Disintegrable Downhole Articles with Energetic Material
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Solution Overview
Problem
Downhole wellbore articles require rapid disintegration after completing their service function to facilitate quicker well recovery, but existing materials with slow corrosion rates are not suitable for rapid disintegration.
Innovation Solution
Development of disintegrable downhole articles comprising an electrolytically degradable metallic matrix and an energetic material, where a first metal reacts with a second metal to generate an alloy, intermetallic compound, or heat when electrically actuated, allowing for controlled rapid disintegration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If articles are formed with slow corrosion rate to maintain mechanical strength during service, then structural integrity is improved, but disintegration speed deteriorates
Solution Approach 1:
The article is segmented into two functional components: a structural matrix material that provides mechanical strength during service, and an energetic material dispersed within it that enables rapid disintegration when activated. This segmentation allows each component to specialize in one function without compromise.
Solution Approach 2:
The energetic material is pre-dispersed throughout the matrix during manufacturing, preparing the structure for rapid disintegration before activation. The reactive components are positioned in advance but remain dormant until electrical activation triggers the exothermic reaction.
2Productivity
If articles are designed for rapid disintegration to facilitate well recovery, then productivity is improved, but mechanical strength during service deteriorates
Solution Approach 1:
Different regions of the article have different properties: the matrix material provides structural integrity in service, while the dispersed energetic material zones are prepared for rapid reaction. The local quality of each component is optimized for its specific function.
Solution Approach 2:
The article transitions from a stable state during service to a rapid disintegration state when activated. The energetic material undergoes parameter changes through exothermic reactions, generating heat and gas that rapidly alter the structural parameters of the entire article.
3Adaptability or versatility
If articles require limited service life for well operations, then adaptability is improved, but reliability deteriorates
Solution Approach 1:
The article transitions from a static, stable structure during service to a dynamic, rapidly disintegrating structure when activated. The system is designed to be stable during operations but capable of rapid change when the electrical trigger is applied.
Solution Approach 2:
The energetic material acts as an intermediary between the electrical activation signal and the mechanical disintegration process. It converts electrical energy into thermal and mechanical energy that drives the rapid breakdown of the matrix structure.
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
Enables the articles to maintain mechanical strength during service and rapidly disintegrate upon electrical activation, facilitating efficient well recovery and production.
Implementation Method 1
the first metal and the second metal being selected such that the first metal reacts with the second metal to generate an alloy, an intermetallic compound, heat, or a combination comprising at least one of the foregoing when electrically actuated
Implementation Method 2
an electrolytically degradable metallic matrix
Data Source
AI summary
A disintegrable downhole article comprises an electrolytically degradable metallic matrix and an energetic material comprising a first metal and a second metal that is in physical contact with the first metal. The first metal and the second metal are selected such that the first metal reacts with the second metal to generate an alloy, an intermetallic compound, heat, or a combination comprising at least one of the foregoing when electrically actuated. A method of controllably removing a disintegrable downhole article comprises disposing the downhole article in a downhole environment; performing a downhole operation; electrically actuating the energetic material; and disintegrating the downhole article.