Dissolvable Tool Manufacturing via Liquid-Solid Molding
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Solution Overview
Problem
Current methods for manufacturing dissolvable tools for oil and gas wells lack increased manufacturing capacity and reduced material costs, and do not offer adjustable and uniform dissolution rates.
Innovation Solution
A liquid-solid state molding method involving a molten metallic matrix material with secondary particles dispersed homogeneously, forming micro- or nano-sized galvanic cells in the dissolvable article, allowing for adjustable corrosion rates and uniform dissolution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manufacturing methods are used for dissolvable tools, then material cost and manufacturing complexity are high, but manufacturing capacity is limited and dissolution rate control is poor
Solution Approach 1:
The invention changes the manufacturing parameters by using a liquid-solid mixture state during molding, allowing the metallic matrix material to be in liquid form mixed with solid secondary particles. This enables better flow and filling characteristics during molding, increasing manufacturing capacity while maintaining control over the final product properties including dissolution rate
Solution Approach 2:
The invention creates a composite material system consisting of a metallic matrix material combined with secondary particles (such as ceramic particles, oxides, or other metals). This composite structure allows optimization of both manufacturing properties and dissolution characteristics, as the secondary particles can control corrosion rate while the metallic matrix provides structural integrity during manufacturing
2Manufacturing precision
If dissolvable tools are made with uniform composition, then material cost is reduced, but dissolution rate uniformity is poor
Solution Approach 1:
The invention applies local quality by distributing secondary particles throughout the metallic matrix to create localized galvanic cells at specific positions within the material. This non-uniform distribution at the micro-scale (with secondary particles typically 1-100 micrometers in size) creates controlled local corrosion sites that collectively provide uniform overall dissolution, while the simple mixing process keeps material costs low
3Volume of moving object
If tool size is increased for larger well applications, then manufacturing capacity is improved, but dissolution rate control becomes difficult
Solution Approach 1:
The liquid-solid molding process allows large tools to be manufactured in a single operation or in modular sections that can be assembled. The liquid state of the metallic matrix during molding ensures complete filling of large mold cavities, and the uniform distribution of secondary particles throughout the large volume ensures consistent dissolution characteristics across the entire tool, regardless of size
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 method enables the production of dissolvable tools with nearly unlimited size, reduced material costs, and adjustable dissolution rates, enhancing manufacturing capacity and tool performance.
Implementation Method 1
the secondary particles and the metallic matrix material form a plurality of micro- or nano-sized galvanic cells in the dissolvable article
Implementation Method 2
such tools or components may be formed of a corrodible material so that they need not be physically removed by, for example, a mechanical operation, but may instead corrode or dissolve under downhole conditions
Implementation Method 3
forming a liquid-solid mixture comprising secondary particles homogeneously dispersed in a molten metallic matrix material; molding the liquid-solid mixture under agitation to form a dissolvable article
Implementation Method 4
a metallic matrix comprising a plurality of grains formed from a metallic matrix material; the grains having a size of about 5 microns to about 300 microns
Data Source
AI summary
A method of manufacturing a dissolvable article comprises forming a liquid-solid mixture comprising secondary particles homogeneously dispersed in a molten metallic matrix material; disposing the liquid-solid mixture in a mold; agitating the liquid-solid mixture in the mold; and molding the liquid-solid mixture under agitation to form a dissolvable article, wherein the secondary particles and the metallic matrix material form a plurality of micro- or nano-sized galvanic cells in the dissolvable article.