Metallic Powder Compacts for Controlled Wellbore Removal
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Solution Overview
Problem
Existing wellbore components and tools require frequent replacement due to limited service life, with conventional removal methods like milling or drilling being time-consuming and expensive, and degradable polymers lacking necessary mechanical strength and durability.
Innovation Solution
Development of lightweight, high-strength metallic powder compacts with electrochemically active cores and nanoscale metallic coatings, allowing for controlled dissolution in wellbore fluids, providing mechanical strength comparable to metals while being selectively and controllably removable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If degradable polymers are used to eliminate milling or drilling operations, then removal time and cost are reduced, but mechanical strength and fracture toughness are insufficient
Solution Approach 1:
The patent uses composite materials consisting of a metallic core (providing mechanical strength and fracture toughness) coated with a degradable polymer layer (enabling controlled dissolution). This composite structure allows the material to maintain the mechanical properties of metals while acquiring the degradable characteristics of polymers, thus resolving the contradiction between strength and removability.
Solution Approach 2:
The patent applies different material properties to different parts of the component: the core maintains metallic strength for structural integrity during service, while the outer polymer coating provides degradable characteristics for controlled removal. This local differentiation of material quality allows simultaneous satisfaction of strength requirements and removal capabilities.
2Adaptability or versatility
If conventional degradable metal alloys are used, then dissolution capability is achieved, but mechanical properties and alloy microstructure are not optimal
Solution Approach 1:
Instead of relying on complex degradable metal alloys with uncertain microstructures, the patent employs a simple two-component composite: a strong metallic core (such as aluminum, magnesium, or zinc) coated with a degradable polymer. This approach guarantees optimal mechanical properties from the metallic core while achieving dissolution capability through the polymer coating, avoiding the microstructural complications of alloy-based solutions.
3Adaptability or versatility
If reactive metal alloys are formed by melting and solidifying, then dissolution characteristics are achieved, but phase equilibria and solidification characteristics result in non-optimal microstructures
Solution Approach 1:
The patent extracts the dissolution function from the bulk alloy material and places it in a separate polymer coating layer. This separation allows the metallic core to be formed by simple melting and solidification without being constrained by complex phase equilibria, while the polymer coating independently provides the dissolution characteristics. The extraction of the dissolution function eliminates the microstructural problems associated with alloy solidification.
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 metallic powder compacts offer a combination of high strength, low density, and controlled dissolution properties, enabling efficient and cost-effective removal of wellbore components without disrupting ongoing operations, maintaining strength until needed and ensuring rapid removal when conditions change.
Implementation Method 1
The coating layer may be applied by physical vapor deposition or chemical vapor deposition
Implementation Method 2
The coating layer may be applied by physical vapor deposition or chemical vapor deposition
Implementation Method 3
applying a temperature and a pressure sufficient to sinter the coated layers of the plurality of coated particle powders
Data Source
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AI summary
A metallic powder is disclosed. The metallic powder includes a plurality of metallic powder particles. Each powder particle includes a particle core. The particle core includes a core material comprising Mg, Al, Zn or Mn, or a combination thereof, having a melting temperature (TP). Each powder particle also includes a metallic coating layer disposed on the particle core. The metallic coating layer includes a metallic coating material having a melting temperature (TC). The powder particles are configured for solid-state sintering to one another at a predetermined sintering temperature (TS), and TS is less than TP and TC.