Crowns for earth-boring casing shoes, earth-boring casing shoes, and methods of forming earth-boring casing shoes

Patent metadata

Field	Value
Publication number	US-9689214-B2
Application number	US-201414310555-A
Country	US
Kind code	B2
Filing date	Jun 20, 2014
Priority date	Apr 8, 2011
Publication date	Jun 27, 2017
Grant date	Jun 27, 2017

Abstract

Earth-boring casing shoes include a crown configured for at least one of drilling and reaming a wellbore when the crown is attached to a section of casing and the casing is advanced into a wellbore. The crown includes a body comprising a corrodible composite material, and at least one cutting structure carried on the body. The casing shoes further include a connection structure configured for attachment to a section of casing. Methods are used to form such casing shoes, and such casing shoes are used to install casing within wellbores.

First claim

What is claimed is:

1. An earth-boring casing shoe, comprising:
a crown configured for at least one of drilling and reaming a wellbore when the crown is attached to a section of casing and the casing is advanced into a wellbore, the crown comprising:
a body comprising a composite material, the composite material including a discontinuous metallic phase dispersed within a corrodible matrix phase, the discontinuous metallic phase comprising a metal or metal alloy, the corrodible matrix phase comprising at least one of a ceramic and an intermetallic compound, the corrodible matrix phase comprising magnesium, oxygen, and at least one of nickel and aluminum; and
at least one cutting structure carried on the body; and

a connection structure configured for attachment to a section of casing.

2. The casing shoe of claim 1 , wherein the composite material of the body has a compressive yield strength between about 250 MPa and about 300 MPa.

3. The casing shoe of claim 1 , wherein the discontinuous metallic phase comprises nanoparticles of the metal or metal alloy.

4. The casing shoe of claim 1 , wherein the discontinuous metallic phase comprises commercially pure magnesium or a magnesium alloy.

5. The casing shoe of claim 1 , wherein the corrodible matrix phase comprises each of magnesium, aluminum, nickel, and oxygen.

6. The casing shoe of claim 5 , wherein the corrodible matrix phase comprises between about 0 atomic percent (0 at %) and about ten atomic percent (10 at %) oxygen.

7. The casing shoe of claim 1 , wherein the corrodible matrix phase comprises between zero atomic percent (0 at %) and about twenty atomic percent (20 at %) aluminum, between zero atomic percent (0 at %) and about ten atomic percent (10 at %) nickel, and between zero atomic percent (0 at %) and about ten atomic percent (10 at %) oxygen.

8. The casing shoe of claim 1 , wherein the corrodible matrix phase comprises at least one of magnesium oxide, aluminum oxide, and nickel oxide.

9. The casing shoe of claim 1 , wherein the corrodible matrix phase is configured to corrode in at least one of a brine solution and an acidic solution.

10. The casing shoe of claim 1 , wherein the composite material has a density between about 2.0 gm/cm 3 and about 2.5 gm/cm 3 at room temperature.

11. The casing shoe of claim 1 , wherein the connection structure comprises a male or female threaded connector.

12. The casing shoe of claim 1 , wherein the connection structure comprises a surface configured to abut against an end of a section of casing and to at least partially define a weld groove.

13. The casing shoe of claim 1 , wherein the casing shoe comprises a casing bit or a casing reamer.

14. A method of forming an earth-boring casing shoe, 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, the corrodible matrix phase comprising magnesium, oxygen, and at least one of nickel and aluminum;
machining the solid three-dimensional body to form a crown of the earth-boring casing shoe;
providing at least one cutting structure on the crown of the earth-boring casing shoe; and
providing a connection structure configured for attachment to a section of casing on the earth-boring casing shoe.

15. The method of claim 14 , wherein consolidating the powder comprises at least one of heating and pressing the powder.

16. The method of claim 15 , wherein at least one of heating and pressing the powder comprises applying isostatic pressure to the powder.

17. The method of claim 16 , wherein at least one of heating and pressing the powder further comprises hot-pressing the powder after applying isostatic pressure to the powder.

18. The method of claim 15 , wherein at least one of heating and pressing the powder comprises hot-pressing the powder.

19. The method of claim 14 , further comprising coating the metallic particles with the at least one of a ceramic and an intermetallic compound to form the powder.

20. A crown for an earth-boring casing shoe, the crown comprising:
a body comprising a composite material, the composite material comprising:
a corrodible matrix phase comprising at least one of a ceramic and an intermetallic compound, the corrodible matrix phase comprising magnesium, oxygen, and at least one of nickel and aluminum; and
a discontinuous metallic phase comprising discrete metallic particles dispersed within the corrodible matrix phase; and

cutting structures on the body.

Assignees

• Baker Hughes Inc

Inventors

• Oxford James Andy

Classifications

• B22F1/16

  Metallic particles coated with a non-metal (coated with lubricating or binding agents or with organic material B22F1/10) · CPC title

• B22F1/02

  Operations & Transport · mapped topic

• B22F3/24

  After-treatment of workpieces or articles {(B22F3/1146 takes precedence)} · CPC title

• B22F5/00

  Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product · CPC title

• B22F2005/001

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