Additive Ported Mandrel Helical Erosion Resistance

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Solution Overview

Problem

The increasing pressures and larger proppant volumes in downhole fracturing operations lead to accelerated erosion of critical parts in ported mandrels, making existing technologies excessively costly due to frequent scrap and repair needs, and uncommon geometries that could reduce erosion are difficult or impossible to machine, rendering them commercially unattainable.

Innovation Solution

A ported mandrel is additively manufactured using at least two different materials, with a base material and erosion-resistant material for the ports and return pathways, allowing for unique geometries like a helical pattern, where carbide is used in erosion-prone areas, either as material or coating, through processes like Direct Metal Laser Sintering, forming a unitary piece without additional components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional machining methods are used to create ported mandrels, then manufacturing simplicity is maintained, but erosion resistance is insufficient due to inability to implement optimal geometries

Engineering Contradiction:

Improveerosion resistanceVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent changes the manufacturing method from traditional machining to additive manufacturing, enabling complex geometries (helical patterns, varying port sizes) that were previously impossible to machine. This parameter change in the manufacturing process allows implementation of erosion-resistant designs without prohibitive complexity

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs multi-material additive manufacturing to combine base metal materials with erosion-resistant materials (such as carbide) in specific regions. This creates a composite structure where high-wear areas have enhanced erosion resistance while maintaining overall mandrel functionality

Inventive Principle:

Principle #40Composite materials

2Productivity

If higher pressures and larger proppant volumes are employed to increase fracturing effectiveness, then production efficiency is improved, but erosion of mandrel parts accelerates

Engineering Contradiction:

Improvefracturing effectivenessVSAvoidmandrel durability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent applies erosion-resistant materials specifically in high-wear regions (ports and adjacent areas) rather than uniformly across the entire mandrel. This local quality enhancement protects critical areas from accelerated erosion caused by high-pressure fluid and large proppant volumes while maintaining overall system productivity

Inventive Principle:

Principle #3Local quality

3Reliability

If uncommon geometries are implemented to reduce erosion rates, then mandrel durability is improved, but manufacturing difficulty increases making them commercially unattainable

Engineering Contradiction:

Improvemandrel durabilityVSAvoidmanufacturing feasibility

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces traditional mechanical machining processes with additive manufacturing technology. This substitution enables the creation of complex geometries (helical patterns, variable port sizes, three-dimensional return pathways) that would be extremely difficult or impossible to machine conventionally, while actually reducing overall manufacturing complexity through digital fabrication

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 reduces erosion and enhances cost control by enabling the production of complex geometries that would be impossible with traditional methods, resulting in a more durable and cost-effective mandrel for downhole fracturing operations.

Implementation Method 1

A unitary ported mandrel includes a mandrel body of a base material; one or more ports including an erosion resistant material

Methodology Applied

Scientific EffectAdditive manufacturing: 3D Printing

Implementation Method 2

through processes like Direct Metal Laser Sintering, forming a unitary piece without additional components

Methodology Applied

Scientific EffectLaser sintering: Selective Laser Sintering

Data Source

PatentUS9868258B2Manufactured ported mandrel and method for making same

Publication Date: 2018.01.16 BAKER HUGHES CO

AI summary

A ported mandrel additively manufactured with at least two different materials. A unitary ported mandrel includes a mandrel body of a base material; one or more ports including an erosion resistant material; and one or more return pathways. A method for making a unitary ported mandrel for a downhole fracturing operation.