In demanding industrial environments, large components often face extreme wear, corrosion, and abrasion. Traditional coatings frequently fall short when applied to oversized parts or those with intricate geometries. At DuraTech, we specialize in advanced electroless nickel composite coatings that deliver consistent, long-lasting protection where it matters most.
Electroless nickel plating is a chemical (autocatalytic) process that deposits a uniform nickel-phosphorus layer without electrical current, ideal for even coverage on complex shapes. At DuraTech, we enhance this with silicon carbide (SiC) composite particles or a composite of diamond particles to create our proprietary Durabide® coating (also known as NiCarb or Ni-Carb). These hard particles are suspended uniformly throughout the nickel matrix, providing superior abrasion and wear resistance.
Uniform Coating for Wear Resistance
What truly sets DuraTech apart is our expertise in achieving even particle distribution and consistent coating thickness across very large parts (up to 40 feet in length) and those with complex geometries. This uniform dispersion ensures equal wear protection over the entire surface, eliminating weak spots that cause premature failure. Maintaining this level of consistency is especially difficult on oversized or intricately shaped components, yet it is a core strength of our process.
Metal Plating the Mud Gas Separators
A prime example is our work on 30’ separators, which are high-performance packer-less downhole tools that have been engineered for rod-pumped wells. Mud gas separators or “gasbuster” use tight clearances to accelerate multiphase flow velocities before fluid, solid and gas mixtures enter a large annular area where they are separated into distinct components. DuraTech Processing uses our Durabide electroless nickel plating chemicals to coat the inside dimensions and OD of these units, which include tight fittings around multiple connection points. Wide variations in the coating thickness or particle density could lead to uneven corrosion or wear and ultimately early failure. DuraTech’s electroless nickel composite process delivers flawless, uniform SiC distribution across the entire unit dramatically extending service life and reducing costly downtime.
Metal Coating With Corrosion Resistance Plus SiC
By combining electroless nickel’s inherent corrosion resistance with the extreme hardness of embedded carbide or diamond particles, DuraTech helps customers maximize equipment reliability and minimize maintenance expenses.
If your operation involves large or geometrically complex components that demand reliable wear protection, contact DuraTech today to discover how our composite electroless nickel solutions can extend the life of your critical equipment.
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