Manufacture of well tools with matrix materials

Patent metadata

Field	Value
Publication number	US-9987675-B2
Application number	US-201214378992-A
Country	US
Kind code	B2
Filing date	May 30, 2012
Priority date	May 30, 2012
Publication date	Jun 5, 2018
Grant date	Jun 5, 2018

Abstract

A method of manufacturing a well tool can include loading a matrix material into a mold, then sintering the matrix material in the mold; and then loading another matrix material into the mold. A well tool can include a longitudinal axis, an erosion resistant layer exposed to one or more erosive factors when the well tool is installed in a well, and a support layer which supports the erosion resistant layer. The erosion resistant and support layers can include respective matrix materials, and the erosion resistant layer can extend greater than approximately 1.27 cm in a direction parallel to the longitudinal axis. Another method of manufacturing a well tool can include forming a rigid layer from a powdered matrix material; and then infiltrating both that matrix material and another matrix material with a hot liquid binder material.

First claim

What is claimed is:

1. A method of manufacturing a well tool, the method comprising:
installing a mandrel in a mold and defining a gap between the mandrel and a surface of the mold;
loading a first matrix material comprising a powder into the gap, wherein the first matrix material extends along the surface of the mold;
sintering the first matrix material in the gap;
removing the mandrel from the mold thereby removing the gap;
loading a second matrix material into the mold: and
infiltrating the sintered first matrix material and the second matrix material with a hot liquid binder material in the mold.

2. The method of claim 1 , further comprising before the sintering, mixing a binding agent with the first matrix material.

3. The method of claim 1 , wherein the gap has a length greater than approximately 1.27 cm allowing for the first matrix material to extend greater than 1.27 cm along the surface of the mold.

4. The method of claim 1 , wherein the gap has a length greater than approximately 2.54 cm allowing for the first matrix material to extend greater than 2.54 cm along the surface of the mold.

5. The method of claim 1 , wherein the powder comprises a powdered tungsten carbide material.

6. The method of claim 1 , wherein the first matrix material has greater erosion resistance as compared to the second matrix material.

7. The method of claim 1 , wherein the second matrix material has greater ductility as compared to the first matrix material.

8. The method of claim 1 , wherein the second matrix material has greater toughness as compared to the first matrix material.

9. The method of claim 1 , wherein the second matrix material has greater impact strength as compared to the first matrix material.

10. A method of manufacturing a well tool, the method comprising:
installing a mandrel having a longitudinal axis that is oriented vertically in a in a mold and defining a vertical gap between the mandrel and a surface of the mold;
loading a first matrix material comprising a powder into the vertical gap, wherein the gap has a length greater than approximately 1.27 cm allowing for the first matrix material to extend vertically greater than 1.27 cm along the surface of the mold;
sintering the first matrix material in the gap;
removing the mandrel from the mold thereby removing the gap;
loading a second matrix material into the mold and
infiltrating the sintered first matrix material and the second matrix material with a hot liquid binder material in the mold.

11. The method of claim 10 , further comprising before the sintering, mixing a binding agent with the first matrix material.

12. The method of claim 10 , wherein the gap length is greater than approximately 2.54 cm allowing for the first matrix material to extend greater than 2.54 cm along the surface of the mold.

13. The method of claim 10 , wherein the powder comprises a powdered tungsten carbide material.

14. The method of claim 10 , wherein the first matrix material has greater erosion resistance as compared to the second matrix material.

15. The method of claim 10 , wherein the second matrix material has greater ductility as compared to the first matrix material.

16. The method of claim 10 , wherein the second matrix material has greater toughness as compared to the first matrix material.

17. The method of claim 10 , wherein the second matrix material has greater impact strength as compared to the first matrix material.

Assignees

• Thomas Jeffrey G
• Halliburton Energy Services Inc

Inventors

• Thomas Jeffrey G

Classifications

• C22C1/1036 Primary

  starting from a melt · CPC title

• B23P15/32

  twist-drills · CPC title

• C04B35/5626 Primary

  based on tungsten carbides · CPC title

• B28B1/008

  made from two or more materials having different characteristics or properties (casting for producing layered articles B28B1/16; feeding several succesive layers, optionally of different materials B28B13/022; coating B28B11/04; applying material to surfaces to form a permanent layer thereon B28B19/00) · CPC title

• E21B10/46

  characterised by wear resisting parts, e.g. diamond inserts · CPC title