Exxonmobil Research and Engineering Company

Neeraj Srinivas Thirumalai

Narasimha-Rao Venkata Bangaru

ChangMin Chun

Christopher John Fowler

John Roger Peterson

Robert Lee Antram

Hyun-Woo Jin

Jayoung Koo

Emery Bela Lendvai-Lintner

Douglas Paul Fairchild

Raghavan Ayer

Steven Jeffrey Ford

Shiun Ling

Daniel B Lillig

Harry William Deckman

Paul Michael Chaikin

Lang Feng

Qiuzi Li

James Ronald Rigby

Glen A Vaughn

Joseph W Krynicki

Jamey A Fenske

Mark Biegler

For method of utilizing a nondestructive evaluation method to inspect a steel material comprising at least one hysteretic ferromagnetic material and/or at least one nonhysteretic material to identify one or more material conditions and/or one or more inhomogeneities in steel material, the method can comprise the steps of: interrogating the hysteretic ferromagnetic material and/or the nonhysteretic material with an input time varying magnetic field; scanning the steel material and detecting a magnetic response and/or acoustic response over time from the hysteretic ferromagnetic material and/or the nonhysteretic material; determining a time dependent nonlinear characteristic of the received magnetic response and/or acoustic response; and correlating the time dependent nonlinear characteristic of the received magnetic response and/or acoustic response to the one or more material conditions and/or one or more inhomogeneities in steel material.

Methods of using nondestructive material inspection systems

A method for determining one or more material conditions of a hysteretic ferromagnetic material and/or a nonhysteretic material can include interrogating the hysteretic ferromagnetic material and/or the nonhysteretic material with an input time varying magnetic field and detecting a magnetic response and/or acoustic response over time from the hysteretic ferromagnetic material and/or the nonhysteretic material. The method can also include determining a time dependent nonlinear characteristic of the received magnetic response and/or acoustic response and correlating the time dependent nonlinear characteristic of the received magnetic response or acoustic response to one or more material conditions of the material.

Methods and systems for nondestructive material inspection

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

The present invention is directed to a method for protecting metal surfaces in oil & gas exploration and production, refinery and petrochemical process applications subject to solid particulate erosion at temperatures of up to 1000&#xb0; C. The method includes the step of providing the metal surfaces in such applications with a hot erosion resistant cermet lining or insert, wherein the cermet lining or insert includes a) about 30 to about 95 vol % of a ceramic phase, and b) a metal binder phase, wherein the cermet lining or insert has a HEAT erosion resistance index of at least 5.0 and a Kfracture toughness of at least 7.0 MPa-m. The metal surfaces may also be provided with a hot erosion resistant cermet coating having a HEAT erosion resistance index of at least 5.0.

Erosion resistant cermet linings for oil and gas exploration, refining and petrochemical processing applications

Provided are metal structures and methods of forming such structures for use in oil, gas and/or petrochemical applications that are joined with non-ferrous weld metal compositions or a high alloy weld metal compositions. The welded metal structures include two or more segments of ferrous or non-ferrous components, and fusion welds, friction stir welds or a combination thereof bonding adjacent segments of the components together, wherein the welds comprise a non-ferrous weld metal composition or a high alloy weld metal composition that is substantially different from the metal composition of the two or more components. The resultant welded structures exhibit improvements in fatigue resistance, toughness, strain capacity, strength, stress corrosion cracking resistance, and hydrogen embrittlement resistance compared to traditional iron-based weld compositions. The structures and methods of forming such structures are advantageous in joining metal components in applications for natural gas transportation and storage, oil and gas well completion and production, and oil and gas refinery and chemical plants.

Weld metal compositions for joining steel structures in the oil and gas industry

A method for welding and repairing cracks in metal parts is provided by subjecting the metal parts to be welded to friction stir welding and the cracks to be repaired to friction stir processing under conditions sufficient to provide a weld joint or crack repair having a preselected property or set of properties based upon the intended use of the weldment. The FSW and FSP methods are advantageous in joining and repairing metal structures and components in applications for natural gas transportation and storage, oil and gas well completion and production, and oil and gas refinery and chemical plants.

Application of high integrity welding and repair of metal components in oil and gas exploration, production and refining

The present invention is directed to a method for protecting metal surfaces in oil & gas exploration and production, refinery and petrochemical process applications subject to solid particulate erosion at temperatures of up to 1000&#xb0; C. The method includes the step of providing the metal surfaces in such applications with a hot erosion resistant cermet lining or insert, wherein the cermet lining or insert includes a) about 30 to about 95 vol % of a ceramic phase, and b) a metal binder phase, wherein the cermet lining or insert has a HEAT erosion resistance index of at least 5.0 and a Kfracture toughness of at least 7.0 MPa-m. The metal surfaces may also be provided with a hot erosion resistant cermet coating having a HEAT erosion resistance index of at least 5.0. Advantages provided by the method include, inter alia, outstanding high temperature erosion and corrosion resistance in combination with outstanding fracture toughness, as well as outstanding thermal expansion compatibility to the base metal of process units. The method finds particular application for protecting process vessels, transfer lines and process piping, heat exchangers, cyclones, slide valve gates and guides, feed nozzles, aeration nozzles, thermo wells, valve bodies, internal risers, deflection shields, sand screen, and oil sand mining equipment.

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

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

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

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Phillipsburg, NJ, United States of America

Neeraj Srinivas Thirumalai