ITSA Annual Meeting

ITSA 2nd Annual Advanced Coatings Symposium (Oil & Gas) & Annual Membership Meeting

October 9-11, 2018
The Woodlands Resort, The Woodlands, Texas

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The International Thermal Spray Association (ITSA) annual meeting remains the premier event for the thermal spray community. Our annual membership meetings provide a mutually rewarding experience for all attendees – both business and personal.

This year join the International Thermal Spray Association in conjunction with the American Welding Society for the 2nd Annual Advanced Coatings Symposium.

  • Advanced Thermal Spray Coatings
  • Tungsten Carbide-Based Overlays
  • Diffused Coating Technology
  • Innovative Materials and Processes
  • and Much more
Network with industry leaders as they deliver the latest coatings research related to oil and gas.

Venue

The Woodlands Resort
2301 North Millbend Drive
The Woodlands, TX 77380

Hotel Reservation Link

ITSA Sponsorship Opportunities

Diamond Sponsorship – $5,000 (Member)   $5,500 (Non-Member)

  • One Full Page 4-color ad in sponsored conference brochure
  • One 1-color logo on drink napkins during lunch
  • One 4-color digital logo on conference website with hyperlink
  • Company logo in sponsored conference brochure
  • Recognition on sponsor “Thank You” sign prominently displayed at event
  • Opportunity to distribute company’s product literature to all attendees
  • One Complimentary attendee registration
  • One Complimentary tabletop exhibit

Gold Sponsorship – $4,000 (Member)   $4,500 (Non-Member)

  • One Full Page 4-color ad in sponsored conference brochure
  • One 4-color digital logo on conference website with hyperlink
  • Company logo in sponsored conference brochure
  • Recognition on sponsor “Thank You” sign prominently displayed at event
  • Opportunity to distribute company’s product literature to all attendees
  • One Complimentary attendee registration
  • One Complimentary tabletop exhibit

Silver Sponsorship – $3,000 (Member)   $3,500 (Non-Member)

  • 1/2 Page 4-color ad in sponsored conference brochure
  • One 4-color digital logo on conference website with hyperlink
  • Company logo in sponsored conference brochure
  • Recognition on sponsor “Thank You” sign prominently displayed at event
  • One Complimentary attendee registration
  • One Complimentary tabletop exhibit

Bronze Sponsorship – $2,000 (Member)   $2,500 (Non-Member)

  • 1/4 Page 4-color ad in sponsored conference brochure
  • One 4-color digital logo on conference website with hyperlink
  • Company logo in sponsored conference brochure
  • Recognition on sponsor “Thank You” sign prominently displayed at event
  • One Complimentary attendee registration

Hospitality Suite Sponsorship (2 1 available)- $3,500 each

  • Company logo on tables
  • Company logo on cocktail napkins and cups
  • Acknowledgement during the evening as the sponsor(s) of the event
  • Company name and logo on signage at the Hospitality Suite
  • Recognition as sponsor on “Thank You” signage at event and Final Program
  • Company name and link displayed included on all promotional e-mails

Bags Sponsorship (Exclusive) – $1,500

Benefits include:

  • Company logo on tote bag* given to each attendee. Production is not included
  • Opportunity to provide a giveaway item* in each bag
  • Company recognition on “Thank You” signage at the conference
  • Company in the Final Program
  • Company name and link displayed on conference “Welcome” Web page and included on all promotional emails

Registration Sponsorship (Exclusive) – $800

  • Opportunity to provide a giveaway item* to each attendee at the registration desk
  • Company logo on one easel sign by the registration desk
  • Company logo on each Attendee’s Name Badge
  • Company recognition on “Thank You” signage at the conference
  • Company recognition in the Final Program (confirmation by September 15, 2018)

*Sponsor responsible for providing giveaway item. Giveaway item must be approved by AWS. Sponsor may choose to ship giveaway item to AWS HQ by October 1, 2018, or sponsor can bring item to conference for distribution.

Luncheon – $1,500 (Limit of 2)

Benefits include:

  • Company recognition on onsite signage displayed at the luncheon, including table tents and an easel sign
  • Opportunity to distribute promotional giveaway or flyer during luncheon. Sponsor is responsible for provided item. Item must be approved by AWS
  • Company recognition on “Thank You” signage at the conference
  • Company in the Final Program
  • Company name and link displayed on conference “Welcome” Web page and included on all promotional emails

* Sponsor is responsible for provided item/flyer distributed during lunch. Item must be approved by AWS.

