Magnesium Alloy Nanomatrix Powder Compacts for Dissolvable Wellbore Tools
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Solution Overview
Problem
Existing wellbore components and tools require frequent replacement due to limited service lives, necessitating time-consuming and costly milling or drilling operations for removal, and there is a need for lightweight, high-strength materials that can be selectively and controllably dissolved or corroded for disposal.
Innovation Solution
Development of lightweight, high-strength magnesium alloy nanomatrix materials with nanostructured dispersed particles and cellular nanomatrix composites that can be formed into powder compacts with controlled corrosion properties, allowing for selective and controllable dissolution in wellbore fluids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional steel materials are used for wellbore components, then strength is sufficient, but weight is excessive and removal requires milling or drilling operations
Solution Approach 1:
The patent changes the material parameters by using magnesium alloy instead of conventional steel, achieving a density reduction from approximately 7.8 g/cm³ to 1.7-1.8 g/cm³ while maintaining adequate strength through alloying elements and controlled microstructure
Solution Approach 2:
The patent employs composite material strategies by combining magnesium with alloying elements (Al, Zn, Mn, RE) to create a multi-phase microstructure that provides both lightweight properties and enhanced strength through precipitation hardening and grain boundary strengthening
2Ease of operation
If dissolvable materials are used for wellbore components, then removal is simplified, but strength is insufficient compared to conventional engineering materials
Solution Approach 1:
The patent changes the corrosion parameter by controlling the dissolution rate through alloy composition and microstructure, enabling the material to maintain strength during service while dissolving at a controlled rate after deployment, achieving both structural integrity and ease of removal
Solution Approach 2:
The patent introduces dynamic properties to the material by making it transition from a stable, strong state during service to a dissolvable state after deployment, allowing the material to adapt its properties based on the operational phase (installation vs. removal
3Weight of moving object
If magnesium alloy is used to reduce weight, then density is improved, but manufacturing precision and corrosion control are challenging
Solution Approach 1:
The patent changes the manufacturing parameters by optimizing casting temperature, cooling rate, and alloy composition to achieve a controlled microstructure that provides both mechanical strength and predictable corrosion behavior, transforming magnesium from a difficult-to-control material to one with precise properties
Solution Approach 2:
The patent applies local quality by creating a non-uniform microstructure with different phases (α-Mg, β-Mg17Al12, precipitates) distributed throughout the material, where each phase contributes specific properties (strength, ductility, corrosion resistance) to achieve overall performance
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
These materials provide a unique combination of mechanical strength, low density, and controlled corrosion properties, enabling efficient and cost-effective removal of wellbore components without the need for milling or drilling, while maintaining high strength and durability.
Implementation Method 1
selectively and controllably dissolved or corroded for disposal
Implementation Method 2
selectively and controllably dissolved or corroded for disposal
Implementation Method 3
fully-dense, sintered powder compacts
Data Source
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AI summary
A powder metal compact is disclosed. The powder metal compact includes a cellular nanomatrix comprising a nanomatrix material. The powder metal compact also includes a plurality of dispersed particles comprising a particle core material that comprises an Mg-Zr, Mg-Zn-Zr, Mg-Al-Zn-Mn, Mg-Zn-Cu-Mn or Mg-W alloy, or a combination thereof, dispersed in the cellular nanomatrix.