Degradable Tool Galvanic Carrier Manufacturing

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current methods for manufacturing degradable tools for oil and gas wells struggle to achieve uniform degradation rates, as heavy disintegration agents tend to precipitate in molten matrix materials, making uniform distribution challenging.

Innovation Solution

The method involves forming composite particles with a carrier and disintegration agent, where the disintegration agent is coated or embedded on the carrier, and the composite particles are dispersed in a metallic matrix material, allowing for uniform distribution and the formation of galvanic cells to control degradation rates.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If heavy disintegration agents are added to molten matrix materials, then degradation function is achieved, but uniform distribution becomes difficult due to precipitation

Engineering Contradiction:

Improvedegradation functionVSAvoiduniform distribution

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent applies composite materials by combining the disintegration agent with a carrier material to form composite particles. This composite structure allows the heavy disintegration agent to be distributed uniformly throughout the molten matrix material via the carrier, preventing precipitation while maintaining the degradation function. The composite particles act as a unified material system that overcomes the density mismatch issue.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The carrier material serves as an intermediary between the heavy disintegration agent and the molten matrix material. By attaching the disintegration agent to the carrier, the system uses the carrier as a mediator to achieve uniform distribution. The carrier facilitates the dispersion of the disintegration agent throughout the matrix material, preventing direct precipitation while ensuring the degradation function is achieved.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If disintegration agents are dispersed in metallic matrix material, then degradation capability is provided, but control over degradation rate becomes difficult

Engineering Contradiction:

Improvedegradation capabilityVSAvoidcontrol over degradation rate

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent applies parameter changes by modifying the physical and chemical properties of the composite particles, including their density, size, and composition. By adjusting these parameters, the patent achieves both uniform distribution and controlled degradation rates. The ability to tune particle parameters allows for precise control over how the disintegration agent releases and degrades the matrix material.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent applies local quality by creating composite particles with specific local properties that differ from the bulk matrix material. The disintegration agent is concentrated in specific locations within the composite particles, allowing for localized degradation control. This enables different regions of the matrix material to degrade at different rates, providing overall control over the degradation process.

Inventive Principle:

Principle #3Local quality

3Manufacturing precision

If uniform distribution of disintegration agents is achieved, then uniform degradation rates are obtained, but manufacturing complexity increases

Engineering Contradiction:

Improveuniform degradation ratesVSAvoidmanufacturing process

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by pre-forming the composite particles before adding them to the molten matrix material. This preliminary preparation ensures that the disintegration agent is already attached to the carrier in a controlled manner, facilitating uniform distribution upon addition to the matrix. This pre-preparation step simplifies the overall manufacturing process while achieving uniform degradation rates.

Inventive Principle:

Principle #10Preliminary action

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

This approach enables the production of degradable articles with controlled and uniform degradation rates, ensuring effective corrosion and dissolution, suitable for various downhole tools and components.

Implementation Method 1

the disintegration agent forms a plurality of galvanic cells with the metallic matrix material, or the carrier, or a combination thereof, in the degradable article

Methodology Applied

Scientific EffectGalvanic cells: Battery (electricity)

Implementation Method 2

the disintegration agent forms a plurality of galvanic cells in the article with the metallic matrix material, the carrier, or a combination thereof

Methodology Applied

Scientific EffectGalvanic corrosion: Crevice Corrosion

Data Source

PatentUS10016810B2Methods of manufacturing degradable tools using a galvanic carrier and tools manufactured thereof

Publication Date: 2018.07.10 BAKER HUGHES CO

AI summary

A method of manufacturing a degradable article comprises: forming a mixture comprising composite particles dispersed in a metallic matrix material; the composite particles comprising a carrier and a disintegration agent coated on the carrier or embedded in the carrier, or a combination thereof and having a density that is about 0.2 to about 2.5 equivalents to that of the metallic matrix material when measured under the same testing conditions; and molding or casting the mixture to form a degradable article. The disintegration agent forms a plurality of galvanic cells with the metallic matrix material, or the carrier, or a combination thereof, in the degradable article.