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

Heliyon (Sep 2024)

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

Journal volume & issue: Vol. 10, no. 17
p. e37333

Abstract

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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.

Published in Heliyon

ISSN: 2405-8440 (Online)
Publisher: Elsevier
Country of publisher: United Kingdom
LCC subjects: Science: Science (General); Social Sciences: Social sciences (General)
Website: https://www.cell.com/heliyon/home

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