Innovative Alloy Design for Acid Stimulation Applications: From Lab to Field Validation, Combining High-Temperature Corrosion Testing and AI-Enhanced Corrosion Predictions

The oil and gas sector encounterssignificant material problems during acid stimulation, particularly under high temperatures, high pressures, and corrosive conditions with CO2 and H2S. This study focused on corrosion and erosion failures of tungsten carbide jetting nozzles in coiled tubing bottom hole assemblies. While tungsten carbide is durable, its high price, restricted machinability, and scarcity necessitate the search for viable alternatives. This study sought to identify and validate a low-cost, readily available, and easily machinable alloy with equivalent performance. A rigorous material selection approach took into account thermochemical stability, mechanical strength, and corrosion resistance under simulated downhole circumstances. Candidate alloys, both coated and uncoated, were subjected to extensive laboratory testing, including acid compatibility, high-temperature corrosion, erosion resistance, and mechanical integrity assessments. The majority failed due to pitting or surface deterioration. However, one coated alloy system was very resistant to chemical and thermal damage. To support long-term performance, a machine learning model relying on Gradient Boosting was created to forecast corrosion behavior using operational factors; demonstrating effective prediction characteristics compared with four other models. This AI-powered tool allows for accurate prediction of corrosion risks and aids decision-making by determining whether the material will maintain integrity under harsh acidic conditions. Field tests proved the selected alloy’s durability and jetting efficiency during many acid stimulation cycles. The corrosion and wear performance of coated 4145 material demonstrates a validated, cost-effective alternative to tungsten carbide with only four times lower corrosion resistance than carbide, outperforming other alloy combinations with up to 35 times higher corrosion rates. These results reveal tremendous opportunities for improving material design in corrosive energy applications.