Sand Screen Component Joining Without Post-Weld Heat Treatment
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Solution Overview
Problem
Current manufacturing methods for sand screens, which use fusion welding to join components, adversely affect the corrosion resistance of materials and require post-weld heat treatments, increasing manufacturing complexity and cost.
Innovation Solution
The use of a friction stir process to join metal components without subsequent heat treatments, retaining corrosion-resistant properties and enabling efficient assembly of sand screen assemblies by creating a friction stir region for secure coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fusion welding is used to join sand screen components to base pipe, then components are securely joined, but corrosion resistance of the base pipe is adversely affected and hardness increases in the weld zone
Solution Approach 1:
The patent replaces the thermal fusion welding process with a mechanical friction stir welding process. A friction stir tool mechanically mixes the base metal and filler metal under friction heat without melting, creating a forged joint that maintains the metallurgical properties and corrosion resistance of the base pipe while achieving secure component joining.
Solution Approach 2:
The patent changes the fundamental parameters of the joining process by using solid-state friction stir welding instead of fusion welding. This involves controlling friction heat, pressure, and stirring speed to create a metallurgically sound joint without the harmful thermal effects of fusion welding, thereby preserving corrosion resistance while achieving strong bonding.
2Reliability
If post weld heat treatments are applied to restore corrosion resistance, then corrosion resistant properties are partially restored, but manufacturing complexity and time increase
Solution Approach 1:
The patent extracts and eliminates the post-weld heat treatment step from the manufacturing process. By using friction stir welding that inherently preserves corrosion resistance without requiring subsequent thermal processing, the method removes the complexity and time associated with post-weld heat treatments while maintaining the desired corrosion resistant properties.
3Strength
If post weld heat treatments are applied to reduce hardness, then hardness in weld zone is reduced, but manufacturing time and costs increase
Solution Approach 1:
The patent eliminates the need for post-weld heat treatments by using friction stir welding that produces joints with controlled, acceptable hardness levels directly during the joining process. The friction stir method creates a forged joint structure that inherently has suitable mechanical properties without requiring additional thermal processing steps, thereby reducing manufacturing time and costs.
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 method reduces manufacturing time and costs by maintaining corrosion resistance and allowing for the efficient construction of sand screen assemblies with secure, low-temperature joins, eliminating the need for post-weld heat treatments.
Implementation Method 1
The components are joined by using a friction stir process which establishes a desired friction stir region
Implementation Method 2
The components are joined by using a friction stir process
Data Source
AI summary
A technique facilitates joining of components without subsequent heat treatments. The components are joined by using a friction stir process which establishes a desired friction stir region at an appropriate location to securely join the desired components. In well applications, various components of sand screen assemblies may be joined by the friction stir process. For example, metal sand screen components may be securely coupled with a corresponding metal base pipe. The joining technique enables retention of the corrosion resistant properties of the materials without applying post weld heat treatments and/or other subsequent treatments.