For more information please contact Alfred Nieves at 1-800-443-9353 Ext. 467 or itsa@thermalspray.org

Diamond Sponsorship

Superior Shot Peening & Coatings International

Gold Sponsorship

Praxair

TechMet

Silver Sponsorship

Alloy Coating Supply
Ardleigh Minerals Incorporated
Hoganas

Reception Sponsorship

Curtiss-Wright Surface Technologies
Hayden Corp.
Polymet

Hospitality Sponsor

Cincinnati Thermal Spray

Show Exhibitors

  • Alloy Coating Supply
  • Ardleigh Minerals Incorporated
  • Blue Sky
  • Dewal Industries Inc.
  • Fusion, Inc.
  • Hoganas
  • Oseir
  • Polymet
  • Praxair
  • Superior Shot Peening & Coatings International
  • TechMet
  • Uniquecoat Technologies

Exhibitors

Tabletop Exhibit – $1,500

    • One 4-color digital logo on conference website
    • Opportunity to distribute company’s product literature to all attendees

Conference Times

Monday, October 8

  • Registration Opens   6 − 8 PM
  • Exhibitor Set Up   6 − 8 PM

Tuesday, October 9

  • Registration Open   7 − 8 AM
  • Attendee Breakfast   7 − 8 AM
  • Exhibit Hours   7:30 AM − 5 PM
  • Technical Sessions   8 AM − 4:45 PM
  • Attendee Lunch   12 − 1 PM
  • Reception   5:30 − 7:30 PM

Wednesday, October 10

  • Attendee Breakfast   7:30 − 8:30 AM
  • Exhibit Hours   8 AM − 12 PM
  • Technical Sessions   8:30 − 11:45 AM
  • Attendee Lunch   11:45 AM − 12:45 PM
  • Tour (Superior Shot Peening)   1 PM
  • Hospitality Suite Happy Hour   5:30 − 7:30 PM

Thursday, October 11

  • ITSA Annual Membership Meeting   8:30 − 10:30 AM
  • ITSA Social Event (TBD)   11 AM

Technical Program

  Tuesday, October 9, 2018
 8:00 am Welcome
 8:15 am

Keynote Address: Addressing Wear in Upstream Oil & Gas: Current Trends & Future Prospects for Thermal Spray Coatings
Krutibas Panda
Krutibas Panda - HalliburtonKrutibas Panda is currently a Technical Advisor with Halliburton – Sperry Drilling Services located in Houston. He has been serving his current job for the past 9 years and in the present capacity he oversees Sperry Drilling’s Materials needs. Prior to joining Halliburton, he spent about 5 years with Sandvik Mining and Construction (USA) and a brief stint with Tata Motors (India) as a Materials Engineer. He is an executive member of ASM International and a member of NACE International. Krutibas Panda is the author and contributing author of more than 20 technical papers, research publications, and patents. His publications have appeared in leading materials journals like Acta Materialia, Computational Materials Science, Metallurgical and Materials Transactions & Journal of Materials. He received his Master of Science degree as well as his Ph.D. degree in Metallurgical Engineering from the University of Utah.

Wear of upstream components are a significant life limiting factor that impact product reliability and product performance. Upstream Oil & Gas components undergo many different modes of wear and hence utilize a range of options engineered to address specific wear modes. This presentation will provide an overview of wear solutions employed in the industry with the help of specific examples. Thermal spray coatings offer a unique solution to address wear in upstream oil & gas. The process encompasses a range of technologies, provides relatively thick coatings with reasonably good interfacial strength at relatively low temperatures. The materials used are highly customizable to address wear issues in addition to providing beneficial effect in terms of corrosion resistance and impact resistance properties. The presentation will include a few successful case studies to highlight the unique advantages thermal spray coatings have to offer. Ongoing developments in the thermal spray coatings, such as small ID HVOF (High velocity Oxy Fuel) and HVAF have broadened the application window for such coatings and a few examples of that will be highlighted. However, there are application areas where thermal spray coating, in its current offering, is inadequate. The presentation will highlight a few examples to emphasize future development needs and prospects for these interesting classes of coatings to be able to truly address the demanding functional requirements under very harsh down-hole conditions.

 8:45 am

Recent Coating Advancements to Meet Oil & Gas Industry Goals for Improved Equipment Performance
Dr. Daming Wang, Praxair Surface Technologies, Inc.
Bio – Dr. Daming Wang is a Director of R&D Thermal Processes at Praxair Surface Technologies in Indianapolis, Indiana. He has worked in the thermal spray industry for 28 years. He has worked for Praxair since 1999 in variety of roles including R&D, productivity, business development and management. He has a Doctorate degree from Cranfield University, UK in the field of Materials Engineering.

