Session: 03-02-03: Applied Innovations in Solid-State Processes and Surface Engineering: Technologies for Advanced and Sustainable Manufacturing III

Paper Number: 163954

Effect of Surface Texturing on Electrostatic PEEK Coatings of SPHC for Improved Wear Resistance 

The wear resistance of metal components is essential for their durability and functionality, particularly in harsh operating conditions where surface deterioration may result in early failure. Materials that can sustain high mechanical stress despite compromising structural integrity are demanded by the oil and gas sector. High-performance thermoplastic Polyetheretherketone (PEEK) has drawn a lot of interest because of its exceptional tribological qualities, chemical resistance, and thermal stability. PEEK provides a viable way to improve the wear resistance of metal substrates as a coating material. This preliminary study examines how surface texturing affects the wear resistance of PEEK coatings applied to SPHC (Steel Plate Hot Rolled Commercial) solid body centralizers, aiming to enhance their durability in oil and gas well construction.

This research contributes to the field of surface engineering by optimizing the electrostatic powder coating process for PEEK, focusing on enhancing the wear resistance and adhesion properties of coated metal substrates. The study provides valuable insights into the role of surface texturing in achieving a uniform, well-adhered, and high-performance PEEK coating. The findings can be instrumental in industries where surface wear is a primary concern, offering a practical approach to improving component reliability and reducing maintenance costs. By refining the coating methodology, this research helps bridge the gap between polymer-based protective coatings and their industrial applications, enabling the widespread adoption of wear-resistant polymer coatings for metal substrates.

To evaluate the influence of substrate surface preparation on coating performance, four different surface preparation techniques—polishing, grinding, sandblasting, and shot blasting—were used. The surface morphology of the prepared substrates was analyzed using optical profilometry to quantify roughness variations and correlate them with coating adhesion and wear behavior. A High-Load-High-Temperature Tribometer was used to perform wear tests, simulating real-world operating conditions and assessing the tribological performance of the coated surfaces.

Preliminary findings indicate that the surface roughness of the substrate significantly affects the wear resistance and adhesion strength of PEEK coatings. Proper surface preparation substantially improves the coating's adhesion to the metal substrate, with specific wear rates of 3.9 x 10-6 mm3/Nm, 6.8 x 10-6 mm3/Nm, and 9.8 x 10-6 mm3/Nm recorded at surface roughness levels of 12.67 µm, 4.3 µm, and 0.71 µm, respectively.

By optimizing the PEEK coating process, this research advances the development of wear-resistant polymer coatings, providing a reliable and sustainable solution for extending the lifespan of SPHC Solid body centralizers. In Future studies, focus will be to systematically analyze this process by conducting full Design of Experiments using Taguchi methodology.

Presenting Author: Muhammad Yasin King Fahd University of Petroleum and Minerals

Presenting Author Biography: Muhammad Yasin is a dedicated Production Engineer in the oil and gas manufacturing industry, with expertise in polymer coating, sheet metal works, CNC machining, and gravity casting. With five years of industry experience, he has successfully contributed to optimizing manufacturing processes, ensuring high-quality production, and implementing advanced engineering solutions.
Muhammad Yasin is currently pursuing a Master of Science in Mechanical Engineering at King Fahd University of Petroleum and Minerals (KFUPM), specializing in Materials and Manufacturing. He is committed to leveraging his academic and industrial experience to drive technological advancements and efficiency improvements in manufacturing.

Authors:

Muhammad Yasin King Fahd University of Petroleum and Minerals
Amal Ameen Seenath King Fahd University of Petroleum and Minerals
Syed Sohail Akhtar King Fahd University of Petroleum and Minerals
Abdul Samad Mohammed King Fahd University of Petroleum and Minerals
Tehmoore Khan EIMP by enpro