Nanomatrix Powder Metal Compact for Wellbore Dissolution
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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 existing degradable materials lack the mechanical strength and properties necessary for wellbore functions.
Innovation Solution
Development of lightweight, high-strength metallic powder compacts with a cellular nanomatrix and dispersed particles, featuring electrochemically active metals and nanoscale coatings for controlled dissolution in wellbore fluids, providing mechanical strength comparable to steels and low density like polymers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If degradable polymers are used to eliminate milling or drilling operations, then removal time is reduced, but mechanical strength is insufficient
Solution Approach 1:
The patent uses a composite material system consisting of a reactive metal matrix (aluminum, zinc, or magnesium) combined with specific alloying elements (gallium, indium, bismuth, tin, and/or their mixtures). This composite structure provides both the necessary mechanical strength during service and controlled degradability for rapid removal, resolving the contradiction between strength and removal speed.
Solution Approach 2:
The patent controls the degradation rate by adjusting compositional parameters (alloying elements and their concentrations) and environmental parameters (wellbore fluid chemistry, temperature, and exposure time). This allows the material to maintain strength during service and then rapidly degrade when removal is needed, addressing both time and strength requirements.
2Ease of operation
If degradable metal alloys with reactive metals are used, then removal by dissolution is enabled, but mechanical properties are insufficient
Solution Approach 1:
The patent develops a specialized composite alloy system where reactive base metals (aluminum, zinc, magnesium) are combined with specific alloying elements (gallium, indium, bismuth, tin) in controlled amounts. This composite structure enhances both mechanical properties and controlled dissolvability, enabling easy removal while maintaining structural integrity during service.
Solution Approach 2:
The patent creates local compositional variations through the dispersed alloying elements within the metal matrix. These local variations in composition create regions of different reactivity and mechanical properties, allowing the material to exhibit both high strength and controlled degradation characteristics in different locations of the same component.
3Ease of operation
If conventional alloying elements are used, then dissolution is achieved, but environmental suitability is compromised
Solution Approach 1:
The patent carefully controls compositional parameters by limiting the use of highly toxic alloying elements and preferring alternatives with lower environmental impact. The specific alloying elements selected (gallium, indium, bismuth, tin) are used in controlled amounts to achieve dissolution while minimizing environmental harm, balancing operational ease with environmental suitability.
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 solution enables selective and controllable degradation of wellbore components, maintaining strength until needed and facilitating rapid removal by dissolving in wellbore fluids, thus reducing operational costs and environmental impact.
Implementation Method 1
the removal of components or tools by dissolution of degradable polylactic polymers using various wellbore fluids has been proposed
Implementation Method 2
a solid-state bond layer extending throughout the nanomatrix between the dispersed particles
Data Source
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AI summary
A powder metal compact is disclosed. The powder metal compact includes a substantially-continuous, cellular nanomatrix comprising a nanomatrix material. The compact also includes a plurality of dispersed particles comprising a particle core material that comprises Mg, Al, Zn or Mn, or a combination thereof, dispersed in the nanomatrix and a solid-state bond layer extending throughout the nanomatrix between the dispersed particles. The nanomatrix powder metal compacts are uniquely lightweight, high-strength materials that also provide uniquely selectable and controllable corrosion properties, including very rapid corrosion rates, useful for making a wide variety of degradable or disposable articles, including various downhole tools and components.