Method of making and using a functionally gradient composite tool
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
E21B-034/06
E21B-033/12
E21B-023/00
E21B-029/00
B22F-007/06
B05D-007/14
B22F-007/02
E21B-017/00
출원번호
US-0158055
(2014-01-17)
등록번호
US-9366106
(2016-06-14)
발명자
/ 주소
Xu, Zhiyue
Johnson, Michael
출원인 / 주소
BAKER HUGHES INCORPORATED
대리인 / 주소
Cantor Colburn LLP
인용정보
피인용 횟수 :
1인용 특허 :
27
초록▼
A method of making a composite downhole article is disclosed. The method include forming at least one removable core member comprising a first metallic material that is removable in a wellbore fluid at a first removal rate; and disposing at least one outer member on the core member, the outer member
A method of making a composite downhole article is disclosed. The method include forming at least one removable core member comprising a first metallic material that is removable in a wellbore fluid at a first removal rate; and disposing at least one outer member on the core member, the outer member comprising a second material that is removable in the wellbore fluid at a second removal rate, wherein the removable core member has a composition gradient or a density gradient, or a combination thereof, and wherein the first removal rate is substantially greater than the second removal rate. A method of using a composite downhole article is also disclosed. The method includes forming a composite downhole article as described above; using the article to perform a first wellbore operation; exposing the article to the wellbore fluid; and selectively removing the second removable member.
대표청구항▼
1. A method of making a composite downhole article, comprising: forming at least one removable core member comprising a first metallic material that is removable in a wellbore fluid at a first removal rate; anddisposing at least one outer member on the core member, the outer member comprising a seco
1. A method of making a composite downhole article, comprising: forming at least one removable core member comprising a first metallic material that is removable in a wellbore fluid at a first removal rate; anddisposing at least one outer member on the core member, the outer member comprising a second material that is removable in the wellbore fluid at a second removal rate, wherein the removable core member has a composition gradient or a density gradient, or a combination thereof, and wherein the first removal rate is substantially greater than the second removal rate, and wherein disposing the outer member on the core member further comprises forming an access point on the outer member, the access point configured to provide access of a wellbore fluid to the core member in response to a change in a wellbore condition, and wherein the access point comprises a localized thinning of the outer member. 2. The method of claim 1, wherein the composite downhole article comprises a downhole tool or component. 3. The method of claim 1, wherein the composite downhole article comprises a ball, ball seat, plug, plug seat, disk, dart, sleeve, or tubular section. 4. The method of claim 1, wherein the composite downhole article comprises a plurality of nested balls, ball seats, plugs, plug seats, disks, darts, sleeves, or tubular sections. 5. A method of making a composite downhole article, comprising: forming at least one removable core member comprising a first metallic material that is removable in a wellbore fluid at a first removal rate; anddisposing at least one outer member on the core member, the outer member comprising a second material that is removable in the wellbore fluid at a second removal rate, wherein the removable core member has a composition gradient or a density gradient, or a combination thereof, and wherein the first removal rate is substantially greater than the second removal rate, and wherein disposing the outer member on the core member further comprises forming an access point on the outer member, the access point configured to provide access of a wellbore fluid to the core member in response to a change in a wellbore condition, and wherein the access point comprises an access point material that is different than the second material. 6. A method of making a composite downhole article, comprising: forming at least one removable core member comprising a first metallic material that is removable in a wellbore fluid at a first removal rate; anddisposing at least one outer member on the core member, the outer member comprising a second material that is removable in the wellbore fluid at a second removal rate, wherein the removable core member has a composition gradient or a density gradient, or a combination thereof, and wherein the first removal rate is substantially greater than the second removal rate, and wherein disposing the outer member on the core member further comprises forming an access point on the outer member, the access point configured to provide access of a wellbore fluid to the core member in response to a change in a wellbore condition, and wherein the access point comprises a check valve. 7. A method of making a composite downhole article, comprising: forming at least one removable core member comprising a first metallic material that is removable in a wellbore fluid at a first removal rate; anddisposing at least one outer member on the core member, the outer member comprising a second material that is removable in the wellbore fluid at a second removal rate, wherein the removable core member has a composition gradient or a density gradient, or a combination thereof, and wherein the first removal rate is substantially greater than the second removal rate, and wherein the composite downhole article comprises a portion of a tubular section and is selectively removable or reconfigurable to define a feature in the tubular section, and wherein the feature comprises a through-hole, opening, blind hole, blind opening, conduit, passage, groove, protruding rib, or shoulder. 