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This work aims to explore the effect of side load and rotational speed on the tribological behavior of a novel ceramic-epoxy composite in Kevlar matrix casing lining that is in contact with a rotating drillpipe tool joint (DP-TJ) coated with the same composite. Three rotational speeds (65, 115, and 154 rpm) and three side loads (500, 700, and 1000 N) were considered under water-based mud (WBM) lubrication. Wear depths, volumes, and specific casing wear rates (K) were determined for each combination of speed and load. The wear depth and K were found to increase with an increasing applied side load. However, the specific casing wear rate at the rotational speed of 115 rpm was found to be the lowest among the three speeds. This is mainly due to a probable lubrication regime change from boundary lubrication at 65 rpm to hydrodynamic lubrication with a thick lubricant film at 115 rpm. The digital microscope images were used to determine the wear mechanism, showing that at low speeds, the main mechanism was abrasive wear, but the increase in the speed brought about more adhesive wear. In contrast, the change in the side load does not affect the wear mechanism of the casing. Scanning electron microscopy and energy-dispersive spectroscopy (EDS) were used to analyze the surface and composition of the novel material before and after the wear tests.
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In this work, friction stir processing using a pinless tool with a featured shoulder was performed to alter the surface properties of Al 6061-O, focusing on the effect of tool traverse speed on surface properties, i.e., microstructure, hardness, and corrosion resistance. All processed samples showed refinement in grain size, microhardness, and corrosion resistance compared to the base material. Increasing tool-traverse speed marginally refined the microstructure, but produced a significant reduction in microhardness. Electrochemical impedance spectroscopy, linear polarization resistance, and potentiodynamic polarization were used to evaluate the effect of the processing conditions on corrosion behavior in a saline environment. All corrosion test results are found to agree and were supported with pictures of corroded samples captured using a field emission scanning electron microscope. A remarkable reduction in the corrosion rate was obtained with increasing traverse speed. At the highest traverse speed, the corrosion current density dropped by approximately 600 times when compared with that of the base alloy according to potentiodynamic polarization results. This is mainly due to the grain refinement produced by the friction stir process.
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To understand and quantify casing wear during drilling operations, an experimental setup with real drill pipe joints (DPJ) and casings was designed and used to carry out wear tests, simulating various operating conditions and environments. P110 steel casing samples were tested under dry and wet conditions. Actual field oil- and water-based fluids were utilized to lubricate the contact area at two different side loads (1000 N and 1400 N) and DPJ speeds (115 and 207 rpm). The results show that for the same testing conditions, the casing wear volume and wear factor under water-based lubrication were more than twice those obtained under oil-based fluid testing. As expected, the wear volume and wear factor were highest under dry conditions. Moreover, it was noticed that, as the normal load was increased at a constant rotational speed (rpm), the wear factor increased. On the other hand, raising the rotational speed at the same applied load reduced the casing wear factor, due to the observed absence of adhesive wear and possible localized softening effects at higher speeds. SEM analyses of the worn areas showed that under dry conditions, the main wear mechanisms were abrasion and delamination. However, both adhesive wear and abrasive wear mechanisms were observed under oil-based lubrication. The energy dispersive spectroscopy (EDS) analysis of the worn surface revealed that at higher loads and speeds, a heavy transfer of particles from the oil-based lubricant took place. On the other hand, some contaminants of the water-based lubricant were observed on the worn surfaces.
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Epoxy clay nanocomposites have been proven to have improved mechanical, thermal and physical properties over pristine matrix. Thus, the fields of application of epoxy-clay nanocomposites along with their hybrid glass/carbon fibre reinforced composites have grown tremendously during the last few decades. The present review paper covers the research work performed on epoxy clay nanocomposites. It includes the influence of the processing techniques and parameters on the morphology of the nanocomposite, the methods of characterization and the effects of adding nanoclay on the mechanical and physical properties of composite. The improvements in the liquid barrier properties brought about by the addition of nanoclay platelets to epoxy resin are discussed. The variation of physical and mechanical properties with nanoclay type and content are reviewed along with the effects of moisture uptake on these properties. The advances in the development, characterization and applications of hybrid glass fibre reinforced epoxy-clay nanocomposites are discussed. Findings of the research work on the influence of nanoclay addition and exposure to water laden atmospheres on the behaviour of the hybrid glass fibre epoxy-nanoclay composites are presented. Finally, the potential health and environmental issues related to nanomaterials and their hybrid composites are reviewed.
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Friction stir processing (FSP) technology has received reasonable attention in the past two decades to process a wide range of materials such as aluminum, magnesium, titanium, steel, and superalloys. Due to its thermomechanical processing nature, FSP is used to alter grain structure and enhance mechanical and corrosion behavior in a wide range of steels. The refinement in grains and phase transformations achieved in steel after FSP affects hardness, tensile properties, fracture toughness, fatigue crack propagation rate, wear resistance, and corrosion resistance. A number of review papers are available on friction stir welding (FSW) or FSP of nonferrous alloys. In this article, a comprehensive literature review on the FSP/FSW of different types of steels is summarized. Specifically, the influence of friction stir processing parameters such as advancing speed, rotational speed, tool material, etc., on steels' performance is discussed along with assessment methodologies and recommendations.
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Owing to recent climate changes, dust storms are increasingly common, particularly in the Middle East region. Dust accumulation and subsequent mud formation on solid surfaces in humid environments typically have adverse effects on surface properties such as optical transmittance, surface texture, and microhardness. This is usually because the mud, which contains alkaline and ionic species, adheres strongly to the surface, often through chemical bonds, and is therefore difficult to remove. In this study, environmental dust and the after-effects of mud formed on a polycarbonate sheet, which is commonly used as a protective glass in photovoltaic cells. Ionic compounds (OH(-)) are shown to significantly affect the optical, mechanical, and textural characteristics of the polycarbonate surface, and to increase the adhesion work required to remove the dry mud from the polycarbonate surface upon drying. Such ability to modify characteristics of the polycarbonate surface could address the dust/mud-related limitations of superhydrophobic surfaces.