The oil & gas industry equipment suppliers must continue to advance technology and prolong component life to create more value for their customers. In recent years, we have been developing solutions to (1) combat fluid leakage on components under high pressure high temperature conditions, (2) improve machinery operating efficiency and/or cost by reducing surface friction, (3) reduce wear and corrosion on inner diameter surfaces, and (4) creating economical wear and corrosion resistant coatings that are REACH compliant. Each solution with be reviewed along with laboratory and field performance data to support the goal of improving equipment performance.

 9:15 am

Ensuring Durability: Testing and Evaluation for Harsh-Service Overlays
Dan Hayden, Hayden Corporation
Bio – Daniel C. Hayden is president of Hayden Corporation, a privately held provider of thermal spray coating and laser cladding services in West Springfield, Massachusetts. Founded in 1919, Hayden Corporation serves the pulp and paper, power generation, oil and gas, military, plastics, pump and valve, steel and other heavy industry markets with overlays that protect and/or restore machine components in harsh service environments. Dan received his BA from Kenyon College, in Gambier, Ohio, and his MBA from the Isenberg School of Management at the University of Massachusetts, Amherst. He is a past chairman of the International Thermal Spray Association, and a member of the American Society of Materials Thermal Spray Society and American Welding Society. He frequently presents on thermal spray and laser cladding applications, and has been published in Welding Journal and Advanced Materials and Processes magazine.

Hard surfacing has been a fundamental component of cap-ex investment protection for decades. As vendor bases expand and globalize, the quality and consistency of surface protection can vary widely. The difference between a high integrity overlay and a substandard one is seldom apparent, and the onus falls upon the consumer to ensure that the protection that has been paid for is the protection that is received. Third party auditing and certification of hard surfacing vendors can remove much of the guesswork from choosing a provider, but the performance of the surface is ultimately up to the customer’s specification, or lack thereof. Several standard coating and overlay tests are commonly used by our industry to characterize surface attributes. Several others are also available that can mimic or reproduce conditions the surface will see in the field. Each, however, will require a quantifiable demarcation between acceptance and rejection. This talk will discuss the availability of these tests, their suitability for use in specifying a surface treatment, and the reasonable criteria for setting quality assurance limits for thermal spray and hardface weld overlay vendors.

 9:45 am Break
 10:00 am

Slurry Applied Tungsten Carbide Hardfacing
Eli Barlow, Intellifuse
Bio – Eli Barlow is currently the Lead Materials Engineer at Innovative Mechanical Solutions in Houston, Texas. He has worked in the hardfacing industry for one year and two years working in environmental compliance for Pratt and Whitney. He obtained a Bachelor of Science and a Master of Science in Materials Science and Engineering from the University of Tennessee in Knoxville, TN.

Components in high wear or high corrosion applications can utilize hardfacing materials increase their longevity and frequency of repair. Traditional means of applying hardfacing materials rely on either flame spray technologies which require direct line-of-sight access to the area, or liquid metal infiltration technologies which require manual application. However, these methods do not allow utilization of hardfacing materials in applications such as conveyance where surfaces can be inaccessible or curvatures or geometric constraints eliminate line-of-sight. The need to apply hardfacing to these areas spurred the development of a slurry applied hardfacing material.

 10:30 am

Advantages and limitations of automation of Thermal Spray
Dan Allford, Arc Specialties
Bio – Daniel Allford has been the President and Owner of ARC Specialties for over 33 years. Dan was an early adopter of industrial robotics and turned his passion into an internationally recognized automation company. Dan holds several patents in the field of welding automation. He has grown ARC Specialties from a one man operation into a 65 person team of engineers and craftsmen. With systems working around the globe ARC is known for Plasma, TIG, MIG, SAW and Resistance welding systems. ARC Specialties was selected as one of the “Best Work Places in Houston” in 2012. Dan has degrees from the University of Houston and Texas State Technical Institute. He is a life member of the American Welding Society. And a member of Society of Manufacturing Engineers, American Society for Metals and Houston Economics Club.

The high velocity oxygen fuel spray process (HVOF) can be used to apply a variety of tungsten carbide coatings with high hardness, high bond strength and low porosity. Coating integrity is very dependent on process variables such as spray distance, torch angle, and travel speed. Manually applied coating quality is very dependent on operator skill and technique.

