CN104285032A - 可分解和贴合的金属性密封件及其制备方法 - Google Patents
可分解和贴合的金属性密封件及其制备方法 Download PDFInfo
- Publication number
- CN104285032A CN104285032A CN201380024060.0A CN201380024060A CN104285032A CN 104285032 A CN104285032 A CN 104285032A CN 201380024060 A CN201380024060 A CN 201380024060A CN 104285032 A CN104285032 A CN 104285032A
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- Prior art keywords
- seal
- matrix
- metallic
- metal
- distintegrant
- Prior art date
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- INAHAJYZKVIDIZ-UHFFFAOYSA-N boron carbide Chemical compound B12B3B4C32B41 INAHAJYZKVIDIZ-UHFFFAOYSA-N 0.000 claims description 3
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Classifications
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- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B33/00—Sealing or packing boreholes or wells
- E21B33/10—Sealing or packing boreholes or wells in the borehole
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- E21B33/1204—Packers; Plugs permanent; drillable
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- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/02—Compacting only
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- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/12—Both compacting and sintering
- B22F3/16—Both compacting and sintering in successive or repeated steps
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- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
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- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F5/10—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
- B22F5/106—Tube or ring forms
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- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/008—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression characterised by the composition
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- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
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- C22C1/04—Making non-ferrous alloys by powder metallurgy
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- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
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- C22C32/00—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
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- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C32/00—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
