CN103688014A - 选择性水力压裂工具及其方法 - Google Patents
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- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
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- E—FIXED CONSTRUCTIONS
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Abstract
一种选择性的井下工具,包括具有能够使流体通过的纵向孔的管。管的壁上具有阀门开口。可膨胀球座能在第一尺寸与更大的第二尺寸之间选择性地移动,第一尺寸设计成捕获球以阻止通过管柱的流动,所述第二尺寸设计成释放该球通过管柱。阀盖在管柱内纵向地移动,阀盖包括可溶解的插入件。还包括一种操作井下工具的方法。
Description
相关申请的交叉引用
本申请要求2011年7月28日提交的美国申请No.13/193,028的优先权,该申请全部内容在此引入作为参考。
背景技术
在钻井和完井工业中,通常形成钻孔以便开采或注入流体。钻孔用于勘探或提取自然资源,例如烃、油、天然气、水、和CO2封存。为了提高从地下钻孔的开采率和提取率,可以利用加压浆体、含支撑剂的压裂流体或其它处理流体。一旦停止注入压裂流体,岩层壁中的压裂就可以通过颗粒而保持打开。
传统压裂系统使加压压裂流体流过管柱,所述管柱向井下延伸穿过横穿待压裂的区域的钻孔。管柱可以包括打开以允许将压裂流体引向目标区域的阀门。为了从地面远程打开这些阀门,一球落入管柱中,着陆在与特定阀门相关联的球座上以阻止流体流过管柱,因而在球的井口方向积聚压力,所述压力迫使套筒下向井下,从而打开管柱壁上的孔口。当涉及多个区域时,球座具有变化的尺寸,最靠井下的座是最小的,最靠井口的座是最大的,这样,直径增加的球顺序落入管柱中从而从井下端到井口端顺序地打开阀门。因而,通过从压裂最靠井下的区域开始并向上朝着最靠井口的区域作业,以“自底向上”的方式压裂钻孔区域。
为避免与采用不同尺寸的球座(最小的球座可能会过多地限制通过管柱的流动)和相应的不同尺寸的球相关联的不可避免的复杂性,已经提议使用可变形的球和球座,然而,迫使球通过球座的速率引起了额外的复杂性,包括处理选定材料的不同的变形率,因为其在井下环境不会像期望的那样起作用。而且,尽管利用不同尺寸的球提供了某些优点,但是,压裂操作的顺序仍然局限于“自底向上”的方式。
发明内容
一种选择性的井下工具,包括:管,所述管具有能够使流体从中通过的纵向孔并且具有所述管的壁中的阀门开口;可膨胀球座,所述可膨胀球座能够选择性地在第一尺寸与更大的第二尺寸之间运动,所述第一尺寸设计成捕获球以阻止通过所述管的流动,所述第二尺寸设计成释放该球通过所述管;和阀盖,所述阀盖能够在所述管内纵向地运动,所述阀盖包括可溶解的插入件。
一种操作井下工具的方法,该方法包括:将井下工具下入到钻孔中,该工具包括具有由阀盖覆盖的阀门开口的管;纵向移动阀盖,以使阀门开口暴露出来;通过阀门开口进行作业之后,通过阀盖重新覆盖阀门开口;和溶解阀盖的一部分,以再次暴露阀门开口。
附图说明
不管怎样,下面的描述都不应看作是限制性的。参照附图,同样的元件标记相同的附图标记表示:
图1描绘了处于送入位置的选择性的水力压裂工具的示例性实施例的截面图;
图2A-图2C描绘了用于图1的选择性的水力压裂工具内的球座的示例性实施例的透视图和截面图;
图3描绘了用于图1的选择性的水力压裂工具的位置的指示路径和指示销的一部分的示例性实施例的示意图;
图4描绘了图1的选择性的水力压裂工具的截面图,球落入其中并在其内建立了压力;
图5描绘了用于图4的选择性的水力压裂工具的位置的指示路径和指示销的一部分的示意图;
图6描绘了图1的选择性的水力压裂工具的截面图,其中球座膨胀;
图7描绘了用于图6的选择性的水力压裂工具的位置的指示路径和指示销的一部分的示意图;
图8描绘了图1的选择性的水力压裂工具的横截面图,其中球座缩回;
图9描绘了用于图8的选择性的水力压裂工具的位置的指示路径和指示销的一部分的示意图;
图10描绘了依照现有技术利用选择性的水力压裂工具可实现的压裂操作顺序的示意图;
图11描绘了利用选择性的水力压裂工具可实现的另一压裂操作顺序的示例性实施例的示意图;
图12描绘了利用选择性的水力压裂工具可实现的又一压裂操作顺序的示例性实施例的示意图;
图13是在此公开的已经嵌在封装材料中并分段的粉末310的微观照片;
图14是粉末颗粒312的示例性实施例的示意图,就好像图13的截面5-5所表示的示例性截面图中显示的那样;
图15是在此公开的粉末压块的示例性实施例的微观照片;
图16是利用粉末制成的图15的粉末压块的示例性实施例的示意图,所述粉末压块具有单层粉末颗粒,就好像沿截面7-7剖取的那样;
图17是利用粉末制成的图15的粉末压块的另一示例性实施例的示意图,所述粉末压块具有多层粉末颗粒,就好像沿截面7-7剖取的那样;和
图18是在此公开的粉末压块的属性作为时间的函数的变化和粉末压块环境的状态变化的示意图。
具体实施方式
参照这些附图,在此以举例而不是限制的方式给出了所披露的设备和方法的一个或多个实施例的详细说明。
在此公开了一种选择性的水力压裂工具100(如图1、4、6和图8所示)及方法,用于以多种配置如图10-图12示意性所示地压裂钻孔10,所述配置包括“自顶向下”、“自底向上”和“中心蚕食”。虽然上面描述的工具和方法已经局限于通过从小直径球开始并用接连变大的球向井口作业的如图10所示的“自底向上”的方式压裂钻孔,但是,选择性的水力压裂工具100提供了能够利用其实现各种压裂顺序的单孔方案。
图1中示出了处于用于将工具100下入到钻孔中的“下入”位置中的选择性的水力压裂工具100的示例性实施例。虽然工具100被描述成压裂工具,但是工具100也可用于在井眼中执行其它作业和任务。为便于描述,工具100包括井口端102和井下端104,不过应当明白,井口端102不一定是工具100的最靠井口端,井下端104不一定是工具100的最靠井下端,因为井下端104和/或井口端102可以连接到工具100的包括如图1所示的用于压裂另外的区域的另外的重复结构的另一段,或者可以连接到油管接头、油管加长段或其它未显示的井下工具部分。工具包括管状本体106,所述管状本体中在中心定位有轴向延伸通过所述管状本体的钻孔108,以用于例如但不限于压裂流体、开采流体等的流动。
工具包括一可膨胀球座150,所述球座允许操作者对全部区域使用单一尺寸的球,并因而用于单孔操作,所述单孔操作增加了工具100制造以及操作这二者的简便性。虽然在这种作业中通常采用球状球,术语球包括能落入孔108中并被捕获并随后从球座150被释放的任何形状的物体。j-机构指示设备200为球座150的置入提供可选择的位置,并允许球穿过球座150,而无需剪切/激活工具100。阀盖250包括可溶解的材料,所述可溶解的材料允许插入件252封闭被压裂区域,然后在没有干预的情况下溶解,以在完成钻孔10之后允许从该区域开采。
