In the relentless quest to enhance the durability and efficiency of industrial components, a groundbreaking study has emerged from the labs of A. H. S. Bueno, shedding light on the potential of Diamond-Like Carbon (DLC) coatings to revolutionize the energy sector. Published in the esteemed journal ‘Materials Research’ (Pesquisa de Materiais), this research delves into the performance of hydrogenated and silicon DLC coatings deposited on carbon steel, offering a glimpse into the future of corrosion and erosion resistance.
The energy industry is no stranger to the challenges posed by harsh operating conditions. From offshore drilling to pipeline transportation, the internal surfaces of components are constantly battered by high-velocity, sand-laden fluids, leading to erosion and corrosion. Traditional coatings, while effective, often come with environmental drawbacks, particularly those involving electroplating. This is where DLC coatings step in, offering a more eco-friendly alternative without compromising on performance.
Bueno and the research team focused on evaluating the erosion and electrochemical corrosion resistance of DLC coatings deposited using Plasma-Enhanced Chemical Vapour Deposition (PECVD) on carbon steel. The experiments simulated the harsh conditions found in multiphase equipment flow, with saline solutions and varying velocities and sand concentrations. The results were striking. “For all impingement velocities, the silicon DLC (Si-DLC) exhibited lower mass loss,” Bueno explained. This enhanced resistance was attributed to the improved ductility of the surface layer and the formation of an effective corrosion barrier, which significantly reduced pitting corrosion and suppressed the anodic reaction.
The implications for the energy sector are profound. By enhancing the integrity of components against erosion-corrosion, these coatings can lead to improved efficiency and prolonged lifetime, translating to substantial cost savings and reduced environmental impact. “The generation of an effective corrosion barrier is crucial in suppressing the anodic reaction, which is a key factor in corrosion processes,” Bueno added, highlighting the potential of Si-DLC coatings in mitigating corrosion-related failures.
As the energy sector continues to push the boundaries of exploration and production, the demand for robust, long-lasting materials will only intensify. This research, published in ‘Materials Research’ (Pesquisa de Materiais), not only provides a viable solution to current challenges but also paves the way for future developments in the field. With further optimization and scaling, DLC coatings could become the go-to choice for protecting critical components in the energy industry, ensuring they stand the test of time and the harshest conditions. The future of corrosion and erosion resistance is here, and it’s diamond-like in its potential.