- C22C32/001—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with only oxides
- C22C32/0015—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with only oxides with only single oxides as main non-metallic constituents
- C22C32/0036—Matrix based on Al, Mg, Be or alloys thereof
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
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- C22C32/00—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
- C22C32/0047—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with carbides, nitrides, borides or silicides as the main non-metallic constituents
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- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B33/00—Sealing or packing boreholes or wells
- E21B33/10—Sealing or packing boreholes or wells in the borehole
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- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B33/00—Sealing or packing boreholes or wells
- E21B33/10—Sealing or packing boreholes or wells in the borehole
- E21B33/12—Packers; Plugs
- E21B33/1208—Packers; Plugs characterised by the construction of the sealing or packing means
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B33/00—Sealing or packing boreholes or wells
- E21B33/10—Sealing or packing boreholes or wells in the borehole
- E21B33/12—Packers; Plugs
- E21B33/1208—Packers; Plugs characterised by the construction of the sealing or packing means
- E21B33/1212—Packers; Plugs characterised by the construction of the sealing or packing means including a metal-to-metal seal element
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B33/00—Sealing or packing boreholes or wells
- E21B33/10—Sealing or packing boreholes or wells in the borehole
- E21B33/12—Packers; Plugs
- E21B33/128—Packers; Plugs with a member expanded radially by axial pressure
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B33/00—Sealing or packing boreholes or wells
- E21B33/10—Sealing or packing boreholes or wells in the borehole
- E21B33/13—Methods or devices for cementing, for plugging holes, crevices or the like
- E21B33/134—Bridging plugs
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16J—PISTONS; CYLINDERS; SEALINGS
- F16J15/00—Sealings
- F16J15/02—Sealings between relatively-stationary surfaces
- F16J15/06—Sealings between relatively-stationary surfaces with solid packing compressed between sealing surfaces
