Patent ID: 7632323

Claim:
A downhole tool element having an abrasion resistant coating for use within an abrasive environment, said abrasion resistant coating comprising: a substrate consisting of a portion of the downhole tool element; a multiphase wear surface coating containing about 40%-60% Tungsten Carbide (WC) by volume in contact with the portion of the downhole tool element and provides as an interface between the portion of the downhole tool element and the abrasive environment, said multiphase wear surface coating having a brittle fracture stress limit; and wherein said multiphase wear surface coating has a conditioned surface finish with a surface roughness (Ra) below a critical surface roughness (Ra) of approximately 1 micrometer (μm), said surface roughness (Ra) selected to reduce the contact stress at the interface of the multiphase wear surface coating and the abrasive environment to below the brittle fracture stress limit of the multiphase wear surface coating.