在可膨胀球座150的示例性实施例中,包括多个指状物154的筒夹152与指示设备200相接合。球座150本身显示在图2A-图2C中。指状物154从可一体地附接于指状物154的固定端158上的基部156纵向延伸。开口157设置在指状物154的固定端158附近从而为指状物154提供柔性。指状物154的自由端160可相对于基部156从第一状态径向运动至第二状态,在所述第一状态中,指状物154的自由端160稍微向内塌陷以提供如图1和图2B所示的减小的第一直径,在所述第二状态中,指状物154的自由端160被偏压回未压缩状态以提供如图6和图2C所示的增大的第二直径。可以理解的是,在操作工具100时,球50与工具100结合使用,当筒夹152处于第一状态中时,球50具有适于被捕获在球座150中的直径,当筒夹152处于第二状态中时,球50可通过球座150。球座150还包括漏斗状部分162,所述漏斗状部分用于将球50引导至球座150中并引向指状物154的自由端160。漏斗状部分162可利用诸如O形环的密封件256相对于阀盖250的阀门套筒254密封。漏斗状部分162的井口端164包括与阀门套筒254的台肩258邻接的肩部166。在漏斗状部分162的井下,指状物154的自由端160还可以包括倾斜表面168,所述倾斜表面朝着工具100的井口端102向外扩张,以便接收筒夹152内的球50。当一起压缩时,指状物154的倾斜表面168形成漏斗形状,球50被接收在所述漏斗形状中。指状物154的自由端160在第一状态中可通过阀门套筒254的倾斜表面260被压缩在一起。
虽然筒夹152已经被描述成用于形成可膨胀球座150,可膨胀球座的替换性的示例性实施例可以包括开口环或“C”形环,其中,指示设备200或连接于指示设备200的结构在本体106与环之间的运动将迫使该环被压缩,从而减少该环的内径,从而防止球50通过该环,直到指示设备200远离该环的运动打开该环,以增大该环的孔尺寸,从而允许球50通过。
在j-机构指示设备200的示例性实施例中,设备200包括具有用于流体流动的中心纵向孔204的指示套筒202,其中,孔204穿过管状本体106的孔108。套筒202还包括诸如凹槽的指示路径206,其形成在套筒202直径周围。图3、5、7和图9中显示了指示路径206的一部分,不过应当明白,路径206可以不中断地围绕套筒202的周边形成,以便使指示销208穿过。路径206包括:第一段210,所述第一段为延伸的纵向井口部分;第二段212,所述第二段为延伸的纵向井下部分,每个第一段210对应两个第二段212;和第三段214,所述第三段为介于第一段210之间的稍微突出的纵向井口部分,其中,第三段214连接两个相邻的第二段212。第一段210和第三段214的井口端226、228为停止点,所述停止点偏压指示销208以使其保持在其中直到从其中有目的地移除。指示销208穿过第一、第二和第三段210、212、214,同时附接于被捕获在指示套筒202和工具100的外中间本体部分110之间的可动管状区段216。可以采用多个指示销208来分配本体106周围的载荷,在这样的情况下,根据工具100的级,每个指示销208将与其它销208相对同时地位于第一、第二或第三段210、212、214上。压缩弹簧218环绕指示套筒202并位于指示销208的井下方以相对于指示套筒202偏压指示销208,指示销208的井口方的弹簧部件220和可动管状区段216也环绕指示套筒202。弹簧部件220的井口端222抵接包括倾斜表面170的内管柱172。弹簧部件220和压缩弹簧218可以包括一系列交替的成叠弹簧垫圈。而且,虽然描绘的不同,但是,压缩弹簧218和弹簧部件220可以为以压缩状态工作的任何形式的弹簧。
工具100的外中间本体部分110连接于工具100的井下本体部分112。工具100的井下本体部分112包括凹进区段114,所述凹进区段包括接触压缩弹簧218的井下端224的井口表面116。井下本体部分112的凹进区段114附接于中间本体部分110的井下端118,其中,中间本体部分凹进以与井下本体部分112的凹进区段114匹配和重叠。阀门套筒254的井下端262固定附接于可动管状区段216,并因此环绕弹簧部件220、球座150和内管柱172。工具100的井口本体部分120环绕阀门套筒254的井口部分。井口本体部分120的井下端122连接于外中间本体部分110。井口本体部分120包括用于通过允许压裂流体流过其中而允许进行压裂操作的阀门开口124。阀门开口124也可用于使开采流体流过或用于其它井下作业。井口本体部分120通过剪切销126连接于阀门套筒254。
在阀盖250的示例性实施例中,阀盖250包括如上所述经由剪切销126连接于井口本体部分120的阀门套筒254,所述阀门套筒254在其井下端262连接于可动管状区段216。用于密封件266的凹进部264设置在阀门套筒254的井口端268上,用于密封件272的凹进部270设置在阀门套筒254的中心区域上。阀盖250还包括由可溶解材料制成的可溶解插入件252,插入件252位于设置在阀门套筒254的井口端268上的密封件266的井下方。在下入位置中,如图1所示,插入件252与阀门开口124对齐,以防止进入任何区域。密封件266、272进一步确保泵送通过孔108的任何流体在有意排出之前都不会排出工具100。可溶解插入件252的外周比阀门开口124的外周大,并可以具有椭圆形或长方形槽形状、环形、矩形或椭圆形、或者被认为压裂作业或其它井下作业所必需的任何其它形状。可溶解插入件252和/或阀盖250可以包括接合结构以将可溶解插入件252保持在阀盖250内的适当位置,直到其被溶解。这样的接合结构可以包括但不限于任意数量的唇部、舌部和凹槽、台肩、啮合齿周边等等。也可以采用诸如销和结合材料等附加结构。替代性地或者另外,可溶解插入件252的材料可直接模制在阀盖250的开口内,使得可溶解插入件252结合到阀盖250,直到可溶解插入件252被溶解。
美国专利公开No.2001/0135952(Xu等)全部内容在此结合作为参考。插入件252的可溶解材料可以包括受控电解金属材料300,如图13所示,例如可从贝克休斯公司(Baker Hughes Inc)获得的CEMTM材料。材料300用作可溶解插入件252,以在压裂之后封闭一区域,并允许其它区域在不泄漏到前面的区域的情况下压裂。在所有区域已被压裂之后,材料300通过暴露于某些化学品就可以被溶解掉,在阀门套筒254中留下孔,从而允许从之前压裂的全部区域进行开采。可溶解插入件252包含至少部分地阻塞或堵塞阀门套筒254中的孔的障碍物、阻挡物、或层形式的可降解材料300。材料300起初至少部分地阻塞/堵塞该孔。基于暴露于与之接触的流体,材料300然后将腐蚀、溶解、降解或以其它方式被移除。一般来说,在此所使用的术语“可降解”应当用来指能够腐蚀、溶解、降解、分散或以其它方式被移除或消除,而“降解”或“降解的”同样是描述材料腐蚀、溶解、分散或以其它方式被移除或消除。任何其它形式的“降解”也应当包含这个意思。流体可以是自然钻孔流体,例如水,油等等,或者可以是为了降解所述材料300的特定目而被添加到钻孔中的流体。材料300可以由上面提到的可降解的各种材料构成,但是,一个实施例特别使用了高可降解的镁基材料,其具有选择性定制的降解率和/或屈服强度。在本发明中,材料本身将在后面详细论述。该材料呈现优越的强度,同时完整而又容易地以受控的方式、在选择的短时间期限内降解。该材料可在水、水基浆体、井下盐水或酸中降解,例如,根据要求,以选定的速率(如上所述)降解。另外,可以利用表面不规则度来增大材料300暴露于降解流体的表面面积,例如凹槽、褶皱、凹陷等等。在材料300降解期间,阀门套筒254中的孔可以被打开、除去堵塞、形成和/或扩大。因为上面公开的材料300可以定制成在约4-10分钟内完全降解材料,所以,该孔可以根据需要实质上立即被打开、除去堵塞、形成和/或扩大。即使初始完全被可降解材料300阻塞,阀门套筒254中的孔也仍然被认为并被称为是孔,这是因为可溶解插入件252的可降解材料300将会被移除的。