- F16J15/08—Sealings between relatively-stationary surfaces with solid packing compressed between sealing surfaces with exclusively metal packing
- F16J15/0806—Sealings between relatively-stationary surfaces with solid packing compressed between sealing surfaces with exclusively metal packing characterised by material or surface treatment
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16J—PISTONS; CYLINDERS; SEALINGS
- F16J15/00—Sealings
- F16J15/16—Sealings between relatively-moving surfaces
- F16J15/26—Sealings between relatively-moving surfaces with stuffing-boxes for rigid sealing rings
- F16J15/28—Sealings between relatively-moving surfaces with stuffing-boxes for rigid sealing rings with sealing rings made of metal
-
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- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/05—Metallic powder characterised by the size or surface area of the particles
- B22F1/054—Nanosized particles
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/07—Metallic powder characterised by particles having a nanoscale microstructure
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- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
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- B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
- B22F2998/10—Processes characterised by the sequence of their steps
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Abstract
一种密封件,包括金属复合材料,其具有:包括金属性纳米基体材料的蜂窝纳米基体,布置在该蜂窝纳米基体中的金属基体,和分解剂;内密封表面;和离开内密封表面径向布置的外密封表面。该密封件可通过以下方法制备:将金属基体粉末、分解剂、和金属纳米基体材料组合以形成组合物;将该组合物压实以形成压实组合物;烧结该压实组合物;和压制该烧结组合物以形成密封件。
Description
相关申请的交叉引用
本申请要求2012年5月8日提交的美国申请第13/466311号的权益,通过引用以其全文并入本文。
背景技术
包括油和天然气井、CO2固定(sequestration)钻井等的井下结构经常利用钻井部件或工具,由于它们的功能,仅需要具有有限的使用寿命,其显著低于井的使用寿命。在部件或工具使用功能完成之后,必须将其移除或处置以便恢复用于使用(包括烃制备、CO2捕获或固定等)的流体通道的原始尺寸。可通过将部件或工具碾磨或钻削出钻井来完成部件或工具的处置,这通常是费时且昂贵的操作。该行业通常易接受消除从钻井移除部件或工具而没有这样的碾磨和钻削操作的新系统、材料和方法。
发明内容
本文中公开了一种密封件,其包含金属复合材料,该金属复合材料包括:包含金属性纳米基体材料的蜂窝纳米基体;布置在该蜂窝纳米基质中的金属基质;和分解剂;第一密封表面;和与第一密封表面相对布置的第二密封表面。
本文中还公开了一种用于制备密封件的方法,该方法包括将金属基体粉末、分解剂、和金属纳米基体材料组合以形成组合物;将该组合物压实以形成压实组合物;烧结该压实组合物;和压制该烧结组合物以形成密封件。
还公开了一种用于暂时密封井下元件的方法,该方法包括:施加压力以使密封件变形(如上所述);使该密封件贴合一定空间以形成暂时密封;和使该暂时密封与井下流体接触以分解该暂时密封。
另外公开了一种分解剂,其包含在受控的电解材料当中布置的金属、脂肪酸、陶瓷颗粒或包含前述的至少一种的组合,其中该分解剂改变受控电解材料的分解速率。
附图说明
以下说明不应视为以任何方式进行限制。参考附图,相似的元件标号相似:
图1描绘了可分解的管状连接(anchoring)系统的横截面视图;
图2描绘了可分解的金属复合材料的横截面视图;
图3是如本文中公开的可分解的金属复合材料的示例性实施方案的显微照片;
图4描绘了用于制备图2中显示的可分解的金属复合材料的组合物的横截面视图。
图5A是没有蜂窝纳米基体的纯金属的显微照片;
图5B是具有金属基体和蜂窝纳米基体的可分解的金属复合材料的显微照片;
图6是对于包括蜂窝纳米基体的各种可分解的金属复合材料的质量损失对时间的图表,其表明选择性地可调节的分解速率;