8. The method of claim 7, wherein at least one of forming the removable core member and disposing the outer member comprises forming an unsintered powder compact. 9. The method of claim 8, wherein forming the unsintered powder compact comprises compacting a powder comprising a plurality of metallic powder particles, each powder particle comprising: a particle core, the particle core comprises a core material comprising Mg, Al, Zn, Fe, or Mn, or a combination thereof, and a metallic coating layer disposed on the particle core, wherein compacting causes the metallic coating layers of adjacent particles to form mechanical bonds to one another sufficient to form the powder compact. 10. The method of claim 7, wherein at least one of forming the removable core member and disposing the outer member comprises forming a sintered powder compact. 11. The method of claim 10, wherein forming the sintered powder compact comprises forming a substantially-continuous, cellular nanomatrix comprising a nanomatrix material, a plurality of dispersed particles comprising a particle core material that comprises Mg, Al, Zn, Fe, or Mn, or a combination thereof, dispersed in the cellular nanomatrix, and a bond layer extending throughout the cellular nanomatrix between the dispersed particles. 12. The method of claim 7, wherein forming the removable core member comprises establishing the composition gradient or the density gradient, or a combination thereof, of the first material from an outer portion proximate the outer member toward an inner portion away from the outer member. 13. The method of claim 12, wherein establishing the composition gradient or the density gradient, or a combination thereof, of the first material from an outer portion proximate the outer member toward an inner portion away from the outer member comprises varying the composition gradient or the density gradient, or a combination thereof, continuously from the inner portion to the outer portion. 14. The method of claim 12, wherein establishing the composition gradient or the density gradient, or a combination thereof, of the first material from an outer portion proximate the outer member toward an inner portion away from the outer member comprises varying the composition gradient or the density gradient, or a combination thereof, in discrete steps from the inner portion to the outer portion. 15. The method of claim 12, further comprising establishing a composition gradient or a density gradient, or a combination thereof, of the second material in the removable core member from the outer portion proximate the outer member toward the inner portion. 16. The method of claim 7, wherein disposing the outer member on the core member comprises disposing a powder compact of the second material on the core member. 17. The method of claim 7, wherein disposing the outer member on the core member comprising depositing a layer of the second material on the core member. 18. The method of claim 17, wherein depositing the layer of the second material comprises dipping, plating, sputtering, cladding, thermal spraying, or laser fusion, or a combination thereof. 19. The method of claim 7, wherein the composite downhole article comprises a sleeve, and wherein the sleeve is configured to close an orifice in a tubular section. 20. The method of claim 7, wherein the composite downhole article comprises a selectively removable downhole article that is selectively removable from a wellbore using the wellbore fluid. 21. The method of claim 7, wherein the composite downhole article comprises a selectively reconfigurable downhole article that is selectively reconfigurable within a wellbore using the wellbore fluid. 22. A method of making a composite downhole article, comprising: forming at least one core member comprising a first material that is removable in a wellbore fluid at a first removal rate; anddisposing at least one removable outer member on the core member and comprising a second material that is removable in the wellbore fluid at a second removal rate, wherein the removable outer member has a composition gradient or a density gradient, or a combination thereof, and wherein at least one of the first material and the second material comprises a metallic material, and wherein the second removal rate is substantially greater than the first removal rate, and wherein the composite downhole article comprises a portion of a tubular section and is selectively removable or reconfigurable to define a feature in the tubular section and wherein the feature comprises a through-hole, opening, blind hole, blind opening, conduit, passage, groove, protruding rib, or shoulder. 23. The method of claim 22, wherein forming the removable core member comprises establishing the composition gradient or the density gradient, or a combination thereof, of the second material from an inner portion proximate the core member toward an outer portion away from the core member. 24. The method of claim 23, wherein establishing the composition gradient or the density gradient, or a combination thereof, of the second material from an inner portion proximate the core member toward an outer portion away from the core member comprises varying the composition gradient or the density gradient, or a combination thereof, continuously from the inner portion to the outer portion. 25. The method of claim 23, wherein establishing the composition gradient or the density gradient, or a combination thereof, of the second material from an inner portion proximate the core member toward an outer portion away from the core member comprises varying the composition gradient or the density gradient, or a combination thereof, in discrete steps from the inner portion to the outer portion. 