Extensive development has been made in the field of wear evaluation of hardfacing materials for downhole applications. These improvements have been industry driven to optimize drilling operations and reduce cost. Previous testing methods such as DEA-42 presented multiple hardware and process deficiencies which recorded results which were inaccurate, unreliable and not repeatable. An evolution of both hardware and processes for hardfacing material testing was developed over a 36-month period through laboratory testing and data evaluation.

This new methodology has been applied to the evaluation of hardfacing materials in both open and cased hole environments. Not only does it provide more reliable data, it also provides the flexibility to test different fluids, casing grades and varying open hole media. Actual material properties such as friction factors and wear rates have been successfully and accurately measured. It has also been used to identify break-in periods for different hardfacing materials.

The methodology has demonstrated repeatable and accurate results for wear characteristics for hardfacing materials under various conditions. Multiple hardfacing materials have been evaluated and their performance compared through this methodology. This methodology greatly surpasses previously established and outdated industry standards. This methodology was employed to engineer and develop a fourth-generation casing friendly hardfacing material currently in service.

This novel approach provides reliable wear characteristics data for available hardfacing materials. It provides a benchmark for industry evaluation of hardfacing materials previously not available in the industry. The use of this technology will aid in the development, selection, and performance evaluation of hardfacing materials for modern and complex well programs. It will improve downhole drilling performance by providing better selection of hardfacing materials.

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