图7A是由纯Mg粉末形成的压块的断裂表面的电子显微照片;
图7B是具有如本文中所述的蜂窝纳米基体的可分解的金属复合材料的示例性实施方案的断裂表面的电子显微照片;
图8是具有蜂窝纳米基体的金属复合材料的压缩强度对蜂窝纳米基体的成分(Al2O3)的重量百分比的图表;
图9A描绘了钻井中可分解的管状连接系统的实施方案的横截面视图;
图9B描绘了在安装位置上图9A的系统的横截面视图;
图10描绘了可分解的截头圆锥零件的横截面视图;
图11描绘了可分解的底部截头的横截面视图;
图12A、12B和12C分别描绘了可分解的套管的透视图、横截面视图和俯视图;
图13A和13B分别描绘了可分解的密封件的透视图和横截面视图;
图14描绘了可分解的管状连接系统的另一个实施方案的横截面视图;
图15描绘了在安装位置上图14的可分解的管状连接系统的横截面视图;
图16描绘了可分解的管状连接系统的另一个实施方案的横截面视图;
图17描绘了在可分解的管状连接系统中具有弹性体支承环的可分解的密封件的另一个实施方案的横截面视图;
图18A和18B分别描绘了可分解的密封件的另一个实施方案的横截面视图和透视图。
具体实施方式
参考附图通过例示而不是限制在本文中呈现所公开的装置和方法的一个或多个实施方案的详细描述。
发明人发现高强度、高延展性还可完全分解的管状连接系统可由选择性和可控地分解以响应与某些井下流体接触或以响应变化的状况的材料制得。这样的可分解的系统包括部件,所述部件为选择性地可腐蚀的并且具有选择性地可调节的分解速率和选择性地可调节的材料性质。此外,该可分解的系统具有部件,所述部件具有不同的压缩和拉伸强度并且包括密封件(以形成例如贴合的金属至金属密封)、圆锥体、可变形的套管(或罩)和底部接头。如本文中使用的,“可分解的”意指材料或部件为可消耗的、可腐蚀的、可降解的、可溶解的、可弱化的或以其它方式可移除的。要理解的是本文中术语“分解(disintegrate)”或其任何形式(例如分解(disintegration))的使用包括所述的含义。
在图1中显示了可分解的管状连接系统的一个实施方案。该可分解的管状连接系统110包括密封件112、截头圆锥零件114、套管116(本文中显示为滑环)、和底部接头118。配置该系统110使得截头圆锥零件114相对于套管116和相对于密封件112的轴向移动导致套管116和密封件112分别径向改变。尽管在该实施方案中径向改变是在径向向外的方向上,但是在替代性的实施方案中径向改变可在其它方向上例如径向向内。此外,在向其施加压缩力时可改变密封件112的壁部分的轴向长度D1和厚度T1。密封件112、截头圆锥零件114、套管116和底部截头118(即系统110的部件)是可分解的并且包含金属复合材料。该金属复合材料包括分解剂和布置在蜂窝纳米基体中的金属基体。
在一个实施方案中,将分解剂布置在金属基体中。在另一个实施方案中,将分解剂布置在金属基体外。在又一个实施方案中,将分解剂布置在金属基体中以及金属基体外。该金属复合材料还包括蜂窝纳米基体,该蜂窝纳米基体包含金属性纳米基体材料。可将分解剂布置在金属性纳米基体材料当中的蜂窝纳米基体中。在美国专利申请序列号12/633,682、12/633,688、13/200,832、和13/358,307中公开了示例性的金属复合材料和用于制备该金属复合材料的方法,通过引用以其全文将这些专利申请的每个并入本文。
金属复合材料例如为如图2所示的粉末压块。该金属复合材料200包括:包含纳米基体材料220的蜂窝纳米基体216和包含分散在蜂窝纳米基体216中的颗粒芯部材料218的金属基体214(例如多个分散颗粒)。颗粒芯部材料218包含纳米结构材料。将这样的具有蜂窝纳米基体并在其中布置金属基体的金属复合材料称作受控的电解材料。
参考图2和4,金属基体214可包括任何合适的金属性颗粒芯部材料218,其包括如本文中描述的纳米结构。在一个示例性实施方案中,金属基体214由颗粒芯部14(图4)形成并且可包括元素例如铝、铁、镁、锌或其组合作为纳米结构的颗粒芯部材料218。更特别地,在一个示例性实施方案中,金属基体214和颗粒芯部材料218可包括各种Al或Mg合金作为纳米结构的颗粒芯部材料218,包括各种可沉淀硬化的合金Al或Mg合金。在一些实施方案中,颗粒芯部材料218包括镁和铝,其中基于金属基体的重量,铝以约1重量%(wt%)-约15wt%、特别是约1wt%-约10wt%、并且更特别是约1wt%-约5wt%的量存在,重量的余量为镁。
在另一个实施方案中,可沉淀硬化的Al或Mg合金是特别有用的,因为通过纳米结构化和经纳入如本文中描述的颗粒沉淀的沉淀硬化两者,它们可强化金属基体214。金属基体214和颗粒芯部材料218还可包括稀土元素、或稀土元素的组合。示例性的稀土元素包括Sc、Y、La、Ce、Pr、Nd、或Er。可使用包含至少一种前述稀土元素的组合。当存在时,基于金属复合材料的重量,稀土元素可以以约5wt%或更少、并且特别是约2wt%或更少的量存在。
金属基体214和颗粒芯部材料218还可包括纳米结构的材料215。在一个示例性的实施方案中,纳米结构的材料215是具有小于约200纳米(nm)、特别是约10nm-约200nm的晶粒尺寸(例如亚晶粒或微晶尺寸),并且特别是小于约100nm的平均晶粒尺寸。金属基体214的纳米结构可包括大角度晶界227(其通常用于限定晶粒尺寸)、或小角度晶界(其可在特定晶粒内作为亚结构出现,有时用于限定微晶尺寸)、或其组合。将理解金属基体214的纳米蜂窝基体216和晶粒结构(包括晶界227和229的纳米结构的材料215)是金属复合材料200的独特特征。特别地,纳米蜂窝基体216不是金属基体214的晶态部分或非晶部分。