26. The method of claim 23, further comprising establishing a composition gradient or a density gradient, or a combination thereof, of the first material in the removable outer member from the inner portion proximate the core member toward the outer portion. 27. The method of claim 22, wherein disposing the outer member on the core member comprises disposing a powder compact of the second material on the core member. 28. The method of claim 22, wherein the composite downhole article comprises a downhole tool or component. 29. The method of claim 22, wherein the composite downhole article comprises a ball, ball seat, plug, plug seat, disk, dart, sleeve, or tubular section. 30. The method of claim 22, wherein the composite downhole article comprises a plurality of nested balls, ball seats, plugs, plug seats, disks, darts, sleeves, or tubular sections. 31. The method of claim 22, wherein the composite downhole article comprises a sleeve, and wherein the sleeve is configured to close an orifice in a tubular section. 32. The method of claim 22, wherein the composite downhole article comprises a selectively removable downhole article that is selectively removable from a wellbore using the wellbore fluid. 33. The method of claim 22, wherein the composite downhole article comprises a selectively reconfigurable downhole article that is selectively reconfigurable within a wellbore using the wellbore fluid. 34. A method of making a composite downhole article, comprising: forming a first member comprising a first material that is removable in a wellbore fluid at a first removal rate; anddisposing a second removable member on the first member, the second removable member comprising a second material that is removable in the wellbore fluid at a second removal rate, the second material comprising a powder compact that comprises a plurality of metallic coated powder particles, wherein the second removal rate is substantially greater than the first removal rate, and wherein the composite downhole article comprises a ball, ball seat, plug, plug seat, disk, dart, sleeve, or tubular section. 35. The method of claim 34, wherein the second member comprises a composition gradient or a density gradient, or a combination thereof. 36. The method of claim 34, wherein the powder compact comprises an unsintered powder compact, a sintered powder compact, or a partially sintered powder compact. 37. The method of claim 34, wherein the plurality of metallic coated powder particles each comprise a particle core of a core material and a metallic coating layer comprising Al, Zn, Mn, Mg, Mo, W, Cu, Fe, Si, Ca, Co, Ta, Re, or Ni, or an oxide, nitride or a carbide thereof, or a combination of any of the aforementioned materials. 38. The method of claim 37, wherein the core material comprises Mg, Al, Mn, Fe or Zn, or a combination thereof. 39. A method of making a composite downhole article, comprising: forming a first member comprising a first material that is removable in a wellbore fluid at a first removal rate; anddisposing a second removable member on the first member, the second removable member comprising a second material that is removable in the wellbore fluid at a second removal rate, the second material comprising a powder compact that comprises a plurality of metallic coated powder particles, wherein the second removal rate is substantially greater than the first removal rate, and wherein the composite downhole article comprises a plurality of nested balls, ball seats, plugs, plug seats, disks, darts, sleeves, or tubular sections. 40. A method of making a composite downhole article, comprising: forming a first member comprising a first material that is removable in a wellbore fluid at a first removal rate; anddisposing a second removable member on the first member, the second removable member comprising a second material that is removable in the wellbore fluid at a second removal rate, the second material comprising a powder compact that comprises a plurality of metallic coated powder particles, wherein the second removal rate is substantially greater than the first removal rate, and wherein the composite downhole article comprises a portion of a tubular section and is selectively removable or reconfigurable to define a feature in the tubular section. 41. The method of claim 40, wherein the feature comprises a through-hole, opening, blind hole, blind opening, conduit, passage, groove, protruding rib, or shoulder. 42. A method of using a composite downhole article, comprising: forming a composite downhole article that comprises a first member comprising a first material that is removable in a wellbore fluid at a first removal rate, and a second removable member disposed on the first member comprising a second material that is removable in the wellbore fluid at a second removal rate, the second material comprising a powder compact that comprises a plurality of metallic coated powder particles, wherein the second removal rate is substantially greater than the first removal rate, and wherein the article comprises a diverter ball, plug or disk and a wellbore operation comprises closing an orifice during fracturing, completion or production;using the article to perform a first wellbore operation;exposing the article to the wellbore fluid; andselectively removing the second removable member. 43. The method of claim 42, wherein exposing the article to the wellbore fluid comprises exposing the article to water, brine, or an acid, or a combination thereof. 44. The method of claim 42, wherein selectively corroding comprises completely corroding the second removable member. 45. The method of claim 42, wherein selectively corroding comprises partially corroding the second removable member. 46. The method of claim 45, wherein partially corroding the second removable member comprises removing a layer of the second removable member. 47. The method of claim 45, wherein partially corroding the second removable member comprises removing a removable portion of the member to provide a remaining portion. 