Advantages

  • Removes the spray operator from the harmful environment of loud noise and toxic dust created by the HVOF process. Typical automated HVOF production cells have sound attenuating spray booths to minimize the sound level the operators are exposed to. Automation allows the spray operator to run and monitor the spray process from outside the spray booth without the need for a respirator and will minimal hearing protection.
  • Maintains optimal spray distance to assure proper powder in flame dwell time- minimizes unmelts and excessive oxides
  • Maintains travel speed- TS coatings should be applied in thin layers to minimize buildup of internal stress. When coatings are applied in excessively thick layers the coating will have shrinkage stress that can cause cracking and dis-bonding at the edges of the coating.
  • Better control of torch positioning. Coatings have high density and less porosity when the torch angle to the substrate being coated is maintained at 90 degrees.
  • Precise control of coating thickness saves process time and reduces the volume of diamond abrasives used during post coat finishing.

Disadvantages

  • High initial investment. Automation adds significant initial cost.
  • Tooling requirement. Parts to be coating must be located in the exact same place every time.
  • Programming time /cost.
 11:00 am

Dimensional Restoration in regards to Wear Coatings incorporating Industry trends and the various methods of repairing components to extend the life in service
Shawn O’Hanlon, Cincinnati Thermal Spray
Bio – Shawn O’Hanlon is General Manager of the Cincinnati Thermal Spray’s Texas Division located in Houston, Texas. He has worked with thermal spray coatings for over 10-years with CTS, including medical, aviation, and industrial applications. He has successfully managed the development of numerous technologies and coatings related to gas turbine, aerospace, industrial and oil & gas components; coatings, repairs and manufacturing.

This presentation focuses on the various underlay and carbide coatings utilized on a variety components within the Oil and Gas market. Providing an in depth look at the most commonly used carbides and their respective undelays that are generating longer wear life with reduced scrap rates by tailoring coatings based on a thorough understanding of individual components’ service environment. This presentation focuses on traditional carbide coatings and their durability incorporating various underlays to both dimensionally restore and protect substrates. Numerous Oil & Gas components are seeing longer life due to advanced repair methods and enhanced coatings formulated by both OEM and Supplier R&D coupled with end-user educational programs. The latest trends in repair and restoration will be evaluated in regards to scrap loss and component life cycles.

 11:30 am

New Developments in HVAF coating equipment and technology
Andrew Verstak, Kermetico
Bio – Andrew A. Verstak is an owner and managing director of Kermetico Inc. (Benicia, CA), a company specializing in design and manufacturing of HVAF and HVAF+HVOF equipment, as well as providing thermal spray coating services for oil and gas, energy and steel industries. He is a graduate of Belarus State Polytechnic University (Minsk, Belarus) with a MS degree in metallurgy.  He received Ph.D. in Material Science from Powder Metallurgy Institute (Minsk, Belarus). Working experience includes 13 years with Powder Metallurgy Institute (Minsk) as engineer then a lab manager, 3 years with Metalspray Inc. (Richmond, VA) as a senior metallurgist. From 1999 till 2005 he worked as a director of UniqueCoat Technologies LLC (Oilville, VA). Dr. Verstak founded Kermetico Inc. in 2006 and is a managing director of this company since that time.

Multiple data confirmed improved quality of HVAF-sprayed WC-coatings as compared to state-of-the art HVOF coatings, resulting in better coating resistance to abrasive wear, cavitation and corrosion. A line of AK HVAF guns of different power is created to address the variety of oil and gas applications with the best efficiency. The hardware allows operation in different modes to balance the coating quality and cost. The Convertible HVAF+HVOF C-guns are introduced to meet existing HVOF specifications, while depositing lower cost coatings utilizing high spray rates of C-guns. Simultaneously new technological windows “in between HVAF and HVOF” processes became available for development of new coatings and materials. The technology for deposition of WC-coatings into small internal diameters (ID) is commercialized. The concept of “Flash Carbide” coating is developed, targeting deposition of high-quality coatings at extremely low cost due to reduction of coating thickness and elimination of the need for dimensional grinding in the process.

 12:00 pm Lunch
 1:00 pm

Combining Thermal Spray Coatings with Heat Treating to Achieve Dense Metallurgically Bonded Coatings for Wear & Corrosion Resistance
Bill Lenling, TST Engineered Coatings
Bio – Bill Lenling is the chief technology officer for TST Engineered Coatings in Sun Prairie, Wisconsin. Bill co-founded TST in 1992.Throughout his career he has identified ripe opportunities to apply standard, or more often cleverly modified thermal spray techniques to provide surface engineering solutions for a number of non-traditional applications. He has several patents and has published many technical publications. Much of his recent work has concentrated on the development of coatings for the oil & gas industry. Bill is a Fellow of ASM, and quite recently, his business development and technical achievements collectively were recognized through his selection to the 2018 class of ASM Thermal Spray Society Hall of Fame inductees.