在此所述的可溶解插入件252的材料300为轻质、高强度金属材料。这些轻质、高强度且能可选择可控制地降解的材料300包括由被涂覆的粉末材料形成的完全致密的烧结粉末压块,所述被涂覆的粉末材料包括各种轻质颗粒芯和具有各种单层和多层纳米级覆层的芯材料。这些粉末压块由被涂覆的金属粉末制成,所述被涂覆的金属粉末包括各种电化学活性的(例如具有较高的标准氧化电势)轻质、高强度颗粒芯和诸如电化学活性金属的芯材料,所述芯材料散布在由金属涂覆材料的各种纳米级金属覆层形成的多孔纳米母体内,并且在钻孔应用中尤其有用。这些粉末压块提供了机械强度属性、低密度和可选择且可控的腐蚀属性的独特、有利的组合,所述机械强度属性例如是压缩和剪切强度,所述可选择且可控的腐蚀属性尤其是在各种钻孔流体中的快速且受控的溶解。例如,可以选择这些粉末的颗粒芯和覆层,以提供适于用作高强度工程材料的烧结粉末压块,所述高强度工程材料具有可与包括碳、不锈钢和合金钢的各种其它工程材料相比的压缩强度和剪切强度,但是还具有可与各种聚合物、弹性体、低密度多孔陶瓷和复合材料相比的较低的密度。作为又一示例,这些粉末和粉末压块材料可以构造成响应于环境条件的改变而提供可选择且可控制的降解或处理,例如,响应于紧邻由该压块形成的可溶解插入件252的钻孔的属性或状态的改变,包括与粉末压块接触的钻孔流体的属性的改变,从非常慢的溶解率转变到非常快的溶解率。所描述的可选择且可控制的降解或处理特性还允许保持由这些材料制成的可溶解插入件252的尺寸稳定性和强度,直到不再需要保持所述尺寸稳定性和强度,这时,可以改变预定环境条件而通过快速溶解加速这些材料的移除,所述预定环境条件例如是钻孔条件,包括钻孔流体温度、压力或pH值。这些被涂覆的粉末材料和粉末压块、由其形成的工程材料以及它们的制造方法在下面进一步描述。
参照图13-图18,可以进一步搜集有关材料300的进一步说明。在图13中,金属粉末310包括多个被涂覆的金属粉末颗粒312。粉末颗粒312可以形成为提供粉末310,包括自由流动粉末,粉末310可以浇注或其它方式设置成具有各种形状和尺寸的各种形式或模(未显示),而且可用来形成在此所述的前体粉末压块和粉末压块400(图15和图16),这些粉末压块可用作或用于制造各种制品,包括可溶解插入件252。
粉末310的每个被涂覆的金属粉末颗粒312包括颗粒芯314和设置在颗粒芯314上的金属覆层316。颗粒芯314包括芯材料318。芯材料318可以包括用于形成颗粒芯314的任何合适的材料,所述颗粒芯提供了粉末颗粒312,所述粉末颗粒可以被烧结以形成具有可选择并可控制的溶解特性的轻质、高强度粉末压块400。适合的芯材料包括标准氧化电势大于或等于Zn的标准氧化电势电化学活性金属,包括Mg、Al、Mn、Zn或它们的组合。这些电化学活性金属与很多常见的钻孔流体都能很好地反应,所述钻孔流体包括许多离子流体或高极性流体,例如包含这种氯化物的那些流体。示例包含氯化钾(KCl)、盐酸(HCl)、氯化钙(CaCl2)、溴化钙(CaBr2)或溴化锌(ZnBr2)的流体。芯材料318还可以包括电化学活性比Zn、非金属材料或它们的组合小的其它金属。适合的非金属材料包括陶瓷、合成物、玻璃或碳、或它们的组合物。芯材料318可以被选择为在预定钻孔流体中提供高的溶解率,但是,也可以被选择为提供较低的溶解率,包括零溶解,其中,纳米母体材料的溶解导致颗粒芯314快速被破坏,并从与钻孔流体交界处的颗粒压块析出,使得利用这些芯材料318的颗粒芯314制成的颗粒压块的有效溶解率高,虽然芯材料318本身的溶解率可能很低,包括在钻孔流体中可能基本上不能溶解的芯材料318。
关于作为芯材料318的电化学活性金属,包括Mg、Al、Mn或Zn,这些金属可作为纯金属使用或者彼此任意组合使用,包括这些材料的各种合金组合,包含这些材料的二元合金、三元合金或四元合金。这些组合也可以包括这些材料的合成物。此外,除了彼此组合之外,Mg、Al、Mn或Zn芯材料318也可以包括其它组分,包括各种合金添加剂,以改变颗粒芯314的一个或多个性质,例如通过增加芯材料318的强度,降低芯材料的密度或改变芯材料的溶解特性。
在这些电化学活性金属中,由于Mg的密度低、能够形成高强度合金、以及因其标准氧化电势比Al、Mn或Zn高而带来的高度的电化学活性,所以Mg无论是作为纯金属、合金、还是复合材料,都特别有用。Mg合金包括Mg作为合金组分的所有合金。组合在此所述的作为合金组分的其它电化学活性金属的Mg合金尤其有用,包括二元Mg-Zn、Mg-Al和Mg-Mn合金,以及三元Mg-Zn-Y和Mg-Al-X合金,其中X包括Zn、Mn、Si、Ca、Y或它们的组合。这些Mg-Al-X合金可以包括按重量计高大约85%的Mg、高达约15%的Al以及高达约5%的X。颗粒芯314和芯材料318,尤其是包括Mg、Al、Mn、Zn或它们的组合的电化学活性金属,也可以包括一种稀土元素或多种稀土元素的组合。在此所使用的稀土元素包括Sc、Y、La、Ce、Pr、Nd、Er或多种稀土元素的组合。如果有,稀土元素或稀土元素的组合的量按重量计约为5%或更少。
颗粒芯314和芯材料318具有熔融温度(TP)。在此所使用的TP包括芯材料318内出现初始熔融或熔解或其它形式的局部熔融时的最低温度,无论芯材料318包括纯金属、具有不同熔融温度的多个相的合金,或是具有不同熔融温度的材料的复合物。
颗粒芯314可以具有任何合适的颗粒尺寸或颗粒尺寸范围或颗粒尺寸分布。例如,颗粒芯314可以被选择成用于提供由如图13所示的在平均值或均值周围呈正态或高斯型单峰分布的所表示的平均颗粒尺寸。在另一个例子中,颗粒芯314可被选择或混合成提供颗粒尺寸的多峰分布,包括多个平均颗粒芯尺寸,例如平均颗粒尺寸的均质双峰分布。颗粒芯尺寸分布的选择可用来确定例如粉末310的颗粒312的颗粒尺寸和颗粒间距315。在一个示例性实施例中,颗粒芯314可以具有约5μm到约300μm的单峰分布和平均颗粒直径,更特别地为约80μm到约120μm的单峰分布和平均颗粒直径,甚至更特别地为约100μm的单峰分布和平均颗粒直径。
颗粒芯314可以具有任何适合的颗粒形状,包括任何规则或不规则的几何形状或其组合。在一个示例性实施例中,颗粒芯314为大体上类似球体的电化学活性金属颗粒。在另一个示例性实施例中,颗粒芯314为大体上不规则形状的陶瓷颗粒。在又一个示例性实施例中,颗粒芯314为碳或其它纳米结构或中空玻璃微珠。
粉末310的每个被涂覆的金属粉末颗粒312还包括设置在颗粒芯314上的金属覆层316。金属覆层316包括金属覆层材料320。金属覆层材料320赋予粉末颗粒312和粉末310金属性质。金属覆层316为纳米级覆层。在一个示例性实施例中,金属覆层316的厚度可以为约25nm到约2500nm。金属覆层316在颗粒芯314表面上的厚度可以是变化的,但是优选具有在颗粒芯314表面上的基本上均匀的厚度。金属覆层316可以包括单个层,如图14所示,或者包括作为多层涂覆结构的多个层。在单层涂覆中,或者在多层涂覆的每个层中,金属覆层316可以包括单组分化学元素或合成物,或可以包括多个化学元素或合成物。在一层包括多个化学组分或合成物的情况下,它们可以具有各种均匀或不均匀的分布,包括金相的均匀或不均匀的分布。这可以包括梯度分布,其中,化学组分或化合物的相对量根据跨该层厚度的相应组分分布而变化。在单层和多层覆层316中,每个相应的层或它们的组合都可以用来为粉末颗粒312或由此形成的烧结粉末压块提供预定属性。例如,预定属性可以包括在颗粒芯314和涂覆材料320之间的冶金结合的结合强度;颗粒芯314和金属覆层316之间的相互扩散特性,包括多层覆层316的层之间的任何相互扩散;多层覆层316的各层之间的相互扩散特征;一个粉末颗粒的金属覆层316与相邻粉末颗粒312的金属覆层之间的相互扩散特征;相邻烧结粉末颗粒312的金属覆层之间的冶金结合的结合强度,包括多层覆层的最外层;和覆层316的电化学活性。
