Methods of forming triggering elements for expandable apparatus for use in subterranean boreholes

Patent metadata

Field	Value
Publication number	US-2017239727-A1
Application number	US-201715591292-A
Country	US
Kind code	A1
Filing date	May 10, 2017
Priority date	May 26, 2011
Publication date	Aug 24, 2017
Grant date	—

Abstract

Expandable apparatus include a triggering element comprising an at least partially corrodible composite material. Methods are used to trigger expandable apparatus using such a triggering element and to form such triggering elements for use with expandable apparatus.

First claim

1 . A method of forming a triggering element for an expandable apparatus for use in a subterranean borehole, comprising:
consolidating a powder comprising metallic particles coated with at least one of a ceramic and an intermetallic compound to form a solid three-dimensional body comprising a discontinuous metallic phase dispersed within a corrodible matrix phase, the metallic phase formed by the metallic particles, the corrodible matrix phase comprising the at least one of a ceramic and an intermetallic compound of the coating on the metallic particles; and sizing and configuring the solid three-dimensional body to be received in a seat formed within the expandable apparatus.

2 . The method of claim 1 , further comprising forming a majority of the corrodible matrix phase with the at least one of a ceramic and an intermetallic compound.

3 . The method of claim 1 , further comprising forming a majority of the at least one of the ceramic and the intermetallic compound with magnesium and at least one of aluminum and nickel.

4 . The method of claim 1 , further comprising forming a majority of the corrodible matrix phase with magnesium and at least one of aluminum and nickel.

5 . The method of claim 1 , further comprising constituting the metallic particles with at least one of a metal or a metal alloy.

6 . The method of claim 1 , further comprising forming the solid three-dimensional body to exhibit a compressive yield strength of at least about 250 MPa.

7 . The method of claim 1 , further comprising constituting the discontinuous metallic phase with nanoparticles of at least one of a metal or a metal alloy.

8 . The method of claim 1 , further comprising constituting the discontinuous metallic phase with at least one of a commercially pure magnesium or a magnesium alloy.

9 . The method of claim 1 , further comprising forming the corrodible matrix phase with at least one of oxygen, magnesium oxide, aluminum oxide, or nickel oxide.

10 . The method of claim 1 , further comprising formulating the corrodible matrix phase to corrode in at least one of a brine solution or an acidic solution.

11 . A method of forming a triggering element for an expandable apparatus for use in a subterranean borehole, comprising:
forming a solid three-dimensional body comprising a discontinuous metallic phase dispersed within a corrodible matrix phase to define at least a portion of the triggering element, the metallic phase formed by the metallic particles coated with at least one of a ceramic and an intermetallic compound; formulating the corrodible matrix phase to corrode in at least one of a brine solution or an acidic solution; and sizing the triggering element to be received in a seat formed within the expandable apparatus.

12 . The method of claim 11 , further comprising forming a shell defining an outer surface of the triggering element comprising a shell material around a core material comprising the solid three-dimensional body, wherein the shell material is formed from a relatively non-corrodible material as compared to the core material.

13 . The method of claim 12 , further comprising defining at least one perforation in the outer surface of the triggering element extending through the shell and into the core by at least some depth.

14 . The method of claim 13 , further comprising dimensioning the at least one perforation to control a rate of intrusion of the at least one of the brine solution or the acidic solution into at least a portion of the triggering element.

15 . The method of claim 11 , wherein forming a solid three-dimensional body comprises:
forming at least two or more portions of a relatively non-corrodible material as compared to the discontinuous metallic phase dispersed within the corrodible matrix phase of the solid three-dimensional body; and binding the at least two or more portions of a relatively non-corrodible material together with the discontinuous metallic phase dispersed within the corrodible matrix phase.

16 . The method of claim 11 , further comprising:
defining at least one stress riser extending through an outer surface of the triggering element and into the triggering element; and configuring the at least one stress riser to concentrate stress in order to accelerate structural degradation of the triggering element.

17 . The method of claim 11 , further comprising:
forming a shell defining an outer surface of the triggering element around the solid three-dimensional body; defining at least one stress riser extending through the outer surface of the triggering element and into the shell of the triggering element; and configuring the at least one stress riser to concentrate stress in order to accelerate structural degradation of the triggering element.

18 . The method of claim 17 , forming the shell from a relatively non-corrodible material as compared to material of the solid three-dimensional body.

19 . A method of forming a triggering element for an expandable apparatus for use in a subterranean borehole, comprising:
consolidating a powder comprising metallic particles coated with at least one of a ceramic and an intermetallic compound to at least partially define a drop ball comprising a discontinuous metallic phase dispersed within a corrodible matrix phase, the metallic phase formed by the metallic particles, the corrodible matrix phase comprising the at least one of a ceramic and an intermetallic compound of the coating on the metallic particles; and sizing the drop ball to be received in a seat formed within the expandable apparatus.

20 . The method of claim 19 , further comprising forming a majority of the corrodible matrix phase with the at least one of a ceramic and an intermetallic compound.

Assignees

• Baker Hughes Inc

Inventors

• Oxford James Andy

Classifications

• B22F2998/10

  Processes characterised by the sequence of their steps · CPC title

• B22F2301/15

  Nickel or cobalt · CPC title

• B28B3/003

  Pressing by means acting upon the material via flexible mould wall parts, e.g. by means of inflatable cores, isostatic presses (isostatic presses in general B30B5/02) · CPC title

• B22F2301/058

  Magnesium · CPC title

• B22F2005/001

  Cutting tools, earth boring or grinding tool other than table ware · CPC title