Metallurgically bonded thermal spray coatings are an important class of protective coatings used in many oil & gas applications. A properly engineered coating and heat-treat process will create coatings with superior adhesion, very low porosity, excellent wear and corrosion resistance, and the ability to withstand plastic deformation without chipping. Known for many years in the thermal spray industry as “spray and fuse technology”, the knowhow has been used with varying degrees of success. This talk will show how this technology can greatly vary in quality, but with robust engineered processes, coatings with unique high-quality structures can be produced repeatably. A variety of coating types will be discussed along with their properties. Oil & gas components that use the technology will also be presented.

 1:30 pm

Wear and corrosion resistant amorphous thermal sprayed coatings
Dr. Evelina Vogli, Liquid Metal Group Holdings, Inc.
Bio – Dr. Evelina Vogli serves as VP of Research and Development of LMGH. She has worked in thermal sprayed coatings and processing for over 15 years. Dr. Vogli obtained her Diplom Engineering Degree in Chemical Engineering from Tirana University (Albania) and received her PhD from the University Erlangen-Nuremberg (Germany) in 2003. Dr. Vogli was awarded the “Private Docent” title in 2011 and received herVenia Legendi in Surface and Coating Technologies, at Dortmund University of Technology (Germany)
.

Amorphous metallic coatings/materials are a new class of metallic materials that have a disordered, non-crystalline, glassy structure, that are created when metals or their alloys are cooled very quickly bypassing crystallization during solidification. Due to their unique microstructure, amorphous alloys combine ultrahigh strength, high hardness and ductility in one single structure. LMC has developed coating compositions that are either fully amorphous or partially amorphous by offering coated surfaces with high wear resistance and low friction. Extensive testing has validated that these coatings have good elasticity, wear resistance and corrosion resistance.

 2:00 pm

Stripping of Coatings – How does acid dissolve metals?
Dave Fairborn, Aeromet
Bio – Dave Fairbourn served six years as a Sergeant in India Company of the 23rd Marines during the Vietnam War.  In 1986 he went to work for GE Aircraft Engines eventually serving until 1997 as a Repair Engineer in Airfoils, responsible for both platinum plating technology and the stripping facilities of ACSC, Springdale Ohio. During this period, GE reimbursed him for six more years full time at the University of Cincinnati. At the university he worked on Analytical Chemistry and Materials Science. He obtained a Masters in Chemistry, but did not publish his thesis in selective platinum deposition for the Doctorate. Instead he sold his stripping technology to Pratt Whitney.  He started Aeromet Technologies, in 1986. Since then his advanced stripping technology has been employed about 50 times worldwide. It has been used for stripping aluminide coatings on airfoils, platinum aluminide coatings, MCrAlY coatings used on IGT Components, the F100 fighter engine for the US Air Force at Tinker AFB, OKC-ALC and lately for fracking augurs in the oil and gas industry. He has installed seven platinum plating systems worldwide, and his small Simple CVD coater technology) in partnership with Meyer Tool Coatings) has been implemented more than 20 times. He has been the author of about 120+ US and Foreign Patents. He is currently trying to retire but is still actively serving his customers, worldwide, as possible. He volunteered to counsel inmates at the Utah State Prison for 9-1/2 years, spending as much as three evenings per week there. He claims to have enjoyed the best life of anyone. His technology is available through Aeromet Technology Solutions in Cleveland, Texas.

A technically rigorous academic explanation for how acids dissolve metal is given in the technical paper. The explanation includes the reaction caused when a category of strong mineral acids are added to water. What follows is a description originally given by Dr. Allen J. Bard (dec.) of the formation of Nernst diffusion layer, and a description of the formation of Werner complexes. This is explained then as to how the metal is dissolved and moved into solution. A description for the driving force based upon tabular values derived from the text Corrosion by Dennis A. Jones is provided. Current improvements and some typical recipes are provided.

 2:30 pm

Overview of Advanced Materials applications of Thermal Spray Coatings and Laser Clad Overlays in O&G Industry
Sunil Musali, FW Gartner Thermal Spraying, Surface Technologies
Bio – Sunil Musali is a Sr. Process engineer at FW Gartner (Curtiss Wright facility in Pearland, TX), he has been with the company since 2009 working with wide array of Thermal spray coating applications. His prior experience includes Flame Spray North America, Greenville, SC, Jet Aviation specialists, Miami and A&A Inc., New Jersey with over 12 years of experience working with Thermal spray coatings development in IGT, O&G, energy, refinery, aerospace etc. He obtained a BS in Mechanical Engineering from Madras University and MS in Materials Engineering from FIU.