金属覆层316和涂覆材料320具有熔融温度(TC)。在此所使用的TC包括涂覆材料320内出现初始熔融或熔化或其它形式的局部熔融时的最低温度,无论涂覆材料320包括纯金属、具有熔融温度各不相同的多个相的合金、还是复合物,其中所述复合物包括具有熔融温度不同的多个涂覆材料层的复合物。
金属涂覆材料320可以包括任何适合的金属涂覆材料320,所述金属涂覆材料320提供了可烧结的外表面321,该外表面321构造成烧结到相邻的粉末颗粒312,粉末颗粒312也具有金属覆层316和可烧结的外表面321。在还包括在此所述的第二或另外的(涂覆或未涂覆)颗粒的粉末310中,金属覆层316的可烧结的外表面321也构造成烧结到第二颗粒的可烧结的外表面321上。在一个示例性实施例中,粉末颗粒312可在预定烧结温度(TS)下烧结,预定烧结温度是芯材料318和涂覆材料320的函数,使得粉末压块400的烧结完全在固态下实现,其中TS小于TP和TC。固态下的烧结限制了颗粒芯314/金属覆层316对固态扩散过程和金相迁移现象的相互作用,并限制了它们之间得到的交界面的生长并提供对它们之间获得的交界面的控制。相反,例如,液相烧结的引入将用于颗粒芯314/金属覆层316材料的快速相互扩散,并使之难以限制它们之间得到的交界面的生长和提供对它们之间得到的交界面的控制,并由此干扰在此所述的颗粒压块400的所希望的微结构的形成。
在一示例性实施例中,将选择芯材料318以提供芯化学成分,将选择涂覆材料320以提供涂覆化学成分,这些化学成分也将被选择成彼此不同。在另一个示例性实施例中,将选择芯材料318以提供芯化学成分,并将选择涂覆材料320以提供涂覆化学成分,这些化学成分也将被选择成在其交界面处彼此不同。涂覆材料320和芯材料318的化学成分可以被选择成不同从而为粉末压块400提供不同的溶解率以及可选择且可控制的溶解,粉末压块400包含这些化学成分,使得粉末压块能可选择且可控制地溶解。这包括响应于钻孔状态的改变(包括钻孔流体中的间接或直接改变)而不同的溶解率。在一个示例性实施例中,由具有制造粉末压块400的芯材料318和涂覆材料320的化学成分的粉末310形成的粉末压块400响应于钻孔状况的改变而能在钻孔流体中可选择地溶解,所述钻孔状态的改变包括温度的改变、压力的改变、流量的改变、pH的改变、或钻孔流体化学成分的改变、或其组合。响应于状态改变的可选择的溶解可以由提高不同溶解率的实际化学反应或过程引起,但也包含与物理反应或过程相关联的溶解响应上的变化,例如钻孔流体压力或流量上的变化。
如图13和图14所示,可以选择颗粒芯314、芯材料318、金属覆层316和涂覆材料320以提供构造成用于压实和烧结以提供如图15-图17所示的粉末压块400的粉末颗粒312和粉末310,所述粉末压块400轻质(即具有较低的密度)、强度高,并且响应于钻孔属性的变化而可选择且可控制地从钻孔移除,包括在适当的钻孔流体中可选择且可控制地溶解,所述钻孔流体包括在此所公开的各种钻孔流体。粉末压块400包括由纳米母体材料420制成的基本上连续的多孔纳米母体416,所述多孔纳米母体416具有散布在整个多孔纳米母体416的多个分散颗粒414。基本上连续的多孔纳米母体416和由烧结金属覆层316形成的纳米母体材料420通过压实和烧结多个粉末颗粒312的多个金属覆层316而形成。由于扩散效应与在此所述的烧结相关联,所以纳米母体材料420的化学成分可不同于涂覆材料320。粉末金属压块400还包括多个分散颗粒414,分散颗粒414包括颗粒芯材料418。当金属覆层316烧结在一起以形成纳米母体416时,分散颗粒芯414和芯材料418对应于并由多个粉末颗粒312的多个颗粒芯314和芯材料318形成。由于扩散效应与在此所述的烧结相关联,所以芯材料418的化学成分可不同于芯材料318。
在此所使用的术语基本上连续的多孔纳米母体416不意味着粉末压块的主要组分,而是指无论按重量计还是按体积计的一种或多种次要组分。这不同于母体包括按重量计或按体积计的主要组分的大多数母体复合材料。使用的术语基本上连续的多孔纳米母体用来表示纳米母体材料420在粉末压块400内的分布的广泛、规则、连续和互连的性质。在此所使用的“基本上连续”表示纳米母体材料在整个粉末压块400中的延伸,使得所述纳米母体材料在分散颗粒414之间延伸,并包围基本上所有的分散颗粒414。基本上连续用来表示每个分散颗粒414周围的纳米母体的完全连续且规则次序不是必须的。例如,某些粉末颗粒312上的颗粒芯314上的覆层316中的缺陷可能导致颗粒芯214在粉末压块400烧结过程中桥接,从而导致多孔纳米母体416内产生局部不连续,虽然粉末压块的其它部分中纳米母体基本上是连续的并且呈现在此所述的结构。在此所使用的“多孔”用来表示纳米母体限定了包围分散颗粒414并且还使所述分散颗粒414互连的纳米母体材料420的基本上重复、互连的隔室或单元的网络。在此所使用的“纳米母体”用来表示母体的尺寸或尺度,尤其是相邻分散颗粒414之间的母体厚度。烧结在一起而形成纳米母体的金属覆层本身也是纳米级厚度的覆层。因为除了多于两个分散颗粒414的相交处之外的大部分部位的纳米母体通常包括具有纳米级厚度的相邻粉末颗粒312与两个覆层316的相互扩散和结合,所以,所形成的母体也具有纳米级厚度(例如,近似于在此所述的覆层厚度的两倍),并因而描述为纳米母体。进一步地,所使用的术语分散颗粒414不意味着粉末压块400的次要组分,而是指无论按重量计还是按体积计的主要组分。所使用的术语分散颗粒用来在粉末压块400内输送不连续、离散分布的颗粒芯材料418。
粉末压块400可以具有任何期望的形状或尺寸,包括可以机加工或以其它方式用于形成包括可溶解插入件252的有用制品的圆柱形坯件或杆。用于形成前体粉末压块的压制以及用于形成粉末压块400并使包括颗粒芯314和覆层316的粉末颗粒312变形的烧结和压制工序提供了粉末压块400的完全致密度和所期望的宏观形状和尺寸及其微观结构。粉末压块400的微观结构包括散布在烧结覆层的整个基本上连续的多孔纳米母体416上并嵌入所述多孔纳米母体内的分散颗粒414的等轴配置。该微观结构有点类似于带有连续晶界相的等轴晶微观结构,不同的是,其不需要使用具有能够生成这种结构的热动力相平衡属性的合金组分。相反,该等轴分散颗粒结构和烧结金属覆层316的多孔纳米母体416可以利用热动力相平衡状态不会生成等轴结构的组分生成。分散颗粒414和颗粒层的多孔网络416的等轴形态是由粉末颗粒312在被压实、相互扩散和变形而填充颗粒间空间315时的烧结和变形引起的(图13)。可以选择烧结温度和压力,以保证粉末压块400的密度实现基本上完全理论密度。
