(1) Zinc Coating (Galvanizing)
Method: Applied through hot-dip galvanizing or electroplating, forming a protective zinc layer that provides sacrificial anodic protection to the steel substrate.
Advantages: Cost-effective, mature technology, suitable for mildly corrosive environments such as freshwater or slightly alkaline conditions.
Limitations: Not ideal for high-temperature (>60°C) or chloride-rich environments, where performance may decline.
(2) Zinc-Aluminum Alloy Coating
Common Types: Galvalume (55% Al-Zn), Galfan (5% Al-Zn)
Advantages: Offers 2–5 times better corrosion resistance compared to pure zinc coatings. It also has excellent high-temperature stability, tolerating temperatures up to 300°C.
(3) Fusion Bonded Epoxy (FBE) Coating
Process: Involves electrostatic spraying of epoxy powder onto a preheated pipe surface, followed by high-temperature curing to form a dense, uniform polymer layer.
Applications: Commonly used on outer casing surfaces, especially in marine environments or highly saline/alkaline geological formations.
Highlights: FBE coatings provide strong adhesion, resistance to impact, and excellent protection against cathodic disbondment. They effectively prevent corrosion caused by water, soil, and chemical agents.
2. Chemical Conversion Treatments
(1) Phosphating
Purpose: Forms a phosphate film on the steel surface to enhance paint or coating adhesion. Commonly used as a pre-treatment step before coating or plating.
(2) Passivation
Applicable Materials: Typically used on stainless steel casings such as 13Cr and Super 13Cr.
Principle: Acid pickling removes surface free iron, allowing a stable chromium oxide film to form, improving corrosion resistance.
(3) Pickling
Function: Removes scale, rust, and old coatings using chemical or electrolytic solutions. Often combined with sandblasting for more thorough cleaning.
Notes: While effective at cleaning and increasing surface roughness, chemical pickling produces a shallow anchor profile and can have environmental drawbacks.
3. Mechanical Strengthening Treatments
(1) Shot Peening/Shot Blasting
Purpose: High-speed impact from steel shot or grit creates a compressive stress layer, boosting fatigue strength.
Process: High-power motors spin blades to accelerate abrasive media (e.g., steel shot, wire cuttings), which strike the pipe surface to remove rust and scale while achieving uniform roughness.
Applications: Shot peening is used both for internal and external surfaces, with external shot blasting being more common.
(2) Thread Surface Treatments
Copper/Tin Plating: Enhances thread sealing performance and reduces the risk of galling, often used in premium thread types like VAM TOP and FOX.
PTFE Coating: A layer of polytetrafluoroethylene (Teflon) is applied to lower the coefficient of friction and improve make-up torque performance.
4. Special Treatments for Extreme Environments
(1) Nickel-Based Alloy Cladding
Use Case: Designed for highly corrosive conditions such as high-temperature, high-pressure wells containing H₂S or CO₂.
(2) Ceramic Coating
Scenario: Commonly applied to casing sections exposed to high-speed sand flow, such as in shale gas well fracturing operations, to resist erosion.
Industry Trends in Surface Treatment
The industry is moving toward composite surface treatments, combining methods like zinc-aluminum coatings with FBE to enhance overall protection. At the same time, intelligent coatings, such as self-healing materials, are gaining attention.
In deep and ultra-deep well applications, surface treatment may account for 15–30% of the total casing cost, yet it significantly lowers long-term maintenance and replacement expenses.
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