Thermal spray coatings and Laser clad overlays have evolved in O&G industry for last 2 decades and there are still a wide range of applications yet to be improved and discovered. Day to day drilling operations in O&G fields pose many challenges to the down-hole drilling and delivery equipment used due to many forms of wear, erosion, fatigue, corrosion etc. Hence opening up tremendous opportunities to utilize surface engineering to improve and increase the life cycle of the OEM equipment, MRO and consumables. Just by increasing life cycle of a consumable parts by 10% would reduce down time and long-term cost savings significantly and thus improving production by many folds. This topic covers some exemplary applications utilizing advance materials and thermal spray and laser cladding processes to enhance performance and extend lifetime of parts used in O&G.

 3:00 pm Break
 3:15 pm

Wear Resistant Weld Overlays with Conventional CTC and Macroline® in Comparison
Oliver Lanz, H.C. Starck Surface Technology and Ceramic Powders GmbH
Bio – Oliver Lanz is Senior Manager Application Engineering at H.C. Starck Surface Technology and Ceramic Powders in Laufenburg, Germany. He is actively working in the fields of hardfacing by welding and thermal spraying by utilizing STC’s Coating Engineering consisting of a well-equipped thermal spray lab, wear testing and metallography. Before he joined H.C. Starck STC, he worked for Deloro Stellite as Senior Engineer R&D in the fields of thermal spraying and PTA welding and has a Diploma Degree in Mechanical Engineering.

Welding technologies such as Plasma Transferred Arc Welding (PTAW) and Laser Cladding can provide highly wear resistant overlays, e.g. for use in abrasive environments. PTA welded and Laser cladded overlays can contain higher volume fractions of homogeneously distributed hard particles, compared to conventional techniques, to combat these challenging wear situations. Cast Tungsten Carbide (CTC) is widely used as the hard phase in combination with a Nickel Self Fluxing (NiSF) as matrix alloy. The composition of these materials can be adjusted to target specific requirements such as hardness, corrosion resistance or toughness. One critical factor often overlooked is the dissolution of the hard phase during the welding process as a result of thermodynamic instability. This investigation compares the abrasive wear resistance of CTC with Ni-, Co- and Fe-base alloys matrices against Macroline® Tungsten Carbide in the same matrices, applied by PTAW and Laser Cladding. The results provide an outlook into potential new solutions for overlays designed to resist abrasive wear. Metallographic investigation of the welded overlays reveals a reaction zone between the Tungsten Carbide and the matrix containing precipitated phases. The analysis of wear scars and precipitated phases using SEM and EDX provide an explanation of the wear behaviour.

 3:45 pm

Kennametal’s Surface Technologies and Materials for the Oil and Gas Market
David Lee, Kennametal Stellite

Kennametal® brand is synonymous with tungsten carbide tooling and other wear resistant products used in wide range of industries. Kennametal Stellite™ and Conforma Clad® products also cover tungsten carbide and other wear and corrosion resistant coating and overlay products applied by variety of processes. This presentation highlights the Conforma Clad®, Utraflex™, Starweld™ and Durastell™ PTA and Jet Kote™ HVOF processes, materials and applications specific to the oil and gas industry.

 4:15 pm

New developments in mud motor rotor coating technology
Kevin Williams, Oerlikon

Bio – Kevin Williams is a member of the Oerlikon Metco global applications management team. Kevin has been a working professional in the coatings industry since 1990 while performing various roles in engineering, operations, and sales. Kevin has developed several trade secret coating processes and is the co-inventor of one patent.

The development of a mud motor rotor coating technology using computational alloy modeling for typical drilling environments including high chlorides that exceeds the value proposition of hard chrome in terms of process costs and tool life. The research investigates current coating failure mechanisms and standard repair practices of hard chrome plating. Novel lower costs alloys are examined with respect to wear properties, simulated mechanical stresses, corrosion rates, process costs, and new repair techniques. Results point to a few promising alloys to perform field testing with industry partners in thru tubing motor rotors, drilling power section rotors, and pcp rotors.

 
  Wednesday, October 11, 2018
 8:30 am

HVAF Applications in the Oil and Gas Industry
Chris Farris, Uniquecoat Technologies LLC
Bio – Chris Farris is the National Sales Manager/Business Development Manager for Uniquecoat Technologies LLC. Prior to coming to Uniquecoat Technologies, he was Materials Manager for the additive manufacturing company Stratasys LTD. He has over thirty years of experience in Business development and Sales. He earned a B.S. Degree in Industrial Technology from Northeastern State University.

