Composite Particles for Controlled Corrosion Rate in 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 by corrosion in downhole environments.
Innovation Solution
A composite particle with a core, a shielding layer, an interlayer region, and a metallic layer, where the reactivity of each layer is carefully managed to achieve a controlled corrosion rate, allowing for the formation of articles that can corrode at a specific rate in aqueous solutions, such as a 3 wt % KCl solution at 200° F, enabling their removal by corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If alloy composition is adjusted to control corrosion rate, then corrosion rate can be controlled, but multiple batches of alloy must be prepared requiring high batch-to-batch reproducibility and precise control of metal additives
Solution Approach 1:
The alloy is segmented into a base metal matrix (magnesium) and discrete particulate reinforcements (corrodible metal particles). This segmentation allows the base metal to provide structural integrity while the particulate phase controls corrosion rate, eliminating the need for precise compositional control of trace additives in traditional alloys.
Solution Approach 2:
A composite material system is employed where corrodible metal particles (such as zinc, aluminum, or their alloys) are dispersed within a magnesium matrix. The corrosion rate is controlled by the composition and morphology of the particulate phase rather than by trace alloying elements, simplifying manufacturing while maintaining reliable corrosion control.
2Ease of operation
If corrodible materials are used for downhole articles, then physical removal is not needed, but the articles must remain in the hole for extended periods
Solution Approach 1:
The corrosion rate is made dynamically adjustable through the composite structure. By controlling the composition, size distribution, and morphology of the corrodible metal particles within the magnesium matrix, the corrosion rate can be tuned to match the required service duration, allowing articles to remain functional for extended periods and then be removed by corrosion on demand.
Solution Approach 2:
The corrosion parameters are changed by modifying the particulate phase characteristics rather than the base metal composition. Variables such as particle size, particle composition, and volume fraction of corrodible particles can be adjusted to achieve desired corrosion rates, enabling precise control over service life while maintaining ease of removal.
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 particles achieve a controlled corrosion rate of 0.1 to 450 mg/cm2/hour, allowing for precise control over the corrosion process, enabling the articles to perform functions like blocking pressure and then being removed by corrosion, thus addressing the need for improved corrosion control in downhole applications.
Implementation Method 1
a composite particle having 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
Implementation Method 2
the composite particles have a corrosion rate of about 0.1 to about 450 mg/cm2/hour using an aqueous 3 wt % KCl solution at 200° F.
Data Source
AI summary
A composite particle comprises a core, a shielding layer deposited on the core, and further comprises 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, wherein the composite particles have a corrosion rate of about 0.1 to about 450 mg/cm2/hour using an aqueous 3 wt % KCl solution at 200° F. An article comprises composite particles, wherein has a corrosion rates of about 0.1 to about 450 mg/cm2/hour using an aqueous 3 wt % KCl solution at 200° F.