Development of an Anti-Corrosion Thermally Sprayed Coating System for Oil and Gas Transmission Pipeline

Corrosion, a leading cause of failure in metallic transmission pipelines, significantly impacts the reliability and safety of metallic pipelines. To prevent and mitigate pipeline corrosion, various non-metallic coatings and assessment methods have been implemented with different coating techniques. However, reliable, cost-effective, and environmental friendly corrosion mitigation approaches are yet needed to be achieved. Thermal metallic sprayed coatings have shown to be an effective means for pipeline corrosion prevention in marine environments with low cost, but it is not yet studied for on-shore buried and cased crossing pipelines. In this project, innovative composite self-sensing thermal sprayed coatings are proposed to prevent, monitor, mitigate, and manage pipeline corrosion for on-shore buried metallic transmission pipelines. This project focuses on developing the metallic corrosion resistant coating with thermal spray techniques. The compositions, mechanical properties, corrosion resistance, and effectiveness of composite thermal sprayed coatings have been investigated and studies theoretically, numerically, and experimentally at mechanical engineering department, NDSU, Fargo, ND.US DOT Pipeline and Hazardous Materials Safety Administration (PHMSA