For nearly a decade HVAF coatings have been protecting oil and gas equipment against corrosion and erosion. We will examine HVAF technology and corrosion, erosion resistant coatings and applications within the industry. Corrosion and erosion exacts a heavy toll on equipment life cycles and has a huge economic cost. According to NACE, it is estimated that corrosion costs United States industries nearly $170 billion dollars annually. And within the oil and gas industry this estimate is $1.37 billion dollars, $589 million in pipeline surface and facility costs and $463 million in downhole tubing expenses and $320 million in capital expenditures. HVAF coatings of stainless steel and tungsten carbide offer cost effective protections against both corrosion and erosion. In Russia, Canada and the United States HVAF coating applications have proven their mettle (no pun intended) with performance benefits in the fight against corrosion. Coating applications include downhole tools, OD coating downhole tubing, ID coating downhole tubing, pumps, valves, motor housings, mud rotors, bearing blocks. Zero porosity, near zero oxidation, excellent bond strength and hardness makes HVAF coatings an economical and valuable tool in corrosion, erosion and abrasion protection.

 9:00 am Diffusion Coatings Methods and Materials
Brian Frazier, AIM-MRO
Bio – Brian Frazier is a Technical leader in the use of Braze Products and processes for the Restoration of Turbine Engine components.  His principal responsibility is the development of new products, new applications and support of existing materials and customers. Experience in both Aircraft and Land Based turbine engines and the manufacturing processes used to produce engine components.   Brian joined AIMMRO in March 1997 after working 8 years at Cincinnati Thermal Spray, in Cincinnati Ohio.  Prior to this he worked 8 years for GE. Starting at GE in Burlington Vermont on the Manufacturing Management Program and working in both Cleveland Ohio and GE Evendale Ohio Aircraft Engine headquarters.   He has 38 years of experience and expertise in the wide range of manufacturing processing including Coatings, Metallurgy, Machining, Quality, Engineering and Brazing.  The last 10 years concentrating on the repair of Nickel and Cobalt based superalloy components primarily used in the Hot Gas path of the turbine engine.

This presentation examines processes and materials for innovative overlay and diffusion coatings.  The discussion will focus on methods and opportunities for both line of sight and non-line of sight applications. Severe applications where metallurgical bonding of the coating provides needed performance. Drawing on Aerospace and Power Generation applications for materials and processing in the Oil& Gas / Mining and Drilling Industries

 9:30 am

Thermal Spray: Beyond Metallographic Analysis
Rob Leonard, Protech Lab Corp.
Bio – Rob Leonard is currently the General Manager of Protech Lab Corp, based out of Hilton Head Island, South Carolina. Rob has more than 20 years of thermal spray experience, which includes production, process engineering, quality engineering, research & development, failure analysis, and material testing (preparation, evaluation and interpretation). Industries supported are the oil and gas, gas turbine, wind turbine, aircraft engine, military, steam turbine, paper and printing, semiconductor, power and water, automotive, nuclear as well as general industry. Engineering Technology and Specialized Business Management support Rob’s educational background in addition to several accredited certifications, continuing education units and coursework. Rob also contributed to the publication of the 2013 ASM Handbook, Volume 5A, Thermal Spray Technology; Testing of Coatings provided by Protech Lab Corp. and a member of the 2017 Thermal Spray Society’s Panel Session and speaker at The Thermal Spray Characterization: Materials, Coatings and Processes conference and exposition.

Metallographic Analysis of coatings and their processes are a vital step in determining the coating(s) overall structural integrity. In addition, mechanical testing methods are utilized as well in order to gather informative test data, which provides additional information in regards to the coatings overall integrity. A few of the most common mechanical testing processes for the Thermal Spray Industries include but are not limited to Hardness testing (micro & macro), Tensile Adhesion Testing, Erosion Testing, Abrasion Testing. These particular mechanical test methods have important value and can be directly linked to the coatings microstructural data obtained through the analytical perspective. As with the metallographic preparation, mechanical testing preparation is a process that must be treated with the same high level of detail to help ensure optimal testing conditions and test results can be obtained and communicated. Interpretation and correlation of all test data must be defined and documented in order to achieve a better understanding of the coating and the process utilized. We will uncover the best practices and nuances in regards to the interpretation and correlation of the metallographic analysis associated with the mechanical testing methods.

 10:00 am Material Advancements in Coatings for Oil and Gas Industry
Vincent Lawless, TechMet Alloys
Bio – Attended Hallam University in Sheffield, U.K. and obtained a BSc. In Metallurgy and a post-grad. Diploma in Management Studies. Has over 40 years in the metals production and processing industry which has included aspects such as Heat Treatment, Thermal Spray Coatings, Vacuum Brazing used in the Aerospace, Oil & Gas, Semiconductor, Medical, Telecommunication, Automotive, Food processing and Agricultural markets.

