Segmented Non-Magnetic Drill Collar Friction Welding

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing drill collars face challenges in manufacturing complex geometries and achieving optimal performance characteristics due to limitations in material selection and traditional welding methods, which can lead to reduced mechanical properties and increased fatigue failures.

Innovation Solution

The use of solid-state welding processes to fuse segments of drill collars made from different materials with varying elastic moduli and densities, allowing for optimized performance and flexibility, while also enabling the replacement of damaged segments without de-rating the drill collar, and utilizing non-magnetic materials to minimize systemic errors in measurement readings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional welding methods are used to join drill collar segments, then manufacturing complexity is reduced, but mechanical properties are reduced and fatigue failures increase

Engineering Contradiction:

Improvemechanical propertiesVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The drill collar is divided into multiple segments that can be manufactured separately using optimized processes for each material type, then joined through friction welding. This allows each segment to be manufactured with optimal material properties while maintaining overall structural integrity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention changes the welding process parameters by using friction welding instead of traditional welding methods. This process generates heat through friction between rotating segments, creating a solid-state bond that preserves the mechanical properties of the base materials without the heat-affected zone problems of conventional welding.

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If a single drill collar is constructed of several distinct materials with complex geometry, then performance characteristics are optimized, but manufacturing difficulty increases

Engineering Contradiction:

Improveperformance characteristicsVSAvoidmanufacturing difficulty

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The drill collar is segmented into distinct sections, each made from materials optimized for specific functions (e.g., non-magnetic materials for sensor housing, magnetic materials for weight). This allows each segment to be manufactured with optimal material properties while maintaining overall structural integrity through friction welding.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses composite construction by joining segments made from different materials (non-magnetic stainless steel, magnetic steel alloys) to create a drill collar with tailored performance characteristics in different zones, optimizing both magnetic interference reduction and mechanical performance.

Inventive Principle:

Principle #40Composite materials

3Measurement precision

If non-magnetic materials are used to minimize systemic errors, then measurement precision is improved, but device complexity increases

Engineering Contradiction:

Improvesystemic errorsVSAvoiddevice complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

Non-magnetic materials are selectively applied only in the regions where sensors are located (local quality), while other portions of the drill collar can use magnetic materials for weight and strength. This minimizes magnetic interference with measurements without requiring the entire device to be constructed from non-magnetic materials.

Inventive Principle:

Principle #3Local quality

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

This approach results in robust drill collars with enhanced fatigue lifespan, improved flexibility, and reduced stress concentrations, along with cost-effective repair and refurbishment, while minimizing systemic errors in measurement readings by using non-magnetic materials.

Implementation Method 1

rotating the first segment with respect to the second segment to generate frictional heat between the segments

Methodology Applied

Scientific EffectFrictional heat: Friction

Implementation Method 2

a supplemental energy source to provide additional heat to the segments being welded

Methodology Applied

Scientific EffectSupplemental heating: Heating

Data Source

PatentUS11654506B2Processing route to design and manufacture highly configurable non-magnetic down-hole sensor collars

Publication Date: 2023.05.23 HALLIBURTON ENERGY SERVICES INC

AI summary

Drill collars may be constructed using solid-state welding processes. Solid-state welding produces robust drill collars with high fatigue lifespans and permits individual segments of the drill collar to be optimized based on their intended use. A drill collar may be formed of a first segment with a different material, density, modulus of elasticity and/or geometry than an adjacent second segment fused thereto. If a segment of a drill collar is damaged in use, the damaged segment may be removed and replaced, possibly without de-rating the drill collar. Methods of forming the solid-state welds may include friction welding adjacent segments to one another such that features in each segment are circumferentially aligned when the weld is formed. Supplemental energy sources may provide additional heat at the welded surfaces to ensure the segments are effectively fused.