Wear characteristics of zirconia-toughened epoxy/Kevlar-honeycomb composite lining for drilling casing
Y. Fouad,
N. Merah,
M.A. Azeem,
Z. Gasem,
A. Alqutub,
A.A. Aleid,
O. Osman,
A. Shaarawi,
A. Aljohar
Affiliations
Y. Fouad
Department of Mechanical Engineering, King Fahd University of Petroleum and Minerals, Dhahran, 31261, Saudi Arabia
N. Merah
Department of Mechanical Engineering, King Fahd University of Petroleum and Minerals, Dhahran, 31261, Saudi Arabia; Interdisciplinary Research Center for Advanced Materials, King Fahd University of Petroleum and Minerals, Dhahran, 31261, Saudi Arabia; Corresponding author. Department of Mechanical Engineering, King Fahd University of Petroleum and Minerals, Dhahran, 31261, Saudi Arabia.
M.A. Azeem
Department of Mechanical Engineering, King Fahd University of Petroleum and Minerals, Dhahran, 31261, Saudi Arabia
Z. Gasem
Department of Mechanical Engineering, King Fahd University of Petroleum and Minerals, Dhahran, 31261, Saudi Arabia; Interdisciplinary Research Center for Advanced Materials, King Fahd University of Petroleum and Minerals, Dhahran, 31261, Saudi Arabia
A. Alqutub
Department of Mechanical Engineering, King Fahd University of Petroleum and Minerals, Dhahran, 31261, Saudi Arabia; Interdisciplinary Research Center for Advanced Materials, King Fahd University of Petroleum and Minerals, Dhahran, 31261, Saudi Arabia
A.A. Aleid
Department of Mechanical Engineering, King Fahd University of Petroleum and Minerals, Dhahran, 31261, Saudi Arabia
O. Osman
Department of Mechanical Engineering, King Fahd University of Petroleum and Minerals, Dhahran, 31261, Saudi Arabia
A. Shaarawi
Drilling Technology Team, EXPEC Advanced Research Center, Saudi Aramco, Dhahran, 31261, Saudi Arabia
A. Aljohar
Drilling Technology Team, EXPEC Advanced Research Center, Saudi Aramco, Dhahran, 31261, Saudi Arabia
Casing wear is a persistent issue in oil and gas drilling facilities that call for innovative more wear-resistant materials to mitigate casing failures. The present work examines the tribological performance of a novel composite lining comprised of Kevlar honeycomb in a matrix of epoxy reinforced with Zirconia particles against hardband drillpipe tooljoint (DP-TJ). Three side loads (1000, 1200, and 1400 N) and three DP-TJ speeds (0.43, 0.76, and 1.02 m/s) were considered under dry sliding conditions. The results showed that the specific wear rate (K) increased with speed at all side loads. However, K value was found to reach a maximum, reaching 20.3*10−8 MPa−1 at 1200 N before dropping to about 8.5*10−8 MPa−1 when the load is increased to 1400 N. This decline in specific wear rate at the load of 1400 N was attributed to the growth of a double transfer layer through the alignment of zirconia particles in the lining. The scanning electron microscope (SEM) images of worn surfaces revealed that higher K values are associated with more adhesion, delamination, and fiber breakage. Energy dispersive spectroscopy (EDS) and X-ray diffraction (XRD) analysis of the worn surface and the debris collected after the wear test reveals minimal wear of DP-TJ. The epoxy/Kevlar-honeycomb composite lining demonstrated appreciable wear resistance even under dry sliding conditions.
