Preparation and Performance Study of Plunger Reinforcement Layer Based on Composite Anode Jet Electrodeposition Technology

Sucker rod pump plungers operating in environments with high sand content, high water content, and highly corrosive media are prone to severe wear and corrosion, resulting in significantly increased failure rates. Traditional strengthening methods, such as ion implantation, thermal spraying, and chemical plating, can partially improve the surface performance of plungers but still face notable limitations, including insufficient coating toughness, limited corrosion resistance, and significant environmental pollution during processing. These drawbacks make it challenging to meet the demands of complex working conditions. Therefore, the development of high-performance plunger reinforcement layer technologies is critical. This study proposes a novel plunger reinforcement layer preparation method based on composite anode jet electrodeposition technology. By incorporating MoS₂ nanoparticles, the comprehensive performance of the reinforcement layer is significantly enhanced. Results show that at a concentration of 6 g/L, the reinforcement layer exhibits optimal performance, with a substantial reduction in friction coefficient and enhanced corrosion resistance. Compared to traditional thermal-sprayed plungers, the prepared reinforcement layer reduces the friction coefficient by 53.3% under normal load conditions (100 MPa) and by 26.7% under high-stress conditions (800 MPa) in wear tests. Additionally, the corrosion weight loss rate in corrosion tests is reduced by approximately 22.2%. These findings demonstrate the superior performance of the prepared reinforcement layer. This study provides a new approach for the development of high-performance plunger reinforcement layers and offers significant potential for improving the operational reliability of sucker rod pumps in challenging environments.