Composite Downhole Article With Gradient Corrosion Control
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Solution Overview
Problem
Existing wellbore components and tools require frequent replacement due to limited mechanical strength and corrosion resistance, making conventional removal methods like milling or drilling time-consuming and costly, and degradable materials lack suitable mechanical properties for effective use.
Innovation Solution
A composite downhole article with a corrodible core member and a more corrosion-resistant outer member, featuring a composition or density gradient, allowing for controlled dissolution in wellbore fluids, enabling the article to maintain mechanical integrity during operation and rapid removal when needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If degradable polymers are used to allow easy removal by dissolution, then removal ease is improved, but mechanical strength and fracture toughness deteriorate
Solution Approach 1:
The patent applies composite materials by combining degradable metallic alloys (such as aluminum-based alloys with gallium, indium, bismuth, or tin) with other materials to create a composite structure that maintains both mechanical strength and degradability. The composite nature allows the material to achieve properties that neither component alone could provide, specifically maintaining structural integrity while enabling controlled dissolution.
Solution Approach 2:
The patent utilizes parameter changes by adjusting the composition of metallic alloys through controlled addition of specific elements (gallium, indium, bismuth, tin) in varying proportions. This changes the degradation rate and mechanical properties of the alloy, allowing optimization of both strength and removability parameters simultaneously.
2Strength
If conventional removal methods like milling or drilling are used, then mechanical strength requirements are maintained, but time consumption and cost increase
Solution Approach 1:
The patent replaces mechanical removal methods (milling, drilling) with chemical dissolution methods. By designing components made of degradable metallic alloys, the removal process transitions from mechanical force application to chemical reaction-based dissolution, significantly reducing time and operational complexity while maintaining adequate mechanical strength during service.
Solution Approach 2:
The patent embraces the disposable concept by designing wellbore components with limited service lives that are intentionally made degradable. These components are engineered to perform their function and then be easily removed through dissolution, eliminating the need for complex retrieval operations and reducing overall operational costs despite the components being single-use.
3Ease of operation
If degradable metal alloys are used to enable controlled dissolution, then removal ease is improved, but environmental harm increases due to heavy metals
Solution Approach 1:
The patent applies local quality by selectively incorporating heavy metals (such as gallium, indium, bismuth, tin) only in specific proportions and locations within the alloy structure, rather than uniformly distributing them. This localized approach allows optimization of degradation properties while minimizing overall heavy metal content and potential environmental harm.
Solution Approach 2:
The patent uses parameter changes by precisely controlling the concentration and composition ratios of alloying elements. By adjusting these parameters, the degradation rate and environmental impact can be optimized to achieve effective removal while minimizing harmful effects, potentially selecting lighter metals or optimizing ratios to reduce toxicity.
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 design ensures the article can withstand wellbore conditions while allowing for controlled reconfiguration or removal, reducing operational costs and time by enabling efficient dissolution in wellbore fluids.
Implementation Method 1
The corrodible core member comprises a metallic first material that is corrodible in a wellbore fluid at a first corrosion rate
Implementation Method 2
The outer member is disposed on the core member and comprises a second material that is corrodible in the wellbore fluid at a second corrosion rate, wherein the first corrosion rate is substantially greater than the second corrosion rate
Data Source
AI summary
A composite downhole article is disclosed. The article is selectively corrodible in a wellbore fluid. The article includes at least one corrodible core member comprising a metallic first material that is corrodible in a wellbore fluid at a first corrosion rate. The article also includes at least one outer member disposed on the core member and comprising a second material that is corrodible in the wellbore fluid at a second corrosion rate, wherein the corrodible core member has a composition gradient or a density gradient, or a combination thereof, and wherein the first corrosion rate is substantially greater than the second corrosion rate.