Exxonmobil Research and Engineering Company

Exxonmobil Upstream Research Company

Posco

Jfe Steel Corporation

Raghavan Ayer

Narasimha-Rao Venkata Bangaru

Charles S Yeh

Douglas Paul Fairchild

Jayoung Koo

Hyun-Woo Jin

Steven Jeffrey Ford

Neeraj Srinivas Thirumalai

Adnan Ozekcin

Glen A Vaughn

Daniel B Lillig

Jeffrey Roberts Bailey

Michael Thomas Hecker

Shigeru Endo

Michael D Barry

Mitsuhiro Okatsu

Mehmet Deniz Ertas

Ning Ma

Shiun Ling

Hak-Cheol Lee

James Ronald Rigby

Hyunwoo Jin

In-Shik Suh

Jong-Kyo Choi

Russell R Mueller

Moriyasu Nagae

Mario Luis Macia

Shinichi Kakihara

Erika Ann Ooten Biediger

Swarupa Soma Bangaru, Legal Representative

Danny Lee Beeson

Nathan Eugene Nissley

William Curtis Elks

Charles Shiao-Hsiung Yeh

Dylan V Pugh

James B LeBleu, Jr

Douglas S Hoyt

Norman Pokutylowicz

Mark Biegler

Shalawn K Jackson

Joseph C Bondos

Russell Robert Mueller

Nathan E Nissley

Mario L Macia

Narasimha V Bangaru

Danny L Beeson

Improved steel compositions and methods of making the same are provided. The present disclosure provides advantageous wear resistant steel. More particularly, the present disclosure provides high manganese (Mn) steel having enhanced wear resistance, and methods for fabricating high manganese steel compositions having enhanced wear resistance. The advantageous steel compositions/components of the present disclosure improve one or more of the following properties: wear resistance, ductility, crack resistance, erosion resistance, fatigue life, surface hardness, stress corrosion resistance, fatigue resistance, and/or environmental cracking resistance. In general, the present disclosure provides high manganese steels tailored to resist wear and/or erosion.

Enhanced wear resistant steel and methods of making the same

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

The present application describes a steel composition that provides enhanced corrosion resistance. This steel composition includes one of vanadium in an amount of 1 wt % to 9 wt %, titanium in an amount of about 1 wt % to 9 wt %, and a combination of vanadium and titanium in an amount of 1 wt % to about 9 wt %. In addition, the steel composition includes carbon in an amount of 0.03 wt % to about 0.45 wt %, manganese in an amount up to 2 wt % and silicon in an amount up to 0.45 wt %. In one embodiment, the steel composition includes a microstructure of one of the following: ferrite, martensite, tempered martensite, dual phase ferrite and martensite, and dual phase ferrite and tempered martensite. Further, the present application describes a method for processing the steel composition and use of equipment such as oil country tubular goods, fabricated with the steel composition.

Low alloy steels with superior corrosion resistance for oil country tubular goods

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 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 relates to a method of forming metallic foams using cold spray processing. The method allows for the formation of metallic foams on existing substrates as a layer. The method includes the steps of providing a substrate for coating of a metallic foam; cold spraying a mixture of metal particles and a foaming agent onto the substrate to form a substrate coated with an unexpanded metallic layer; foam heat treating the substrate coated with an unexpanded metallic layer at a temperature above the decomposition temperature of the foaming agent for a time sufficient to form a heated substrate coated with an expanded metal foam layer; and cooling the heated substrate coated with an expanded metal foam layer to about ambient temperature to form a cooled substrate coated with an expanded metal foam layer. The method of forming metallic foams on substrates finds application in the oil, gas, and chemical industry by being an integral part of casings, pipelines, transfer lines, and other flow lines.

Method of forming metal foams by cold spray technique

An ultra-high strength, weldable, low alloy steel with excellent cryogenic temperature toughness in the base plate and in the heat affected zone (HAZ) when welded, having a tensile strength greater than about 830 MPa (120 ksi) and a microstructure comprising (i) predominantly fine-grained lower bainite, fine-grained lath martensite, fine granular bainite (FGB), or mixtures thereof, and (ii) up to about 10 vol % retained austenite, is prepared by heating a steel slab comprising iron and specified weight percentages of some or all of the additives carbon, manganese, nickel, nitrogen, copper, chromium, molybdenum, silicon, niobium, vanadium, titanium, aluminum, and boron; reducing the slab to form plate in one or more passes in a temperature range in which austenite recrystallizes; finish rolling the plate in one or more passes in a temperature range below the austenite recrystallization temperature and above the Ar,transformation temperature; quenching the finish rolled plate to a suitable Quench Stop Temperature (QST); stopping the quenching; and either, for a period of time, holding the plate substantially isothermally at the QST or slow-cooling the plate before air cooling, or simply air cooling the plate to ambient temperature.

Ultra-high strength ausaged steels with excellent cryogenic temperature toughness and method of making thereof

An ultra-high strength, weldable, low alloy, triple phase steel with excellent cryogenic temperature toughness in the base plate and in the heat affected zone (HAZ) when welded, having a tensile strength greater than about 830 MPa (120 ksi) and a microstructure comprising a ferrite phase, a second phase of predominantly lath martensite and lower bainite, and a retained austenite phase, is prepared by heating a steel slab comprising iron and specified weight percentages of some or all of the additives carbon, manganese, nickel, nitrogen, copper, chromium, molybdenum, silicon, niobium, vanadium, titanium, aluminum, and boron; reducing the slab to form plate in one or more passes in a temperature range in which austenite recrystallizes; further reducing the plate in one or more passes in a temperature range below the austenite recrystallization temperature and above the Ar.sub.3 transformation temperature; finish rolling the plate between the Ar.sub.3 transformation temperature and the Ar.sub.1 transformation temperature; quenching the finish rolled plate to a suitable Quench Stop Temperature (QST); and stopping the quenching.

Ultra-high strength triple phase steels with excellent cryogenic

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Basking Ridge, NJ, United States of America

Raghavan Ayer