System and method for manufacturing downhole tool components

Patent metadata

Field	Value
Publication number	US-11078729-B2
Application number	US-201816198065-A
Country	US
Kind code	B2
Filing date	Nov 21, 2018
Priority date	Nov 24, 2014
Publication date	Aug 3, 2021
Grant date	Aug 3, 2021

Abstract

A method is provided for manufacturing a segment of a drill string, such as a tubular tool, from a plurality of layers. The method includes arranging a plurality of layers based on a selected length of the segment. Each of the plurality of layers includes an aperture that is received over an alignment feature that restricts movement of the plurality of layers to two or fewer degrees of freedom. A joining process is performed to join the plurality of layers, which may include at least one replacement layer.

First claim

What is claimed is:

1. A system for assembling a segment of a drill string, the system comprising:
a plurality of unfused physical layers including an aperture formed therein, the plurality of unfused physical layers manufactured based on a plurality of planned layers, the plurality of planned layers determined by slicing a virtual three-dimensional tubular structure into the plurality of planned layers;
an alignment feature having the plurality of unfused physical layers inserted over the alignment feature to align the aperture formed therein from the plurality of unfused physical layers, and
wherein the plurality of unfused physical layers are fused to form the segment, the aperture of each of the plurality of unfused physical layers together forming a common bore.

2. The system of claim 1 , wherein the plurality of unfused physical layers are fused via electron beam welding.

3. The system of claim 1 , wherein the plurality of unfused physical layers are arranged in a preselected order over the alignment feature.

4. The system of claim 1 , wherein the alignment feature is spiral shaped.

5. The system of claim 1 , wherein the alignment feature maintains design tolerances for the segment.

6. The system of claim 1 , wherein the alignment feature comprises parallel rods and each of the plurality of unfused physical layers includes two or more apertures formed therein to receive the parallel rods.

7. The system of claim 6 , wherein the parallel rods comprise a large rod and a small rod, the large rod having a larger diameter than the small rod.

8. The system of claim 7 , further comprising fitting an insert over at least one of the large rod or the small rod before arranging the plurality of unfused physical layers over the alignment feature.

Assignees

• Halliburton Energy Services Inc

Inventors

• Wong Alston Jun Ngai
• Kew Jia Ming
• Ho Doren Hui Ping
• Chan Guan Yee

Classifications

• B23K15/0053

  Seam welding · CPC title

• B22F3/105

  by using electric current {other than for infrared radiant energy}, laser radiation or plasma (B22F3/11 takes precedence){; by ultrasonic bonding (B22F3/115 takes precedence)} · CPC title

• B23K15/0006

  specially adapted for particular articles or work · CPC title

• B22F7/062

  involving the connection or repairing of preformed parts · CPC title

• E21B17/00 Primary

  Drilling rods or pipes; Flexible drill strings; Kellies; Drill collars; Sucker rods; {Cables;} Casings; Tubings · CPC title