Tribological Characterization of an Epoxy Composite Coating for Enhanced Wear Resistance in Oil Well Casing Applications

The tribological performance of a novel nonmetallic composite casing coating is investigated under dry wear conditions and different side loads and rotational speeds. The coating is composed of a short-glass-fiber-reinforced epoxy matrix with silicon carbide, aluminum oxide, and calcium carbonate nanofillers to provide a protective barrier against contact with hardened drill pipe tool joints. The results revealed that the wear behavior was highly dependent on the applied side load and rotational speed. Under high-load conditions, the formation of a compacted tribofilm significantly reduced the coefficient of friction and specific wear factor by limiting direct surface contact. Lower rotational speeds and moderate side loads resulted in adhesive wear with formation of stable tribofilms that mitigated material loss.