Degradable high shock impedance material

Patent metadata

Field	Value
Publication number	US-9347119-B2
Application number	US-201113225413-A
Country	US
Kind code	B2
Filing date	Sep 3, 2011
Priority date	Sep 3, 2011
Publication date	May 24, 2016
Grant date	May 24, 2016

Abstract

A selectively corrodible powder compact that may be used to make the components of a selectively corrodible perforating system is disclosed. The selectively corrodible powder compact includes a cellular nanomatrix comprising a nanomatrix material. The selectively corrodible powder compact also includes a plurality of dispersed particles comprising a particle core material having a density of about 7.5 g/cm 3 or more, dispersed in the cellular nanomatrix. The selectively corrodible powder compact further includes a bond layer extending throughout the cellular nanomatrix between the dispersed particles.

First claim

The invention claimed is:

1. A selectively corrodible powder compact, comprising:
a cellular nanomatrix comprising a nanomatrix material;
a plurality of dispersed particles comprising a plurality of different particle core materials dispersed in the cellular nanomatrix, 50 volume percent or more of the particle core materials comprising a metal having a density of about 7.5 g/cm 3 or more; and
a bond layer extending throughout the cellular nanomatrix between the dispersed particles.

2. The powder compact of claim 1 , wherein the particle core materials further comprise at least one of ceramic, cermet, glass or carbon, or a composite thereof, or a combination of any of the foregoing materials.

3. The powder compact of claim 1 , wherein the particle core materials comprise Fe, Ni, Cu, W, Mo, Ta, U or Co, or a carbide, oxide or nitride comprising at least one of the foregoing metals, or an alloy comprising at least one of the aforementioned materials, or a composite comprising at least one of the aforementioned materials, or a combination of any of the foregoing.

4. The powder compact of claim 1 , wherein the particle core materials are ductile.

5. The powder compact of claim 1 , wherein the dispersed particles further comprise a rare earth element.

6. The powder compact of claim 1 , wherein the dispersed particles have an average particle size of about 50 nm to about 500 μm.

7. The powder compact of claim 1 , wherein the dispersion of dispersed particles comprises a substantially homogeneous dispersion within the cellular nanomatrix.

8. The powder compact of claim 1 , wherein the dispersion of dispersed particles comprises a multi-modal distribution of dispersed particle sizes within the cellular nanomatrix.

9. The powder compact of claim 1 , wherein the dispersed particles have an equiaxed particle shape or a substantially elongated particle shape.

10. The powder compact of claim 1 , further comprising a plurality of dispersed second particles, the dispersed second particle having a density greater than 7.5 g/cm 3 , wherein the dispersed second particles are also dispersed within the cellular nanomatrix and with respect to the dispersed particles.

11. The powder compact of claim 10 , wherein the dispersed second particles comprise Fe, Ni, Cu, or Co, or a carbide, oxide or nitride comprising at least one of the foregoing metals, or an alloy comprising at least one of the aforementioned materials, or a composite comprising at least one of the aforementioned materials, or a combination of any of the foregoing.

12. The powder compact of claim 1 , wherein the nanomatrix material comprises Al, Zn, Mn, Mg, Mo, W, Cu, Fe, Si, Ca, Co, Ta, Re or Ni, or an oxide, carbide or nitride thereof, or a combination of any of the aforementioned materials, and wherein the nanomatrix material has a chemical composition and the particle core material has a chemical composition that is different than the chemical composition of the nanomatrix material.

13. The powder compact of claim 1 , wherein the cellular nanomatrix has an average thickness of about 50 nm to about 5000 nm.

14. The powder compact of claim 1 , wherein the compact is formed from a sintered powder comprising a plurality of powder particles, each powder particle having a particle core that upon sintering comprises a dispersed particle and a single metallic coating layer disposed thereon, and wherein the cellular nanomatrix between adjacent ones of the plurality of dispersed particles comprises the single metallic coating layer of one powder particle, the bond layer and the single metallic coating layer of another of the powder particles.

15. The powder metal compact of claim 1 , wherein the compact is formed from a sintered powder comprising a plurality of powder particles, each powder particle having a particle core that upon sintering comprises a dispersed particle and a plurality of metallic coating layers disposed thereon, and wherein the cellular nanomatrix between adjacent ones of the plurality of dispersed particles comprises the plurality of metallic coating layers of one powder particle, the bond layer and plurality of metallic coating layers of another of the powder particles, and wherein adjacent ones of the plurality of metallic coating layers have different chemical compositions.

16. The powder compact of claim 1 , wherein the powder compact comprises a plurality of unsintered powder particles.

17. The powder compact of claim 16 , wherein the powder compact has a density that is less than a theoretical density of the powder particles.

18. The powder compact of claim 16 , wherein the powder compact is formed by a method of uniaxial pressing, isostatic pressing, roll forming, forging, or extrusion at a forming temperature.

19. The powder compact of claim 18 , wherein the forming temperature comprises an ambient temperature.

20. The powder compact of claim 1 , wherein the powder compact comprises a plurality of sintered powder particles.

21. The powder compact of claim 20 , wherein the powder compact has a density that is substantially the same as a theoretical density of the powder particles.

22. The powder compact of claim 20 , wherein the powder compact is formed by a method of uniaxial pressing, isostatic pressing, roll forming, forging, or extrusion at a forming temperature.

23. The powder compact of claim 22 , wherein the forming temperature is about 20° C. to about 300° C. below a melting temperature of the powder particles.

24. The powder compact of claim 1 , wherein at least one of the particle core materials has a density of about 8.5 g/cm 3 or more.

25. The powder compact of claim 1 , wherein at least one of the particle core materials has a density of about 10 g/cm 3 or more.

Assignees

• Xu Zhiyue
• Baker Hughes Inc

Inventors

• Xu Zhiyue

Classifications

• B22F1/17

  Metallic particles coated with metal · CPC title

• Y10T428/249921

  Web or sheet containing structurally defined element or component · CPC title

• B22F3/17

  by forging · CPC title

• C22C29/00 Primary

  Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides {(C22C26/00 takes precedence)} · CPC title

• Y10T428/268

  Monolayer with structurally defined element · CPC title