在如图16和图17所示的示例性实施例中,分散颗粒414由散布在烧结金属覆层316的多孔纳米母体416中的颗粒芯314形成,纳米母体416包括固态冶金结合部417或结合层419,所述固态冶金结合部417或结合层419在整个多孔纳米母体416上的分散颗粒414之间延伸,所述多孔纳米母体416在烧结温度(TS)下形成,其中TS小于TC和TP。如图所示,固态冶金结合部417通过相邻粉末颗粒312的覆层316之间的固态相互扩散形成为固态,所述覆层在用于形成粉末压块400的压实和烧结工序过程中被压缩成接触,正如在此所述的。由此,多孔纳米母体416的烧结覆层316包括固态结合层419,所述固态结合层419的厚度(t)由覆层316的涂覆材料320的相互扩散的程度限定,而涂覆材料320相互扩散的程度又由覆层316的性质限定,包括:覆层是单层覆层还是多层覆层,覆层被选定为促进这样的相互扩散还是限制这样的相互扩散以及其它因素,正如在此所述的,以及烧结和压实状态,包括用于形成粉末压块400的烧结时间、温度和压力。
当形成纳米母体416时,包括结合部417和结合层419,可以改变金属覆层316的化学成分或相分布或者两者都改变。纳米母体416也具有熔融温度(TM)。在此所使用的TM包括纳米母体416内出现初始熔融或熔化或其它形式的局部熔融时的最低温度,无论纳米母体材料420包括纯金属、具有熔融温度各不相同的多个相的合金、复合物(包括具有熔融温度不同的多层各种涂覆材料的复合物)、它们的组合、或是其它。由于分散颗粒414和颗粒芯材料418是与纳米母体416一起形成的,所以,金属覆层316的组分也可以扩散到颗粒芯314中,这会导致颗粒芯314化学成分或相分布或者这两者的变化。因而,分散颗粒414和颗粒芯材料418的熔融温度(TDP)不同于TP。在此所使用的TDP包括分散颗粒414内出现初始熔融或熔化或其它形式的局部熔融时的最低温度,无论颗粒芯材料418包括纯金属、具有熔融温度各不相同的多个相的合金、复合物、或是其它。粉末压块400在烧结温度(TS)下形成,其中TS小于TC、TP、TM和TDP。
分散颗粒414可以包括在此所述的用于颗粒芯314的任何材料,即使分散颗粒414的化学成分可能由于在此所述的扩散效应而不同。在一个示例性实施例中,分散颗粒414由包括标准氧化电势大于或等于Zn的材料的颗粒芯314形成,包括Mg、Al、Zn、Mn或它们的组合,可以包括与颗粒芯314一起的各种二元、三元和四元合金或在此所公开的这些成分的其它组合。这些材料中,具有包括Mg的分散颗粒414的材料和由在此所述的金属涂覆材料316形成的纳米母体416材料尤其有用。由Mg、Al、Zn、Mn或它们的组合制成的分散颗粒414和颗粒芯材料418还可以包括稀土元素、或在此公开的稀土元素与颗粒芯314的组合。
在另一个示例性实施例中,分散颗粒414由颗粒芯314形成,所述颗粒芯314包括电化学活性比Zn小的金属材料或非金属材料。适合的非金属材料包括陶瓷、玻璃(空心玻璃微珠)或碳、或它们的组合物,正如在此所述的。
粉末压块400的分散颗粒414可以具有任何适合的颗粒尺寸,包括在此所述的用于颗粒芯414的平均颗粒尺寸。
根据为颗粒芯314和粉末颗粒312选定的形状以及用于烧结和压实粉末310的方法,分散颗粒314可以具有任何适合的形状。在一个示例性实施例中,粉末颗粒312可以为类似球体或基本上类似球体,分散颗粒414可以包括在此所述的等轴颗粒配置。
分散颗粒414的散布性质受所选定的用于制造颗粒压块400的一种或多种粉末310的影响。在一个示例性实施例中,可以选择具有单峰分布的粉末颗粒312尺寸的粉末310来形成粉末压块400,并在多孔纳米母体416内生成分散颗粒414的颗粒尺寸的基本上均质单峰散布,如图15所示。在另一个示例性实施例中,如在此描述的,可以选择并均匀地混合多个粉末310,以提供具有粉末颗粒312尺寸均质多峰分布的粉末310,所述多个粉末310具有带有颗粒芯314的多个粉末颗粒,所述颗粒芯314具有相同的芯材料318、不同的芯尺寸和相同的涂覆材料320,并且可用来形成在多孔纳米母体416内具有分散颗粒414颗粒尺寸的均质多峰散布的粉末压块400。同样,在又一个示例性实施例中,可以选择并以非均匀的方式分布多个粉末310,以提供粉末颗粒尺寸的非均质多峰分布,所述多个粉末310具有多个颗粒芯314,所述颗粒芯314可具有相同的芯材料318、不同的芯大小和相同的涂覆材料320,并且可用来形成在多孔纳米母体416内具有分散颗粒414颗粒尺寸的非均质多峰散布的粉末压块400。颗粒芯尺寸分布的选择可用来确定例如由粉末310制成的粉末压块400的多孔纳米母体416内的分散颗粒414的颗粒尺寸和颗粒间距。
纳米母体416为烧结到彼此的基本上连续的多孔网络金属覆层316。纳米母体416的厚度取决于用来形成粉末压块400的一种或多种粉末310的性质以及任何第二粉末的引入,尤其是与这些颗粒相关的覆层的厚度。在一个示例性实施例中,纳米母体416的厚度在粉末压块400的整个微结构上基本上都是均匀的,并且包括大约2倍于粉末颗粒312的覆层316的厚度。在另一个示例性实施例中,多孔网络416在分散颗粒414之间具有大约50nm到大约5000nm的基本上均匀的平均厚度。
如在此所述,借助通过相互扩散和形成结合层419将相邻颗粒的金属覆层316烧结到彼此,而形成纳米母体416。金属覆层316可以是单层或多层结构,并且金属覆层可以选定成促进和/或抑制金属覆层316的层内或金属覆层316的层之间、或金属覆层316与颗粒芯314之间、或金属覆层316和相邻粉末颗粒的金属覆层316之间的扩散,烧结过程中金属覆层316的相互扩散的程度取决于涂覆厚度、所选定的一种或多种涂覆材料、烧结条件及其它因素可受到限制或广泛。尽管组分的相互扩散和相互作用具有潜在复杂性,但是,对所获得的纳米母体416和纳米母体材料420的化学成分的描述可以简单地理解为覆层316的组分的组合,该组合还可以包括分散颗粒414的一个或多个组分,这取决于分散颗粒414与纳米母体416之间发生的相互扩散(如果有)的程度。同样,分散颗粒414和颗粒芯材料418的化学成分可以简单地理解为颗粒芯314的组分的组合,该组合还可以包括纳米母体416和纳米母体材料420的一个或多个组分,这取决于分散颗粒414与纳米母体416之间发生的相互扩散(如果有)的程度。
在一示例性实施例中,纳米母体材料420具有化学成分,颗粒芯材料418的化学成分与纳米母体材料420的化学成分不同,化学成分的不同可以配置成提供可选择且可控制的溶解率,包括,响应于紧邻压块400的钻孔的属性或状态的受控改变(包括与粉末压块400接触的钻孔流体的属性的改变),从非常慢的溶解率可选择地转变到非常快的溶解率,正如在此所述的。纳米母体416可以由具有单层和多层覆层316的粉末颗粒312形成。这种设计灵活性尤其是在多层覆层316的情况中提供了大量的材料组合,通过控制给定层内以及覆层316和与该覆层相关联的颗粒芯314或相邻粉末颗粒312的覆层316之间的覆层组分的相互作用,这些材料组合可用于定制多孔纳米母体416和纳米母体材料420的成分。下面提供了表明该灵活性的几个示例性实施例。
如图16所示,在一个示例性实施例中,粉末压块400由其中覆层316包括单个层的粉末颗粒312形成,由此在多个分散颗粒414中的相邻分散颗粒之间形成的纳米母体416包括一个粉末颗粒312的单个金属覆层316、结合层419以及另一个相邻粉末颗粒312的单个覆层316。结合层419的厚度(t)由单个金属覆层316之间相互扩散的程度确定,并且可以包围纳米母体416的整个厚度或纳米母体416的仅仅一部分。在利用单层粉末310形成的粉末压块400的一个示例性实施例中,粉末压块400可以具有包含在此所述的Mg、Al、Zn、Mn或它们的组合的分散颗粒414,纳米母体316可以包括Al、Zn、Mn、Mg、Mo、W、Cu、Fe、Si、Ca、Co、Ta、Re、或Ni、或其氧化物、碳化物或氮化物、或者任意上述材料的组合,包括这样的组合,其中包括结合层419的多孔纳米母体416的纳米母体材料420具有化学成分,分散颗粒414的芯材料418的化学成分与多孔纳米母体416的化学成分不同。纳米母体材料420和芯材料418的化学成分上的不同可用来响应于在此所述的钻孔属性的改变(包括钻孔流体属性的改变)而提供可选择且可控制的溶解。在由具有单个覆层配置的粉末310形成的粉末压块400的又一示例性实施例中,分散颗粒414包括Mg、Al、Zn、Mn或它们的组合,多孔纳米母体416包括Al、Ni或它们的组合。