The need for wear and corrosion resistant materials developed for applications unique to the Oil and Gas Industrial Segment are available but in many cases are not specified. Standard coating materials, i.e.; WC-10Co-4Cr, WC-Co and CrC-NiCr are very common thermal spray coating materials that are specified for the Oil & Gas industry. This presentation provides suggestions on materials developed specifically for applications found in the Oil and Gas industry. The featured coating materials are Co free and are cost effective wear & corrosion resistance alternatives to the current specified thermal spray coatings, as well as alternative coating materials for chrome plate replacement applications of off shore and down hole components.

 10:30 am Break
 10:45 am

Thermal Spray of Oilfield Down Hole Tubulars for Wear and Corrosion Mitigation
Joe Scott, WhiteHorse Technology, LLC
Bio – Joe Scott graduated LeTourneau College in 1976 with a degree in Welding Engineering. Joe worked for welding filler metal manufacturing companies until 1991 when he started Devasco International to manufacture custom designed welding filler metals. In 2005 he helped start WearSox which is a thermal spray applications company that sprayed centralizer ribs onto oilfield casing. In 2013 they sold that company and Joe started WhiteHorse Technology, which designs and applies thermal spray materials to oilfield products.

Oil field tubulars are used in the drilling and production of oil and gas. Amongst these drill pipe and down hole tools are subject to abrasive wear from cuttings and contact with open hole formations. This a very difficult application as the pipe is subjected to rotational bending, torsion and severe impact with the open hole formations resulting in deflections of the substrate that make it difficult to keep a thermal spray material intact during use. This presentation discusses successful field applications of twin wire arc sprayed coatings to equipment used in the exploration and production of oil and gas wells.

 11:15 am WC/Co/Cr Thermal Spray Powder …Beyond the chemistry
Jean-Marc Tetevuide’, Lineage Alloys
Bio – Graduated from National superior engineer school of industrial ceramic in Limoges France. Interned at Rutgers University in the sol-gel laboratory. Got first involved with tungsten carbide material while interning at Sandvick’s powder metallurgy research center in Grenoble France. After graduation, worked for Technogenia manufacturing spherical tungsten carbide for hardfacing applications then transferred to Houston as a sales engineer supporting technical sales and introducing laser cladding wear protection in the oil drilling industry. Spent 15 years at Durum USA as a sales engineer then managing sales and operations including laser and PTA powder manufacturing, PTA equipment integration and wear coating development. In 2012 started and ran PT-MAT manufacturing integrated robotic PTA systems and tungsten carbide based  consumables for GMAW, PTA, laser and thermal spray.. Development of metal matrix composite coatings with tungsten carbides, diamonds. Currently operation manager for Lineage Alloys a Fisher Barton Company manufacturing thermal spray powders used in aerospace, energy, mining and agriculture industries.

Lineage Alloys manufactures and supplies thermal spray powders with a strong focus on tungsten carbide crushed sintered material. WC/Co/Cr (86/10/4) is a very versatile material and one of the most common tungsten carbide thermal spray powder used to protect components from wear, erosion and corrosion. This presentation aims to recap the different powders commercially available, looking at specifications, raw material, chemistry, sizing, morphology and manufacturing process as well as reporting of those powder properties.  Many studies are still dedicated to the relationship between powder, spray process and coating properties, though as the industry evolves, new spray equipment are coming on line, coatings are subjected to more abuse and economic factors are driving additional requirements. Thermal spray operators have to provide coatings with increase wear of course but also corrosion, erosion, ductility, toughness, as sprayed surface Ra… while balancing consumable pricing, production cost, and additional technical challenges.
 

 11:45 am Lunch
 1:00 pm Tour – Superior Shot Peening
(must register separately for tour)
 

Attendee Pricing

Member Non-Member
Early Bird (before August 1st) $575 $705
Regular $675 $805
Guest $300 $400
Speaker $575 $575
Plant Tour
Superior Shot Peening
$25 $25

Registration includes:

  • Breakfast, Lunch and breaks on 10/9
  • Reception (2 hour open bar) on 10/9
  • Breakfast, Lunch and breaks 0n 10/10
  • Access to hospitality suite (2 hour open bar) on 10/10

Golf Outing

Golf information

Thursday, October 11, 2018

The Woodlands Resort
Course: Panther Trail
www.woodlandsresort.com/activities/golf/panther_trail/

Green Fees:
$97 before 1pm, $65 after 1pm

For more info contact:
Terry Nelson 281.726.4293 or terry.nelson@clubcorp.com

 

Online Registration