Composite Particle Corrosion Control for Downhole Articles

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Solution Overview

Problem

There is a need for controlling the corrosion rate of magnesium alloys used in downhole articles without requiring fine adjustments to the alloy composition, and with improved corrosion control, to facilitate their removal after downhole operations.

Innovation Solution

A composite particle with a multilayer structure comprising a magnesium or magnesium alloy core coated with a shielding layer, an intermetallic phase, and a noble metal layer, along with an adhesive metal layer, which allows for adjustment of the corrosion rate by varying the composition and thickness of these layers, enabling controlled corrosion in downhole environments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If alloy composition is adjusted to control corrosion rate, then corrosion rate can be controlled, but manufacturing complexity increases due to need for multiple batches and precise control of metal additives

Engineering Contradiction:

Improvecorrosion rate controlVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The alloy is segmented into a base metal matrix and discrete second metal particles. This segmentation allows the second metal to be added as pre-formed particles rather than requiring precise control of trace additives during alloying, simplifying the manufacturing process while maintaining corrosion control.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The second metal particles are prepared in advance as separate entities with controlled size and composition, then incorporated into the base metal matrix. This preliminary preparation eliminates the need for precise control of trace additives during the alloying process itself, reducing manufacturing complexity.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If trace contaminants are added to magnesium alloy to increase corrosion rate, then corrosion rate increases, but batch-to-batch reproducibility becomes difficult to achieve

Engineering Contradiction:

Improvecorrosion rateVSAvoidbatch-to-batch reproducibility

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

Instead of adding trace contaminants as微量 additives during alloying, the invention uses discrete second metal particles (0.1-10 micrometers) that are incorporated into the base metal matrix. This segmentation provides a measurable and controllable amount of second metal, improving batch-to-batch reproducibility while maintaining consistent corrosion enhancement.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The chemical approach of adding trace metal additives is replaced with a physical approach of incorporating pre-formed metal particles. This substitution allows for better control and measurement of the second metal content, improving reproducibility across batches.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of operation

If downhole articles are made of corrodible material, then mechanical retrieval is unnecessary, but control over corrosion timing and rate becomes less precise

Engineering Contradiction:

Improveremoval facilitationVSAvoidcorrosion rate control

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The downhole article has non-uniform corrosion susceptibility due to the distributed second metal particles within the base metal matrix. This creates localized galvanic cells that can be controlled to provide consistent corrosion rates, combining the ease of corrodible material removal with improved corrosion control.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The invention creates a composite material consisting of base metal matrix with dispersed second metal particles. This composite structure provides both the corrodible nature needed for easy removal and the controlled corrosion rate through the galvanic interaction between the two metals.

Inventive Principle:

Principle #40Composite materials

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The composite particle achieves a controlled corrosion rate, allowing for precise adjustment of the corrosion process, ensuring effective removal of downhole articles without the need for mechanical retrieval, while maintaining structural integrity and reproducibility.

Implementation Method 1

a composite particle with a multilayer structure comprising a magnesium or magnesium alloy core coated with a shielding layer, an intermetallic phase, and a noble metal layer

Methodology Applied

Scientific EffectGalvanic corrosion: Electrolysis

Data Source

PatentEP2737108B1Method of controlling the corrosion rate of alloy particles, alloy particle with controlled corrosion rate, and articles comprising the particle

Publication Date: 2019.08.21 BAKER HUGHES CO

Figure 1A~1B
Figure 2A~2B
Figure 3

AI summary

A composite particle comprises a core, a shielding layer deposited on the core, and further comprising an interlayer region formed at an interface of the shielding layer and the core, the interlayer region having a reactivity less than that of the core, and the shielding layer having a reactivity less than that of the interlayer region, a metallic layer not identical to the shielding layer and deposited on the shielding layer, the metallic layer having a reactivity less than that of the core, and optionally, an adhesion metal layer deposited on the metallic layer.