在另一个示例性实施例中,粉末压块400由其中的覆层316包括具有多个覆层的多层覆层316的粉末颗粒312形成,由此在多个分散颗粒414中的相邻分散颗粒之间形成的纳米母体416包括包含一个颗粒312的覆层316的多个层(t)、结合层419以及具有另一个粉末颗粒312的覆层316的多个层。在图16中,示出的是双层金属覆层316,但是应当明白,多个层的多层金属覆层316可以包括任何所希望的数量的层。结合层419的厚度(t)也由相应覆层316的多个层之间相互扩散的程度确定,并且可以包围纳米母体416的整个厚度或纳米母体416的仅仅一部分。在该实施例中,包括各覆层316的多个层可用来控制结合层419的相互扩散、形成和厚度(t)。
如在此所述的具有包括Mg的分散颗粒414和包括各种纳米母体材料的纳米母体416的烧结和锻造的粉末压块400已经展示了机械强度和低密度的极好组合,这例示了在此所公开的轻质、高强度材料。例如,粉末压块400具有纯Mg分散颗粒414和由粉末310形成的各种纳米母体416,所述粉末310具有纯Mg颗粒芯314以及各种单层和多层金属覆层316,所述覆层316包括Al、Ni、W或Al2O3或它们的组合。这些粉末压块400已经受各种机械及其它测试,包括密度测试,并且它们的溶解性和机械属性退化行为也已经被表征,正如在此所公开的。结果表明,这些材料可以构造成提供更大范围的可选择且可控制的腐蚀或溶解特性,从非常低的腐蚀速率到非常高的腐蚀速率,尤其是比没有引入多孔纳米母体的粉末压块(例如由纯Mg粉末通过与在此处所述的各种多孔纳米母体中包括纯Mg分散颗粒相同的压制和烧结过程形成的压块)低和高的腐蚀速率。这些粉末压块400也可以构造成与由不包括在此所述的纳米级涂覆的纯Mg颗粒形成的粉末压块相比提供明显提高的属性。具有包括Mg的分散颗粒414和包括在此所述的各种纳米母体材料420的纳米母体416的粉末压块400已经展示了至少约37ksi的室温压缩强度,并且进一步展示了超过约50ksi的室温压缩强度,无论是干式还是浸于200℉的3%KC1溶液中都是如此。相反,由纯Mg粉末形成的粉末压块的压缩强度为约20ksi或更小。可以通过优化粉末310进一步提高纳米母体金属粉末压块400的强度,尤其是用来形成多孔纳米母体416的纳米级金属覆层316的重量百分比。可以通过优化粉末310进一步提高纳米母体金属粉末压块400的强度,尤其是用来形成多孔纳米母体416的纳米级金属覆层316的重量百分比。例如,与0wt%矾土相比,改变由被涂覆的粉末颗粒312形成的多孔纳米母体416内的矾土覆层的重量百分比(wt.%)即厚度,可提供21%的增加,所述粉末颗粒312包括在纯Mg颗粒芯314上的多层(Al/Al2O3/Al)金属覆层316。
具有包括Mg的分散颗粒414和包括在此所述的各种纳米母体材料的纳米母体416的粉末压块400还展示了至少约20ksi的室温剪切强度。这与由纯Mg粉末形成的粉末压块形成对比,由纯Mg粉末形成的粉末压块的室温剪切强度为约8ksi。
在此所公开的类型的粉末压块400能够实现的实际密度基本上等于基于粉末310的成分的压块材料的预定理论密度,包括颗粒芯314和金属覆层316的组分的相对量,在此也描述为完全致密粉末压块。具有包括Mg的分散颗粒414和包括在此所述的各种纳米母体材料的纳米母体416的粉末压块400已经展示了约1.738g/cm3到约2.50g/cm3的实际密度,这基本上等于预定理论密度,与预定理论密度相差最多4%。
在此所公开的粉末压块400可配置成响应于钻孔内的状态改变而在钻孔流体内可选择且可控制地溶解。可用来提供可选择且可控制的溶解度的状态改变的例子包括温度变化、压力变化、流量变化、pH变化、钻孔流体的化学成分变化或它们的组合。包括温度变化的状态改变的例子包括钻孔流体温度变化。例如,具有包括Mg的分散颗粒414和包括在此所述的各种纳米母体材料的多孔纳米母体416的粉末压块400在室温3%KCl溶液中具有范围从约0到约11mg/cm2/hr的较慢腐蚀速率,与之相比,在200℉下具有范围从约1到约246mg/cm2/hr的较高的腐蚀速率,这取决于不同的纳米级覆层216。包括化学成分变化的状态改变的例子包括钻孔流体氯离子浓度或pH值或两者的变化。例如,具有包括Mg的分散颗粒414和包括在此所述的各种纳米级覆层的纳米母体416的粉末压块400在15%HCl中展示了范围从约4750mg/cm2/hr到约7432mg/cm2/hr的腐蚀速率。因而,响应于钻孔状态改变、即钻孔流体化学成分从KCl到HCl的变化的可选择且可控制的溶解度可用来实现如图18所图示的特性响应,图18示出了在选定的预定临界服务时间(CST),在粉末压块应用于给定应用(例如钻孔环境)时,可对粉末压块400施加状态上的改变,这导致粉末压块400响应于其所应用于的环境的状态改变而在属性上发生可控制的改变。例如,在预定CST,将与粉末压块400接触的钻孔流体从第一流体(例如KCl)改变到第二钻孔流体(例如HCl),第一流体提供了作为时间函数的第一腐蚀速率和相关的重量损失或强度,第二钻孔流体提供了作为时间函数的第二腐蚀速率和相关的重量损失或强度,其中与第一流体相关的腐蚀速率比第二流体相关的腐蚀速率小得多。这种对钻孔流体状态改变的特性响应可用来例如将临界服务时间与尺寸损失极限或特定应用所需的最小强度相关联,使得当由在此所公开的粉末压块400形成的钻孔工具或部件不再需要在钻孔中使用时(例如CST),钻孔中的状态(例如钻孔流体的氯离子浓度)可改变成使得粉末压块400快速溶解而从钻孔移除。在如上所述的例子中,粉末压块400以从约0到约7000mg/cm2/hr范围的速率可选择地溶解。该响应范围提供了例如通过改变钻孔流体在1小时不到的时间内从钻孔移除由该材料形成的3英寸直径球的能力。上述的可选择且可控制的可溶解行为连同在此所述的优异的强度和低密度属性限定了新的工程分散颗粒-纳米母体材料,其配置成用于接触流体,并配置成随着与流体接触的时间提供下列之一可选择且可控制的转变:从第一强度状态到低于功能性强度阈值的第二强度状态;或从第一重量损失量到大于重量损失极限的第二重量损失量。分散颗粒-纳米母体复合物是在此所述的粉末压块400的特征,所述分散颗粒-纳米母体复合物包括纳米母体材料420制成的多孔纳米母体416和多个分散颗粒414,所述多个分散颗粒包括散布在母体内的颗粒芯材料418。纳米母体416的特征在于固态结合层419,所述固态结合层419在整个纳米母体上延伸。与上面描述的与流体接触的时间可以包括如上所述的CST。CST可以包括溶解与所述流体接触的粉末压块400预定部分所希望或所需要的预定时间。CST也可以包括对应于工程材料或流体或其组合的属性改变的时间。在工程材料的属性改变的情况下,这种改变可以包括工程材料温度的改变。在流体的属性改变的情况下,这种改变可以包括流体温度、压力、流量、化学成分、pH或其组合的改变。可以定制工程材料及工程材料属性的改变这两者、或流体、或其组合,以提供所希望的CST响应特性,包括特定属性(例如重量损失、强度损失)在CST之前(例如,阶段1)和CST之后(例如,阶段2)的改变率,如图18所示。
