Innovative Laser Cladding System for Internal and External Ni Coating of OCTG as a Cost-Effective Alternative to Solid Ni Alloys

Abstract Laser cladding of corrosion-resistant alloys (CRAs) onto carbon steel is widely accepted as a cost-effective alternative to solid CRA components, meeting standards like NACE MR0175/ISO 15156. However, its use in oil country tubular goods (OCTG) has been limited by the technical challenge of accessing and uniformly coating long, narrow internal diameters. To solve this, a compact robotic system was developed, enabling precision laser cladding inside OCTG over 10 meters long and with IDs under 300 mm. An integrated AI-enabled inspection robot ensures defect-free coatings and strict quality control. Full-length P110 and N80 tubulars were successfully cladded with Inconel 625 on both inner and outer surfaces. Corrosion tests under simulated field conditions showed performance equivalent to solid Inconel 625, but at only one-third of the cost. Field deployments in energy storage projects confirmed excellent corrosion resistance, technical reliability, and significant cost savings. Beyond oil and gas, this robotic cladding technology offers transformative potential in midstream and downstream applications, as well as in aerospace, chemical processing, and medical devices—where high-performance, reliable cladding in confined geometries is critical.