48. The method of claim 47, wherein the remaining portion has a shape that is different than a shape of the second removable member. 49. The method of claim 42, wherein exposing the article to the wellbore fluid comprises opening an access point in the first member to allow the wellbore fluid to access the second removable member. 50. The method of claim 42, wherein the second corrodible member has a composition gradient or a density gradient, or a combination thereof. 51. The method of claim 42, wherein the second member is a core member and the first member is an outer member disposed on the core member. 52. The method of claim 42, wherein the first member is a core member and the second member is an outer member disposed on the core member. 53. The method of claim 42, wherein the powder compact comprises an unsintered powder compact, a sintered powder compact, or a partially sintered powder compact. 54. The method of claim 42, wherein the plurality of metallic coated powder particles each comprise a particle core of a core material and a metallic coating layer comprising Al, Zn, Mn, Mg, Mo, W, Cu, Fe, Si, Ca, Co, Ta, Re, or Ni, or an oxide, nitride or a carbide thereof, or a combination of any of the aforementioned materials. 55. The method of claim 54, wherein the core material comprises Mg, Al, Mn, Fe or Zn, or a combination thereof. 56. A method of using a composite downhole article, comprising: forming a composite downhole article that comprises a first member comprising a first material that is removable in a wellbore fluid at a first removal rate, and a second removable member disposed on the first member comprising a second material that is removable in the wellbore fluid at a second removal rate, the second material comprising a powder compact that comprises a plurality of metallic coated powder particles, wherein the second removal rate is substantially greater than the first removal rate, and wherein the composite downhole article comprises a ball, ball seat, plug, plug seat, disk, dart, sleeve, or tubular section;using the article to perform a first wellbore operation;exposing the article to the wellbore fluid; andselectively removing the second removable member. 57. A method of using a composite downhole article, comprising: forming a composite downhole article that comprises a first member comprising a first material that is removable in a wellbore fluid at a first removal rate, and a second removable member disposed on the first member comprising a second material that is removable in the wellbore fluid at a second removal rate, the second material comprising a powder compact that comprises a plurality of metallic coated powder particles, wherein the second removal rate is substantially greater than the first removal rate, and wherein the composite downhole article comprises a plurality of nested balls, ball seats, plugs, plug seats, disks, darts, sleeves, or tubular sectionsusing the article to perform a first wellbore operation;exposing the article to the wellbore fluid; andselectively removing the second removable member. 58. A method of using a composite downhole article, comprising: forming a composite downhole article that comprises a first member comprising a first material that is removable in a wellbore fluid at a first removal rate, and a second removable member disposed on the first member comprising a second material that is removable in the wellbore fluid at a second removal rate, the second material comprising a powder compact that comprises a plurality of metallic coated powder particles, wherein the second removal rate is substantially greater than the first removal rate, and wherein the composite downhole article comprises a portion of a tubular section and is selectively removable or reconfigurable to define a feature in the tubular sectionusing the article to perform a first wellbore operation;exposing the article to the wellbore fluid; andselectively removing the second removable member. 59. The method of claim 58, wherein the feature comprises a through-hole, opening, blind hole, blind opening, conduit, passage, groove, protruding rib, or shoulder. 60. A method of using a composite downhole article, comprising: forming a composite downhole article that comprises a first member comprising a first material that is removable in a wellbore fluid at a first removal rate, and a second removable member disposed on the first member comprising a second material that is removable in the wellbore fluid at a second removal rate, the second material comprising a powder compact that comprises a plurality of metallic coated powder particles, wherein the second removal rate is substantially greater than the first removal rate, and wherein the powder compact further comprises a plurality of second powder particles. 61. A method of using a composite downhole article, comprising: forming a composite downhole article that comprises a first member comprising a first material that is removable in a wellbore fluid at a first removal rate, and a second removable member disposed on the first member comprising a second material that is removable in the wellbore fluid at a second removal rate, the second material comprising a powder compact that comprises a plurality of metallic coated powder particles, wherein the second removal rate is substantially greater than the first removal rate, and wherein the first wellbore operation comprises partially or completely closing an orifice in a wellbore as part of a fracturing, completion or production operation.
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Baugh John L. (7519 Plum Tree Forest Ct. Houston TX 77095) Melenyzer George J. (19730 Burle Oaks Ct. Humble TX 77346), Straight Bore metal-to-metal wellbore seal apparatus and method of sealing in a wellbore.
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