不受理论限制,粉末压块400由被涂覆的粉末颗粒312形成,所述粉末颗粒312包括颗粒芯314和相关的芯材料318以及金属覆层316和相关的金属涂覆材料320,以形成基本上连续的三维多孔纳米母体416,所述多孔纳米母体416包括通过烧结并相关联地扩散结合相应覆层316而形成的纳米母体材料420,所述覆层316包括由颗粒芯材料418制成的多个分散颗粒414。这种独特结构可以包括材料的亚稳定组合,而这种亚稳定组合很难或不可能通过由具有相同相对量的组成材料的熔融物固化形成。可以选择覆层和相关联的涂覆材料,以在预定的流体环境(例如钻孔环境)中提供可选择且可控制的溶解,其中预定流体可以是或者注入到钻孔内的或者从钻孔提取出的常用钻孔流体。从这里的描述可进一步明白,纳米母体的受控溶解使芯材料的分散颗粒暴露出来。也可以选择颗粒芯材料从而在钻孔流体中也提供可选择且可控制的溶解。作为替代,它们也可以被选择成为粉末压块400提供特定的机械属性,例如压缩强度或剪切强度,而不必提供芯材料本身的可选择且可控制的溶解,这是因为围绕这些颗粒的纳米母体材料的可选择且可控制的溶解将必定会释放这些颗粒以便使之由钻孔流体带走。可被选择以提供强化相材料的基本上连续的多孔纳米母体416的显微结构形态与可被选择以提供等轴分散颗粒414的分散颗粒414,提供了机械属性(包括压缩强度和剪切强度)增强的这些粉末压块,这是因为可以控制由此形成的纳米母体/分散颗粒的形态以通过类似于传统强化机制(例如晶粒尺寸减小、通过利用杂质原子、沉淀或经时硬化而进行溶液硬化)和强度/加工硬化机制的工序提供强化。纳米母体/分散颗粒结构趋向于借助于众多的颗粒纳米母体交界面以及在此所述的纳米母体材料内离散层之间的交界面限制错位移动。这在这些材料的压裂行为中给予了说明。利用未被涂覆的纯Mg粉末制成并承受足以导致故障的剪切应力的粉末压块400证实了晶间压裂。相反,利用具有纯Mg粉末颗粒芯314以形成分散颗粒414的粉末颗粒312和包括Al以形成纳米母体416的金属覆层316制成并承受足以导致故障的剪切应力的粉末压块400证实了晶间压裂和明显更高的压裂应力,如此处所述。因为这些材料具有高强度特性,芯材料和涂覆材料可选择成使用低密度材料或其它低密度材料,例如低密度金属、陶瓷、玻璃或碳,否则将不会提供供所希望的应用(包括钻孔工具和部件)之用的必要的强度特性。
图1显示了处于下入位置中的工具100,阀盖250处于使得可溶解插入件252与井口本体部分120的阀门开口124对齐的位置,以防止任何流体通过阀门开口124流入孔108或从孔108流出。阀盖250的阀门套筒254通过阀门开口124附近的剪切销126附接于井口本体部分120。在下入位置中,剪切销126和阀门开口124之间的井口本体部分120上的台肩128与阀门套筒254上的肩部274相抵接。也是在下入位置中,阀门套筒254的倾斜表面260向内压缩球座150的筒夹152的指状物154,以使球座150处于球捕捉位置,准备接收球50。指示销208设置在指示路径206的第二段212内,如图3所示。
图4显示了球座150内接收球50时的工具100。由于球50完全地或至少大体上阻塞流体流过孔108,所以,球50的井口方向建立压力,所述压力迫使球50伴随着球座150下向井下方向。由于球座150的基部156附接于抵接指示设备200的内管柱172,指示设备200也朝井下方向运动,这使得指示销208如图5所示定位在作为压裂/转换位置的指示路径206的第三段214内。因为阀门套筒254通过剪切销126固定地附接于井口本体部分120,所以,球座150和指示设备200在剪切销126被剪切之前不能沿井下方向进一步移动。如果压力在达到剪切值之前卸载,球座150将回到下入位置,指示销208将位于指示路径206的第二位置212处。如果压力增大超过剪切值,剪切销126将剪切,阀盖250、球座150和指示设备200将沿井下方向移动并压缩压缩弹簧218,并由此使阀门开口124暴露在井口本体部分120中。通过阀门开口124,可以压裂该区域,或者可以进行其它井下作业。在此阶段,球座150由于指示设备200的作用而被锁定就位,如图5所示,所述指示设备200使指示销208保持在第三段214的井口端228,并且在压力被释放前不会从该井口端移动。球座150的筒夹152仍然处于直径受限的状态,以将球50保持在其中。只要筒夹152位于倾斜表面260的井口方向,筒夹152就会保持在直径受限的状态。
图6显示了处于适当位置的工具100,例如在特定区域上的压裂作业完成之后,其中泵压力从工具100的孔108释放,使得压力从球座150释放。由于球50和球座150被允许朝着井口位置返回,阀门套筒254回到如图1所示的位置,在该位置,插入件252再次阻塞阀门开口124。压缩弹簧218的弹簧力将阀门套筒254带回该位置,所述弹簧力推在阀门套筒254所连接的可动管状部分216上。阀门套筒254的肩部274抵接井口本体部分120的台肩128,使得插入件252与阀门开口124适当对齐。指示销208指示到如图4和6所示的位置之间的第二段212。当压力再次施加到球座150上的球50时,指示套筒202指示为使得指示销208与相当于“通过”段的第一段210对齐。在指示销208一直处在第一段210的延伸的纵向部分上的情况下,弹簧元件220变得被压缩,内管柱172被向井下拉,使得所连接的筒夹152也被向井下拉。因而,球座150的漏斗状部分162不与阀门套筒254上的台肩258抵接,内管柱172的倾斜表面170不与阀门套筒254的倾斜表面260抵接,使得指状物154的自由端160不再一起被压缩,因而它们呈现筒夹152的内径足够大以允许球50通过筒夹至下部区域或更井下区域的状态。
参照图8和图9,球50通过后,弹簧部件220使得指示套筒202回到路径206的第二段212,球座150回到下入位置期间的如图1所示的直径减小的状态。但是,不同于图1,图1中的可溶解插入件252在图8中显示为,材料在操作者认为适当的选定时间溶解,通常在全部区域已经被压裂之后。一旦可溶解插入件252被溶解,就提供了阀盖250中的孔253,该孔可选择性地与管状本体106中的阀门开口124对齐。
如图10所示,当前通过传统装备实现的以及通过选择性的水力压裂工具实现的压裂操作顺序为“自底向上”方式。钻孔10的示意图包括最靠近地表部位的井口端12和最远离地表部位的井下端14,其中地表部位是井底工具的进入位置。所示的钻孔10带有七个作为压裂作业目标的区域,包括区域16、18、20、22、24、26和28,不过可以将不同数量的区域作为目标。在“自底向上”的方式中,第一压裂作业1在区域28进行,第二压裂作业2在区域26进行,第三压裂作业3在区域24进行,第四压裂作业4在区域22进行,第五压裂作业5在区域20进行,第六压裂作业6在区域18进行,第七压裂作业7在区域16进行。因而,以“自底向上”的顺序,最下方/最远处的区域28首先被压裂,然后沿着钻孔向上,通过压裂各个接续区域而完成压裂作业。在传统压裂工具中,初始压裂可通过将小直径球落入工具中实现,然后将更大尺寸的球接连落入,同时拓展(working up)井眼。在所有区域被压裂之后,球流回地表,以便开采。
