Advanced ceramics and coatings for erosion‐related applications in mineral and oil and gas production: A technical review

Abstract

The applications of advanced ceramics, composites and coatings in mineral, mining, fuel production, and processing are reviewed. The materials include oxide and non‐oxide ceramics (specifically SiC‐based), ceramic–ceramic, and ceramic–metal composites, coatings on metallic components where functional application properties can be achieved. Some principles of materials selection, specifically for erosion wear and corrosion applications, and manufacturing are considered. The examples of the successful development and processing of ceramics, coatings, and composites with manageable structures and phase compositions, in the erosion‐related applications, particularly conducted by the author, are discussed and reviewed. Specifically, industrially employed types of ceramics and processing routes were focused on the considered applications. Particular demands for advanced materials with high reliability and complex shapes or for protective coatings on complex shape steel components and long tubing with inner surface protection require novel and optimized processing. The factors affecting erosion and erosion–corrosion resistance and the paths for the erosion resistance enhancement of ceramic and coating materials are considered. Ceramic components design, technology, and installation features are reviewed.

Numerical analysis of a protective coating for mining industry feed chute

“…Wolfe et al [14] highlighted the fact that ceramic coatings provide a durable protective barrier for underlying substrates, surpassing many alternative film barrier materials such as polymers, metals, and glasses in terms of performance and effectiveness. Medvedovski [5] adds that ceramic coatings exhibit superior hardness compared to the particles they encounter during processing, making them a preferred choice for wear applications in comparison to stainless steel protective skin. Additionally, the cracks that may form in ceramic coatings tend to be minimal due to the dominance of fracture toughness and brittleness, factors that contribute significantly to crack propagation and erosion resistance.…”

Enamel (glassy) coatings for steel protection against high temperature corrosion

“…Although the C contents in steels are desired to be lower for enamel production, as mentioned above, the obtained results indicated that the satisfactory enamel surface quality may be attained for different grades of steels significantly expanding technology application. Since the corrosion resistance is basically higher when the ceramic surface has fewer defects and irregularities, which strongly depend on the processing features [37][38][39][40], the proposed routes of the steel surface preparation should promote enamel corrosion resistance.…”

Effect of ferrous, nickel, and tungsten fillers reinforcement on glass fiber reinforced vinyl ester/polyester composites

“…They are immensely dense, making them identical for applications requiring higher radiation shielding and temperature resistance. 44,45 All the above metal-based micro-particles can enhance composite materials' physical, mechanical, and thermal characteristics, along with incremented impact resistance. The novelty of this investigation presents a significant development in the sector of polymer composites, as it studies the influences of tungsten, nickel, and ferrous microparticles as reinforcement in glass fabric reinforced polyester and vinyl-ester hybrid composites.…”

“…On the other hand, the tungsten micro‐particles possess higher melting points. They are immensely dense, making them identical for applications requiring higher radiation shielding and temperature resistance 44,45 . All the above metal‐based micro‐particles can enhance composite materials' physical, mechanical, and thermal characteristics, along with incremented impact resistance.…”