Downhole Tool Inserts with Segmented Hard-Soft Material Structure
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Solution Overview
Problem
Current downhole drilling slips with tungsten carbide or similar materials for slip inserts are difficult to remove and often damage drilling bits, with remnants often left in the borehole.
Innovation Solution
Development of hollow inserts with a hard and brittle material, featuring a soft material core and a hard material shell, allowing effective biting into the casing while being easily removable and buoyant in downhole fluids, reducing milling time and bit wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If tungsten carbide or difficult-to-remove materials are used for slip inserts, then the inserts can effectively bite into the casing and anchor tools, but the inserts become very difficult to remove by drilling or milling operations
Solution Approach 1:
The insert is divided into two distinct materials: a hard outer material for biting and a soft inner material for easy removal. This segmentation allows each portion to have optimized properties for its specific function - the hard outer material provides biting effectiveness while the soft inner material enables easy removal by drilling or milling operations.
Solution Approach 2:
Different portions of the insert have different material properties tailored to their specific functions. The outer portion uses hard material (tungsten carbide, ceramic, or hard steel) for effective biting into the casing, while the inner portion uses soft material (low carbon steel or aluminum alloy) for easy removal. This local quality differentiation resolves the contradiction between needing hard material for anchoring and soft material for removal.
2Strength
If hard materials like tungsten carbide are used for slip inserts, then the inserts can effectively anchor tools in the borehole, but the milling or drilling operations become damaging to the bits used
Solution Approach 1:
The insert is segmented into hard outer material for anchoring and soft inner material for removal. This segmentation ensures that only the necessary outer layer provides the hard anchoring surface, while the soft inner core protects the drilling bit during removal operations by being easier to mill or drill through, thereby reducing bit damage.
Solution Approach 2:
The outer surface of the insert has hard material properties for effective anchoring, while the inner portion has soft material properties for easy removal. This local quality differentiation reduces the harmful effect on drilling bits during removal operations, as the soft inner material is much easier to mill or drill through compared to solid tungsten carbide.
3Strength
If traditional solid inserts are used, then the inserts provide sufficient structural strength for anchoring, but the inserts take the longest time to mill or drill and remain in the borehole after milling
Solution Approach 1:
The insert is segmented into hard outer material for structural integrity and soft inner material for rapid removal. The soft inner material allows drilling or milling operations to proceed much faster since it is easier to remove, significantly reducing the time spent on well cleanup operations while the hard outer material maintains the necessary structural integrity for anchoring.
Solution Approach 2:
The outer portion of the insert has hard material properties for maintaining structural integrity during anchoring, while the inner portion has soft material properties that enable rapid removal by drilling or milling. This local quality differentiation directly addresses the time loss issue by making the removal process much faster while preserving the anchoring functionality.
4Strength
If hard materials are used for slip inserts, then the inserts can effectively bite into the casing, but the inserts are very difficult to fish out after milling operations
Solution Approach 1:
The insert is segmented into hard outer material for biting effectiveness and soft inner material for easy retrieval. After milling operations, the soft inner material can be easily fished out using standard well cleanup tools, while the hard outer material maintains its biting effectiveness for anchoring. This segmentation directly improves retrievability compared to solid hard inserts.
Solution Approach 2:
The outer surface maintains hard material properties for effective biting into the casing, while the inner portion has soft material properties that make it easy to fish out after milling operations. This local quality differentiation resolves the contradiction between needing hard material for anchoring and soft material for easy retrieval.
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 inserts effectively anchor tools, reduce milling time, extend bit life, and facilitate easy retrieval by becoming buoyant and removable with downhole fluids, minimizing material left in the borehole.
Implementation Method 1
the hollow inserts have a bulk density that is less than the density of the downhole fluids. Once other parts of the tools are milled or disintegrated, the inserts become afloat in the downhole fluids. Accordingly the hollow inserts can be carried back to the surface by the downhole fluids
Data Source
AI summary
An anchor member comprises a substrate; and at least one insert secured to the substrate and extending outwardly from an outer surface of the substrate. The insert is configured for engagement with another member. In an embodiment, the insert comprises a shell at least partially defining an empty core. Alternatively, the insert comprises an inner portion and an outer portion disposed on the inner portion; the inner portion comprising a soft material which comprises one or more of the following: a low carbon steel or an aluminum alloy; and the outer portion comprising the soft material and a hard material and having a gradient in the weight ratio of the soft material to the hard material, the hard material comprising one or more of the following: an intermetallic compound; a ceramic; a hard steel; or a titanium alloy.