图11和图12分别显示了通过在此所述的选择性的水力压裂工具、而不是通过传统井下工具实现的两个替代性的压裂作业顺序。图11显示了与图10所示的“自底向上”方式相反的“自顶向下”方式。换句话说,第一压裂作业1在区域16进行,第二压裂作业2在区域18进行,第三压裂作业3在区域20进行,第四压裂作业4在区域22进行,第五压裂作业5在区域24进行,第六压裂作业6在区域26进行,第七压裂作业7在区域28进行。以该“自顶向下”顺序,最高处的区域16首先被压裂,然后沿着钻孔向下作业,通过压裂各个接续区域而完成压裂。该顺序利用传统压裂工具是不可能的,因为座上的球会防止操作者形成下方的区域,并且即使能够从座上移除球,刚刚压裂的区域也会保持开口,因此当试图在下部区域进行压裂时,所有的泵送都不能到达上部区域。但是,在选择性的压裂工具中,在压裂上部区域之后,球必须通过可膨胀的球座以压裂任何下部的区域,使用单个球就可以压裂所有区域。
图12显示了“中心蚕食”压裂作业顺序,其中,第一压裂作业1在区域28进行,第二压裂作业2在区域16进行,第三压裂作业3在区域26进行,第四压裂作业4在区域18进行,第五压裂作业5在区域24进行,第六压裂作业6在区域20进行,第七压裂作业7在区域22进行。因而,在“中心蚕食”压裂作业中,从最低区域到最高区域以交替的方式压裂这些区域,直到到达中心区域。在压裂上部区域之后,球必须通过可膨胀的球座以压裂任何下部区域。压裂上部区域之后,利用该球压裂相应的下部区域。在所示的实施例中,区域16球然后将通过区域26,然后压裂该区域。
虽然已经描述了两个另外的压裂作业顺序,但是,应当明白,可以利用该选择性的水力压裂工具以操作者认为合适的任何顺序或者适合于钻孔状态的任何顺序对钻孔的区域进行压裂。
虽然本发明是参照示例性实施例进行描述的,本领域技术人员应当明白,在没有背离本发明的范围的情况下,可以进行各种改变,也可以利用等效物来代替其元件。另外,在没有脱离本发明的实质范围的情况下,可以进行许多改进,以使具体情形或材料适应本发明的教导。所以,本发明不局限于作为执行本发明的最佳方式的所公开的特定实施例,而是,本发明包括落入权利要求书的范围之内的所有实施例。而且,在附图和说明书中披露的都是本发明的示例性实施例,虽然可能采用了特定术语,但是,除非另有说明,这些特定术语仅用于一般和描述性意义,而不是用于限制目的,本发明的范围不由此限定。此外,术语第一、第二等的使用不表示任何次序或重要程度,而是用来将一个元件与另一个元件相互区分开。此外,术语“一”等的使用不表示数量的限制,而是表示存在至少一个所引用的对象。
Claims (20)
1.一种选择性的井下工具,包括:
管,所述管具有能够使流体从中通过的纵向孔并且具有位于所述管的壁中的阀门开口;
可膨胀球座,所述可膨胀球座能够选择性地在第一尺寸与更大的第二尺寸之间运动,所述第一尺寸设计成捕获球以阻止通过所述管的流动,所述第二尺寸设计成释放该球通过所述管;和
阀盖,所述阀盖能够在所述管内纵向地运动,所述阀盖包括可溶解的插入件。
2.如权利要求1所述的选择性的井下工具,其中,阀盖与球座配合,并能够响应于管内的压力变化而与球座一起纵向移动。
3.如权利要求1所述的选择性的井下工具,其中,插入件在第一状态中覆盖所述阀门开口,并能够在管内纵向运动以在第二状态中暴露阀门开口。
4.如权利要求3所述的选择性的井下工具,其中,插入件在第三状态中重新覆盖所述阀门开口,其中,球座在第一状态和第二状态中具有第一尺寸,在第三状态中具有第二尺寸。
5.如权利要求4所述的选择性的井下工具,其中,插入件在第四状态中被溶解。
6.如权利要求1所述的选择性的井下工具,其中,可膨胀的球座包括具有多个指状物的筒夹,指状物的自由端从所述第一尺寸运动到所述第二尺寸,一基部连接到指状物的固定端。
7.如权利要求1所述的选择性的井下工具,还包括能与可膨胀的球座相接合的指示设备,所述指示设备能够将可膨胀的球座锁定在第一尺寸和第二尺寸之一。
8.如权利要求7所述的选择性的井下工具,其中,指示设备包括具有指示路径的指示套筒、能相对于指示套筒运动的指示销和作用在指示销上的至少一个弹簧偏压部件。
9.如权利要求8所述的选择性的井下工具,其中,所述至少一个弹簧偏压部件包括位于指示销一侧上的压缩弹簧和位于指示销相反一侧上的压缩弹簧。
10.如权利要求8所述的选择性的井下工具,其中,指示路径包括用于将球座锁定在所述第二尺寸的向井口延伸的第一段、允许指示销运动的向井下延伸的第二段、和用于将球座锁定在所述第一尺寸的向井口延伸的比第一段短的第三段。
11.如权利要求10所述的选择性的井下工具,其中,指示路径为围绕指示套筒的直径的连续路径,所述指示路径包括介于每个第一段和第三段之间的第二段。
12.如权利要求1所述的选择性的井下工具,还包括在工具下入状态下将阀盖固定地连接于所述管的剪切销。
13.如权利要求1所述的选择性的井下工具,其中,可溶解的插入件包括能选择性降解的材料,所述能选择性降解的材料具有由电化学活性金属形成的烧结粉末压块。
14.一种操作井下工具的方法,该方法包括:
将井下工具下入到钻孔中,该井下工具包括管,所述管具有由阀盖覆盖的阀门开口;
纵向移动阀盖,以使阀门开口暴露出来;
在通过阀门开口进行作业之后,通过阀盖重新覆盖阀门开口;和
溶解阀盖的一部分,以再次暴露阀门开口。
15.如权利要求14所述的方法,还包括:对于多个阀门开口和相应的阀盖重复地进行暴露阀门开口、通过阀门开口进行作业和重新覆盖阀门开口,随后溶解这些阀盖上的一部分以暴露这些阀门开口。
16.如权利要求15所述的方法,其中,所述作业是在钻孔的多个区域上进行的压裂作业,所述方法还包括:在溶解阀盖上的一部分之后,允许开采流体通过阀门开口进入。
17.如权利要求15所述的方法,其中,通过阀门开口进行的作业顺序是自顶向下的顺序,其中,通过最靠井口的阀门开口进行首先的作业,通过最靠井下的阀门开口进行最后的作业。
18.如权利要求15所述的方法,其中,通过阀门开口进行的作业顺序是中心蚕食顺序,其中,通过靠近中心阀门开口的井下阀门开口和井口阀门开口,交替进行连续作业。
19.如权利要求14所述的方法,还包括:
使球落入管中可膨胀的球座中;
将球捕获在球座内;
在管内建立压力,并向井下方向对球和球座施力;和,
排放泵送压力;
其中,阀盖随着管内压力的建立而进行纵向运动,并且阀门开口随着泵送压力的排放而被阀盖重新覆盖。
20.如权利要求14所述的方法,其中,在将井下工具下入到钻孔内的同时,将阀盖通过剪切螺纹件固定地附接到管上,所述方法还包括:在阀门开口与钻孔内的目标区域对齐之后,剪切掉该剪切螺纹件。
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WO2013015992A2 (en) | 2013-01-31 |
AU2012287346B2 (en) | 2016-09-22 |
GB2506772A (en) | 2014-04-09 |
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US8783365B2 (en) | 2014-07-22 |
WO2013015992A3 (en) | 2013-04-04 |
GB201322012D0 (en) | 2014-01-29 |
CA2841078C (en) | 2016-04-12 |
CA2841078A1 (en) | 2013-01-31 |
US20130025876A1 (en) | 2013-01-31 |
CN103688014B (zh) | 2016-12-28 |
AU2012287346A1 (en) | 2014-01-09 |
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