Shape Memory Connection Members for Brittle Downhole Components
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Solution Overview
Problem
The challenge lies in connecting brittle materials, such as ceramics or hard metals, to other structures in downhole tools without relying on press-fit or gluing procedures, due to their difficulty in machining and lack of elastic material properties.
Innovation Solution
The use of connection members made from shape memory materials that can transition between different states in response to stimuli like temperature or stress, allowing for secure connections to brittle structures without the need for precise machining or interference fits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If press-fit or gluing procedures are used to connect brittle materials, then connection strength may be achieved, but machining precision and elastic material properties are required which brittle materials lack
Solution Approach 1:
The connection member changes its physical state between austenite (high temperature) and martensite (low temperature) phases, utilizing parameter changes in material properties to enable easy assembly at low temperature and secure connection at high temperature without requiring precise machining of brittle materials
Solution Approach 2:
The connection member utilizes phase transition of shape memory alloy between austenite and martensite phases. In martensite phase (low temperature), the material is soft and easily deformable for assembly. In austenite phase (high temperature), the material becomes hard and maintains secure connection, eliminating the need for press-fit or gluing procedures
2Object-affected harmful factors
If brittle materials are used for downhole tool components, then resistance to abrasion and corrosion is improved, but the ability to machine and form elastic connections deteriorates
Solution Approach 1:
The downhole tool is divided into two parts: brittle material components (valve body, valve seat) that provide abrasion and corrosion resistance, and a shape memory alloy connection member that provides ease of manufacture and assembly. This segmentation allows each component to fulfill its optimal function
Solution Approach 2:
The shape memory alloy connection member acts as an intermediary between brittle material components. It facilitates easy assembly and disassembly of brittle components that would otherwise be difficult to machine and connect, while the brittle materials maintain their superior resistance to abrasion and corrosion
3Ease of operation
If shape memory materials are used for connection members, then ease of assembly and secure connection are achieved, but the complexity of temperature-controlled transition processes increases
Solution Approach 1:
The shape memory alloy connection member performs the transition and securing function automatically through temperature change. The material self-adjusts its properties between soft (martensite) and hard (austenite) states based on temperature, eliminating the need for complex external control mechanisms
Solution Approach 2:
The connection member utilizes thermal effects of phase transition in shape memory alloy. Heating to austenite phase causes the material to become hard and secure the connection, while cooling to martensite phase makes it soft and removable. This thermal response simplifies the assembly process without adding mechanical complexity
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 enables reliable and secure connections between brittle and other materials in downhole tools, facilitating the assembly of downhole tools while overcoming the limitations of brittle materials in machining and elastic properties.
Implementation Method 1
a body including a shape memory material configured to transition from a first state having a first configuration to a second state having a second configuration in response to application of a stimulus
Implementation Method 2
The connection member secured to the first downhole component at a corresponding surface of the one of the inner diameter and the outer diameter and to the second downhole component via the first connection feature and the second connection feature
Data Source
AI summary
A downhole valve system for use in a borehole is disclosed. The downhole valve system includes a first downhole component formed of a brittle material, a second downhole component, and a connection member. The connection member formed from a shape memory material and includes: an outer surface including an outer diameter; an inner surface including an inner diameter, one of the outer and inner diameter modifiable by applying a stimulus to the shape memory material; and a connection feature, complimentary of a connection feature of the second downhole component, formed on one of the outer surface and the inner surface. The connection member secured to the first downhole component at a corresponding surface of the one of the inner and outer diameter and to the second downhole component via the first connection feature and the second connection feature to connect the second downhole component to the first downhole component.