Additively manufactured components for downhole operations

Patent metadata

Field	Value
Publication number	US-10240633-B2
Application number	US-201615263560-A
Country	US
Kind code	B2
Filing date	Sep 13, 2016
Priority date	Sep 13, 2016
Publication date	Mar 26, 2019
Grant date	Mar 26, 2019

Abstract

Downhole tools for use in downhole operations and electrical submersible pumping systems having an additively manufactured first part including a first layer having a first predetermined material property and a second layer having a second predetermined material property, wherein the first and second layers are layers of an integral piece and the first predetermined material property is different from the second predetermined material property and a second part configured to rotationally engage with the additively manufactured first part. One of the first part and the second part is rotated relative to the other of the first part and the second part in operation.

First claim

What is claimed is:

1. A downhole tool for use in downhole operations, the downhole tool comprising:
an additively manufactured first part including an inner layer having a first predetermined material property and an outer layer having a second predetermined material property, wherein the inner and outer layers are layers of an integral piece and the first predetermined material property is different from the second predetermined material property; and
a second part configured to rotationally engage with the additively manufactured first part,
wherein one of the first part and the second part is rotated relative to the other of the first part and the second part in operation, and
at least one seal configured to define a sealed volume within the inner layer of the first part, the sealed volume bounded by the at least one seal, the outer layer, and the second part.

2. The downhole tool of claim 1 , wherein the second part is installed within the first part.

3. The downhole tool of claim 1 , wherein the first part is a stationary bearing housing of an electrical submersible pumping system and the second part is a shaft of the electrical submersible pumping system.

4. The downhole tool of claim 1 , wherein the first part is a stationary bushing, and the second part is a rotating shaft, the downhole tool further comprising a bearing housing, wherein the bushing is housed within the bearing housing.

5. The downhole tool of claim 1 , wherein the first part is a stationary bearing housing and the second part is a shaft that rotates within the stationary bearing housing, the downhole tool further comprising a sleeve that is fixedly connected to the shaft and disposed between stationary bearing housing and the shaft.

6. The downhole tool of claim 1 , wherein the first part is a rotating sleeve and the second part is a rotating shaft, the downhole tool further comprising a stationary bearing housing that supports the first part and the second part.

7. The downhole tool of claim 1 , wherein the first part is a rotating sleeve and the second part is a rotating shaft, the downhole tool further comprising a stationary bearing housing and a stationary bushing within the bearing housing, wherein the bearing housing and the bushing support the first part and the second part.

8. The downhole tool of claim 1 , wherein the first predetermined material property has a lower density than the second predetermined material property.

9. The downhole tool of claim 1 , wherein the first predetermined material property has at least one of voids, cavities, pores, matrix structure, or lattice structure.

10. The downhole tool of claim 1 , wherein a gradient exists between the inner layer and the outer layer such that a material of the additively manufactured first part includes a transition from the first predetermined material property to the second predetermined material property.

11. The downhole tool of claim 1 , further comprising a pressurized fluid within the inner layer of the first part.

12. The downhole tool of claim 11 , further comprising at least one seal configured to define a sealed volume within the outer layer of the first part, the sealed volume bounded by the at least one seal, the outer layer, and the second part, wherein the pressurized fluid is contained within the sealed volume.

13. The downhole tool of claim 11 , further comprising a pressure control system fluidly connected to the inner layer, wherein the pressure control system is configured to control a fluid pressure of the pressurized fluid within the inner layer.

14. The downhole tool of claim 13 , wherein the pressure control system includes a fluid conduit that passes through a pressure control aperture of the outer layer to fluidly connect a fluid supply with the inner layer.

15. An electrical submersible pumping system comprising:
an additively manufactured first part including an inner layer having a first predetermined material property and an outer layer having a second predetermined material property, wherein the inner and outer layers are layers of an integral piece and the first predetermined material property is different from the second predetermined material property; and
a second part configured to rotationally engage with the additively manufactured first part,
wherein one of the first part and the second part is rotated relative to the other of the first part and the second part in operation, and
at least one seal configured to define a sealed volume within the outer layer of the first part, the sealed volume bounded by the at least one seal, the outer layer, and the second part and a pressurized fluid within the inner layer of the first part.

16. The electrical submersible pumping system of claim 15 , wherein the first predetermined material property has a lower density and the second predetermined material property.

17. The electrical submersible pumping system of claim 15 , wherein the first predetermined material property has at least one of voids, cavities, pores, matrix structure, or lattice structure.

18. The electrical submersible pumping system of claim 15 , wherein a gradient exists between the inner layer and the outer layer such that a material of the additively manufactured first part includes a transition from the first predetermined material property to the second predetermined material property.

19. A downhole tool for use in downhole operations, the downhole tool comprising:
an additively manufactured first part including an inner layer having a first predetermined material property and an outer layer having a second predetermined material property, wherein the inner and outer layers are layers of an integral piece and the first predetermined material property is different from the second predetermined material property; and
a second part configured to rotationally engage with the additively manufactured first part,
wherein one of the first part and the second part is rotated relative to the other of the first part and the second part in operation, and
a pressurized fluid within the inner layer of the first part.

20. The downhole tool of claim 19 , further comprising at least one of:
at least one seal configured to define a sealed volume within the outer layer of the first part, the sealed volume bounded by the at least one seal, the outer layer, and the second part, wherein the pressurized fluid is contained within the sealed volume; and
a pressure control system fluidly connected to the inner layer, wherein the pressure control system is configured to control a fluid pressure of the pressurized fluid within the inner layer.

Assignees

• Semple Ryan P
• Baker Hughes A Ge Co Llc

Inventors

• Semple Ryan P

Classifications

• F16C2220/00

  Shaping · CPC title

• F16C2360/00

  Engines or pumps · CPC title

• E21B43/128

  Adaptation of pump systems with down-hole electric drives · CPC title

• F16C33/04 Primary

  Brasses; Bushes; Linings · CPC title

• F16C2352/00

  Apparatus for drilling · CPC title