Exxonmobil Research and Engineering Company

Exxonmobil Upstream Research Company

Exxonmobil Technology and Engineering Company

Hyun-Woo Jin

Narasimha-Rao Venkata Bangaru

Jayoung Koo

ChangMin Chun

Christopher John Fowler

John Roger Peterson

Robert Lee Antram

Neeraj Srinivas Thirumalai

Adnan Ozekcin

Raghavan Ayer

Douglas Paul Fairchild

Jeffrey Roberts Bailey

Mehmet Deniz Ertas

Steven Jeffrey Ford

Erika Ann Ooten Biediger

Swarupa Soma Bangaru, Legal Representative

Michael Thomas Hecker

Michael D Barry

Shiun Ling

Daniel B Lillig

William Curtis Elks

Charles Shiao-Hsiung Yeh

Shigeru Endo

Mitsuhiro Okatsu

Ning Ma

Andrew J Wasson

Vishwas Gupta

Emery Bela Lendvai-Lintner

Mario Luis Macia

Moriyasu Nagae

Shinichi Kakihara

Danny Lee Beeson

Neerav Verma

James B LeBleu, Jr

Nathan Eugene Nissley

Haiping He

Douglas S Hoyt

Nathan E Nissley

Mario L Macia

Methods disclosed herein include using additive manufacturing to create a joint between a first metallic material and a second metallic material that is different from the first metallic material, wherein the porosity of the joint is less than about 0.1 percent by volume measured according to ASTM B-962. The additive manufacturing can be performed such that no intermetallic brittle phase forms between the first metallic material and the second metallic material.

Multi-metallic articles of manufacture

Mooring chains used in offshore environments are typically formed from carbon steels due to their wear and fatigue resistance properties. Although carbon steels may exhibit robust mechanical properties, they are susceptible to corrosion, which can shorten the usable working lifetime of mooring chains, particularly in a seawater environment. Austenitic steels comprising high percentages of manganese may have comparable mechanical properties to the carbon steels commonly used in mooring chains, yet exhibit less susceptibility to corrosion. Austenitic steels suitable for use in mooring chains and other structures in contact with or exposed to a seawater environment may comprise: 0.4-0.8 wt. % C, 12-25 wt. % Mn, 4-15 wt. % Cr, a non-zero amount of Si&#x3c;3 wt. %, a non-zero amount of Al&#x3c;0.5 wt. %, a non-zero amount of N&#x3c;0.1 wt. %, &#x3c;5 wt. % Mo, and balance Fe and inevitable impurities.

Mooring chains comprising high manganese steels and associated methods

A steel composition and method from making a dual phase steel therefrom. The dual phase steel may have carbon of about 0.05% by weight to about 0.12 wt %; niobium of about 0.005 wt % to about 0.03 wt %; titanium of about 0.005 wt % to about 0.02 wt %; nitrogen of about 0.001 wt % to about 0.01 wt %; silicon of about 0.01 wt % to about 0.5 wt %; manganese of about 0.5 wt % to about 2.0 wt %; and a total of molybdenum, chromium, vanadium and copper less than about 0.15 wt %. The steel may have a first phase consisting of ferrite and a second phase having one or more of carbide, pearlite, martensite, lower bainite, granular bainite, upper bainite, and degenerate upper bainite. A solute carbon content in the first phase may be about 0.01 wt % or less.

Low yield ratio dual phase steel linepipe with superior strain aging resistance

Weld metals and methods for welding ferritic steels are provided. The weld metals have high strength and high ductile tearing resistance and are suitable for use in strain based pipelines. The weld metal contains retained austenite and has a cellular microstructure with cell walls containing lath martensite and cell interiors containing degenerate upper bainite. The weld metals are comprised of between 0.02 and 0.12 wt % carbon, between 7.50 and 14.50 wt % nickel, not greater than about 1.00 wt % manganese, not greater than about 0.30 wt % silicon, not greater than about 150 ppm oxygen, not greater than about 100 ppm sulfur, not greater than about 75 ppm phosphorus, and the balance essentially iron. Other elements may be added to enhance the properties of the weld metal. The weld metals are applied using a power source with current waveform control which produces a smooth, controlled welding arc and weld pool in the absence of COor oxygen in the shielding gas.

High toughness weld metals with superior ductile tearing resistance

Provided are strain hardened high strength nickel based alloy welds that yield improved properties and performance in joining high strength metals. The advantageous weldments include two or more segments of ferrous or non-ferrous components, and fusion welds, friction stir welds, electron beam welds, laser beam welds, or a combination thereof bonding adjacent segments of the components together, wherein the welds comprise a strain hardened nickel based alloy weld metal composition including greater than or equal to 10 wt % Mo based on the total weight of the nickel based alloy weld metal composition. Also provided are methods for forming the welds from the nickel based alloy weld compositions. The strain hardened high strength nickel based alloy welds are useful in the oil, gas and petrochemical industry in applications for natural gas transportation and storage, oil and gas well completion and production, and oil and gas refinery and chemical plants.

High strength nickel alloy welds through strain hardening

Provided are precipitation hardened high strength nickel based alloy welds that yield improved properties and performance in joining high strength metals. The advantageous weldments include two or more segments of ferrous or non-ferrous components, and fusion welds, friction stir welds, electron beam welds, laser beam welds, or a combination thereof bonding adjacent segments of the components together, wherein the welds comprise a precipitation hardened nickel based alloy weld metal composition including greater than or equal to 1.4 wt % of combined aluminum and titanium based on the total weight of the nickel based alloy weld metal composition. Also provided are methods for forming the welds from the nickel based alloy weld compositions, wherein the precipitation hardening occurs in the as-welded condition. The nickel based welds do not require a separate heat treatment step after welding to produce advantageous strength properties.

