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High-Performance Metal Solutions in Corrosion Resistant Alloys for the Oil and Gas Industry

Friday, January 8, 2021

Get Tough on Downtime with Corrosion Resistant Alloys to Cut Maintenance Costs

The oil and gas industry is currently facing unprecedented global challenges that require resilient and cost-effective metal solutions that perform without failure in hostile subsea, downhole, and onshore environments. The demand for premium quality, corrosion resistant exotic alloy metals that operate in increasingly demanding environments is therefore higher than ever across the globe.

Enter AMETEK Specialty Metal Products (SMP), a company, consisting of five specialist metal manufacturers, that has worked in the global oil and gas arena for over 50 years. AMETEK SMP’s wide breadth of products offer customers valuable flexibility and are tailor-made to exact requirements. The high-performance metal solutions are engineered for optimum toughness, hardness, and strength – delivering exceptional pressure, corrosion, and wear resistance in extreme working conditions.

Extended Operational Life

Being able to rely on premium quality, corrosion resistant products from a company like AMETEK SMP gives the oil and gas sector a key advantage. Reduced downtime and maintenance costs mean that energy companies can continue to deliver vital functions across critical infrastructure industries in the face of worldwide challenges to health, safety, and productivity. AMETEK SMP’s businesses have years of advanced metallurgical expertise and engineering capabilities, which allows them to create products with higher strength alloys, offering longer life and enhanced performance.

AMETEK SMP benefits hugely from the combined expertise of its five businesses: AMETEK Eighty Four, Hamilton Precision Metals, Fine Tubes, Superior Tube and AMETEK Wallingford. Together, these businesses manufacture specialist metal products for some of the oil and gas industry’s most demanding, complex, and critical applications.

According to Nicholas Head, AMETEK SMP’s Oil and Gas Market Manager: “As a leading manufacturer of exotic metals, we really hold a unique market position in offering the full spectrum of specialty metal products. Our expertise in processing higher corrosion resistant alloys delivers longer term and more cost-effective solutions than the industry standard.”

Exotic Alloy, “Fit and Forget” Tubes up to 60,000 psi

 

Precision metal tubing products are engineered to offer high corrosion and pressure resistance up to 60,000 psi. High quality seamless and welded tubes are manufactured in sizes ranging from 3mm to 31mm outer diameter for optimum versatility and choice.

Fine Tubes, based in Plymouth, UK, specializes in manufacturing high performance tubing in a range of exotic grades, including stainless steel 904L and NORSOK-approved 6 Moly; as well as super duplex and high-quality nickel alloys, including grades 825 and 625. The tubes offer an excellent product life, reduced downtimes and reduced costs for re-fitting traditional corroded products, making them ideal for applications that demand long in-service life in hostile environments.

Critical applications include downhole hydraulic control lines, high pressure control and instrumentation and pressure housings, among others.

Hardfacing and Thermal Spray Powders for Coatings

Hardfacing and Thermal Spray Powders for Coatings

AMETEK’s metal powder plant in Eighty Four, PA, produces many different powders for thermal spray surface coating applications. Metal powder is manufactured through an advanced water atomization process that enables the business to offer high levels of customization. The powder is engineered to have desirable thermal spraying characteristics that produce high quality coatings, enhancing the performance of the component being coated.

The powders are used in coatings that increase the hardness, wear, abrasion, and/or corrosion resistance of the surface to extend a product’s lifespan and offer total component cost savings. High performance alloys used include Ni-Cr-Si-Fe-B family products, Ni-based corrosion alloys, and Co-based wear alloys that offer a wide variety of hardness levels and machinability. These products are highly sought-after for several deposition techniques, both with and without carbide reinforcement.

These products are commonly used for valving, pump components, corrosion protection, and flow path wear mitigation. Each alloy used is designed to allow for maximum density of the coating.

Exotic Spinodal Alloys for Superior Strength

Spinodal alloys are highly specialized and possess excellent corrosion resistance. They benefit from age hardening techniques that further increase their strength and hardness while offering superior mechanical and physical properties in comparison to conventional high-performance alloys. These exceptional properties are advantageous for demanding oil and gas and drilling applications where performance is critical. Spinodal alloys offer a non-sparking and non-magnetic alternative to Beryllium containing materials with similar mechanical and electrical properties.

AMETEK SMP Wallingford has developed a small family of highly specialized spinodal alloys, Pfinodal® (C72900) copper alloy and AM-388™ (UNS C72650). These grades are manufactured using sophisticated wrought powder metallurgy and are engineered into multiple product forms of Strip, Wire, and Machined Components.

Hardenable Spinodal Strip via Wrought Powder Metallurgy

Hardenable Spinodal Strip via Wrought Powder Metallurgy

Pfinodal® strip can be age hardened with a heat treatment to ensure the high hardness required for deep hole penetration applications. The heat treatment produces superior mechanical properties up to 195 ksi ultimate tensile strength (1344 MPa) and 410 Hardness (VHN). Critical applications include electronic connectors and parabolic cone shaped charges for the perforation of oil and gas well liners.

AM-388™ strip can be also be age hardened up to 155 ksi ultimate tensile strength (1068 MPa) and 380 Hardness (VHN). AMETEK SMP engineers a range of age hardenable, non-magnetic, non-conductive alloys that reach conductivities of 14-15 per cent AICS. Applications include strip for non-sparking tools and electronic connectors.

Both of these hardenable strip products can be roll-tempered to meet highly precise mechanical properties.

High Hardness Pfinodal® Shaped Components for Demanding Drill Bit Applications

High Hardness Pfinodal¬ Shaped Components for Demanding Drill Bit Applications

AMETEK SMP has led the industry in the production of Pfinodal® shaped components with specific physical properties that are advantageous for tri-cone drill bits in demanding rock bit bearing applications.

The production processes and heat treatments employed at the specialist plant, based in Wallingford, PA, combine to ensure the high hardness and non-magnetic properties required in bearing material for bearing sleeves, bushings, washers and caps. The low distortion of Pfinodal® during hardening allows for the complex forming of parts and shapes prior to heat treatment without the need for costly fixtures.

Customers around the world turn to AMETEK SMP to significantly extend their drill bit life with this performance enhancing material.

Highly Conductive Nickel Strip for Battery Connectors

Highly Conductive Nickel Strip for Battery Connectors

Other strip products include nickel 200, 201, and 270 for rechargeable battery collectors and connectors available with the highest conductivity of commercially available nickel products.

The metallurgists at AMETEK SMP employ a wrought powder metallurgy process that produces 99.97% minimum purity nickel and delivers 15-20 percent higher conductivity than traditional cast nickel strip connectors. This higher conductivity results in a greater transmission of battery power.

Corrosion Resistant Clad Plate

Roll bonded clad plate is a multi-layer plate composed of two or more different materials called base metal (usually carbon steel or low alloy steel) and a higher alloy cladding metal, such as stainless steel, nickel alloys, or titanium. The clad plate combines higher strength and better thermal conductivity of lower cost base material with the corrosion resistance of higher cost cladding material.

This high-quality composite plate is engineered to meet critical standards in pressure vessels, autoclaves, and similar applications where corrosion, pressure resistance, and structural performance are key. Other applications include chemical processing chambers, transition joints, refining, flue gas desulfurization, and catalytic cracking.

Quality, Safety and Longevity First

AMETEK SMP, together with its five specialist businesses, places a high priority on the quality, safety, and longevity of its metal products’ critical working life. Its high-performance materials are manufactured within strict quality standards from state-of-the-art engineering facilities that ensure extended operational life in critical oil and gas applications.