Enhancing wear and corrosion resistance of electroless Ni-P coatings in CO2-saturated NaCl solution through polytetrafluoroethylene incorporation.

In the realm of oil and natural gas, material durability is compromised by sand particle abrasion, corrosive media, and hydrogen-induced cracking. This study investigates the impact of PTFE on wear and corrosion resistance of Ni-P coatings in a CO 2 environment. Hydrogen barrier properties of the substrate, Ni-P, and PTFE are evaluated using the Devanathan-Stachursky cell. Results show that incorporating PTFE enhances the coating's wear and corrosion resistance, and hydrogen barrier performance compared to substrate and Ni-P alone. The coating effectively hinders corrosive media transmission. A comprehensive analysis of the Ni-P-PTFE corrosion mechanism is provided, along with a robust corrosion model. • Examined the influence of varied PTFE levels on morphology and wear traits of chemically deposited Ni-P coatings. PTFE's innate hydrophobicity reduces grain size. A minor PTFE addition enhances hardness via dispersion strengthening. Simultaneously, PTFE's self-lubrication reduces direct material-wear debris contact, bolstering wear resistance. • Examined PTFE's hydrogen barrier in the petroleum sector. PTFE notably fortified hydrogen resistance, curbing coating's hydrogen-induced cracking susceptibility. This, ascribed to enhanced coating integrity, curtails hydrogen ingress, thus minimizing cracking. • Conducted an extensive study on Ni-P-PTFE coating's corrosion resistance in CO2-saturation. PTFE improved surface integrity, functioning as a corrosion inhibitor via stable C-F bonds. The "maze effect" by PTFE and Ni-P thwarted corrosive media. • An in-depth analysis of the corrosion mechanism of Ni-P-PTFE in a saturated CO2 environment yielded a robust corrosion model, offering a thorough elucidation of the excellent CO2 saturation corrosion resistance of Ni-P-PTFE coatings. [ABSTRACT FROM AUTHOR]