High strength nickel alloy welds through precipitation hardening

Provided are coated sleeved oil and gas well production devices and methods of making and using such coated sleeved devices. In one form, the coated sleeved oil and gas well production device includes an oil and gas well production device including one or more bodies and one or more sleeves proximal to the outer or inner surface of the one or more bodies, and a coating on at least a portion of the inner sleeve surface, outer sleeve surface, or a combination thereof, wherein the coating is chosen from an amorphous alloy, a heat-treated electroless or electro plated based nickel-phosphorous composite with a phosphorous content greater than 12 wt %, graphite, MoS, WS, a fullerene based composite, a boride based cermet, a quasicrystalline material, a diamond based material, diamond-like-carbon (DLC), boron nitride, and combinations thereof. The coated sleeved oil and gas well production devices may provide for reduced friction, wear, erosion, corrosion, and deposits for well construction, completion and production of oil and gas.

Coated sleeved oil and gas well production devices

Provided are coated oil and gas well production devices and methods of making and using such coated devices. In one form, the coated oil and gas well production device includes an oil and gas well production device including one or more bodies, and a coating on at least a portion of the one or more bodies, wherein the coating is chosen from an amorphous alloy, a heat-treated electroless or electro plated based nickel-phosphorous composite with a phosphorous content greater than 12 wt %, graphite, MoS, WS, a fullerene based composite, a boride based cermet, a quasicrystalline material, a diamond based material, diamond-like-carbon (DLC), boron nitride, and combinations thereof. The coated oil and gas well production devices may provide for reduced friction, wear, corrosion, erosion, and deposits for well construction, completion and production of oil and gas.

Coated oil and gas well production devices

Provided are drill stem assemblies with ultra-low friction coatings for subterraneous drilling operations. In one form, the coated drill stem assemblies for subterraneous rotary drilling operations include a body assembly with an exposed outer surface including a drill string coupled to a bottom hole assembly or a coiled tubing coupled to a bottom hole assembly and an ultra-low friction coating on at least a portion of the exposed outer surface of the body assembly, wherein the coefficient of friction of the ultra-low friction coating is less than or equal to 0.15. The coated drill stem assemblies disclosed herein provide for reduced friction, vibration (stick-slip and torsional), abrasion and wear during straight hole or directional drilling to allow for improved rates of penetration and enable ultra-extended reach drilling with existing top drives.

Ultra-low friction coatings for drill stem assemblies

The invention is related to a method for protecting a metal surface subject to erosion temperatures up to 850&#xb0; C. The method comprises providing the metal surface with a cermet composition represented by the formula (PQ)(RS) comprising: a ceramic phase (PQ) and binder phase (RS) wherein,

Advanced erosion-corrosion resistant boride cermets

Multimodal cermet compositions comprising a multimodal grit distribution of the ceramic phase and method of making are provided by the present invention. The multimodal cermet compositions include a) a ceramic phase and b) a metal binder phase, wherein the ceramic phase is a metal boride with a multimodal distribution of particles, wherein at least one metal is selected from the group consisting of Group IV, Group V, Group VI elements of the Long Form of The Periodic Table of Elements and mixtures thereof, and wherein the metal binder phase comprises at least one first element selected from the group consisting of Fe, Ni, Co, Mn and mixtures thereof, and at least second element selected from the group consisting of Cr, Al, Si and Y, and Ti. The method of making multimodal boride cermets includes the steps of mixing multimodal ceramic phase particles and metal phase particles, milling the ceramic and metal phase particles, uniaxially and optionally isostatically pressing the particles, liquid phase sintering of the compressed mixture at elevated temperatures, and finally cooling the multimodal cermet composition. Advantages disclosed by the multimodal cermets are high packing density of the ceramic phase, high fracture toughness and improved erosion resistance at high temperatures up to 1000&#xb0; C. The disclosed multimodal cermets are suitable in high temperature erosion/corrosion applications in various chemical and petroleum environments.

Bimodal and multimodal dense boride cermets with superior erosion performance

One embodiment of the invention includes a cermet composition represented by the formula (PQ)(RS) comprising: a ceramic phase (PQ) and a binder phase (RS) wherein,

Method for protecting metal surfaces utilizing erosion resistant oxide cermets

Cermets are provided in which the ceramic phase is selected from the group consisting of CrC, CrC, CrCand mixtures thereof. The binder phase is selected from certain specified Ni/Cr alloys and certain Fe/Ni/Cr alloys. These cermets are particularly useful in protecting surfaces from erosion at high temperatures.

Erosion-corrosion resistant carbide cermets for long term high temperature service

Cermets, particularly composition gradient cermets can be prepared starting with suitable bulk metal alloys by a reactive heat treatment process involving a reactive environment selected from the group consisting of reactive carbon, reactive nitrogen, reactive boron, reactive oxygen and mixtures thereof.

Composition gradient cermets and reactive heat treatment process for preparing same

The invention includes a cermet composition represented by the formula (PQ)(RS) comprising: a ceramic phase (PQ) and a binder phase (RS) wherein,

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Phillipsburg, NJ, United States of America

Hyun-Woo Jin