在金属复合材料200中包括分解剂以控制金属复合材料200的分解速率。可将分解剂布置在金属基体214、蜂窝纳米基体216、或其组合中。根据一个实施方案,分解剂包括金属、脂肪酸、陶瓷颗粒或包含前述的至少一种的组合,将分解剂布置在受控的电解材料当中以改变受控的电解材料的分解速率。在一个实施方案中,将分解剂布置在金属基体外的蜂窝纳米基体中。在一个非限制性实施方案中,分解剂增加金属复合材料200的分解速率。在另一个实施方案中,分解剂减小金属复合材料200的分解速率。分解剂可为金属,包括钴、铜、铁、镍、钨、锌、或包含前述的至少一种的组合。在另一个实施方案中,分解剂为脂肪酸,例如具有6-40个碳原子的脂肪酸。示例性的脂肪酸包括油酸、硬脂酸、月桂酸、羟基硬脂酸、二十二烷酸、花生四烯酸、亚油酸、亚麻酸、蓖麻油酸、棕榈酸、褐煤酸、或包含前述的至少一种的组合。在又一个实施方案中,分解剂为陶瓷颗粒,例如氮化硼、碳化钨、碳化钽、碳化钛、碳化铌、碳化锆、碳化硼、碳化铪、碳化硅、硼碳化铌、氮化铝、氮化钛、氮化锆、氮化钽、或包含前述的至少一种的组合。此外,陶瓷颗粒可为下面关于强化剂讨论的陶瓷材料之一。这样的陶瓷颗粒具有5μm或更小、特别是2μm或更小、并且更特别是1μm或更小的尺寸。分解剂可以以有效引起金属复合材料200以所需的分解速率分解的量存在,基于金属复合材料的重量,特别是约0.25wt%-约15wt%、特别是约0.25wt%-约10wt%、特别是约0.25wt%-约1wt%。
在一个示例性的实施方案中,蜂窝纳米基体216包括铝、钴、铜、铁、镁、镍、硅、钨、锌、其氧化物、其氮化物、其碳化物、其金属间化合物、其金属陶瓷、或包含前述的至少一种的组合。基于密封件的重量,金属基体可以以约50wt%-约95wt%、特别是约60wt%-约95wt%、并且更特别是约70wt%-约95wt%的量存在。此外,基于密封件的重量,金属纳米基体材料的量为约10wt%-约50wt%、特别是约20wt%-约50wt%、并且更特别是约30wt%-约50wt%。
在另一个实施方案中,金属复合材料包括第二颗粒。如图2和4一般性地说明的,可使用涂覆的金属性粉末10和额外或第二粉末30形成金属复合材料200,即两种粉末10和30可具有基本上相同的粒料结构而不具有相同的化学化合物。额外粉末30的使用提供了金属复合材料200,该金属复合材料200还包括多个分散的第二颗粒234,如本文中描述的,第二颗粒234分散在蜂窝纳米基体216内并且相对于金属基体214也是分散的。因此,分散的第二颗粒234源于在粉末10、30中布置的第二粉末颗粒32。在一个示例性的实施方案中,分散的第二颗粒234包括Ni、Fe、Cu、Co、W、Al、Zn、Mn、Si、其氧化物、其氮化物、其碳化物、其金属间化合物、其金属陶瓷、或包含前述的至少一种的组合。
再次参考图2,金属基体214和颗粒芯部材料218还可包括添加剂颗粒222。添加剂颗粒222向金属基体214提供弥散强化机制并且向金属基体214的各个颗粒内的位错移动提供阻挡体或充当限制。此外,可将添加剂颗粒222布置在蜂窝纳米基体216中以强化金属复合材料200。添加剂颗粒222可具有任何合适的尺寸,并且在一个示例性实施方案中,可具有约10nm-约1微米、并且特别是约50nm-约200nm的平均颗粒尺寸。这里,尺寸意指添加剂颗粒的最大线性尺度。添加剂颗粒222可包括任何合适形式的颗粒,包括嵌入颗粒224、沉淀颗粒226或弥散体颗粒228。嵌入颗粒224可包括任何合适的嵌入颗粒,包括各种硬颗粒。嵌入颗粒可包括各种金属、碳、金属氧化物、金属氮化物、金属碳化物、金属间化合物、金属陶瓷颗粒、或其组合。在一个示例性实施方案中,硬颗粒可包括Ni、Fe、Cu、Co、W、Al、Zn、Mn、Si、其氧化物、其氮化物、其碳化物、其金属间化合物、其金属陶瓷、或包含前述的至少一种的组合。基于金属复合材料的重量,添加剂颗粒可以以约0.5wt%-约25wt%、特别是约0.5wt%-约20wt%、并且更特别是约0.5wt%-约10wt%的量存在。
在金属复合材料200中,分散在整个蜂窝纳米基体216中的金属基体214可在基本上连续的蜂窝纳米基体216中具有等轴结构或可沿着一根轴为大体狭长的,使得金属基体214的各个颗粒例如为扁圆或扁长形状的。在其中金属基体214具有大体狭长的颗粒的情况下,金属基体214和蜂窝纳米基体216可为连续或不连续的。构成金属基体214的颗粒尺寸可为约50nm-约800μm、特别是约500nm-约600μm、并且更特别是约1μm-约500μm。颗粒尺寸可为单分散或多分散的,并且颗粒尺寸分布可为单峰或双峰的。这里的尺寸意指颗粒的最大线性尺度。
参考图3,显示了金属复合材料的示例性实施方案的显微照片。金属复合材料300具有金属基体214,金属基体214包括具有颗粒芯部材料218的颗粒。此外,将金属基体214的每个颗粒布置在蜂窝纳米基体216中。这里,蜂窝纳米基体216显示为白色网络,该白色网络基本上围绕金属基体214的组分颗粒。
根据一个实施方案,金属复合材料由例如粉末成分的组合形成。如图4所说明的,粉末10包括粉末颗粒12,该粉末颗粒12具有:具有芯部材料18的颗粒芯部14和具有涂层材料20的金属性涂覆层16。可选择和配置这些粉末成分用于压实和烧结以提供金属复合材料200,该金属复合材料200为轻质的(即具有相对低的密度)、高强度并且例如通过分解为从钻井可选择和可控制地移除的,以响应钻井性质的变化,包括在合适的钻井流体(包括如本文中公开的各种钻井流体)中为可选择和可控制地分解的(例如通过具有选择性地可调节的分解速率曲线)。
可通过任何合适的方法在用于形成金属基体214的颗粒芯部14中形成纳米结构,包括:例如可通过球磨粉末以提供颗粒芯部14、并且更特别是通过低温碾磨(在低温下或在低温流体例如液氮中在球磨介质中球磨)粉末以提供用于形成金属基体214的颗粒芯部14来提供变形诱发的纳米结构。可通过任何合适的方法将颗粒芯部14成形为纳米结构的材料215,例如通过本文中描述的材料的预合金化粉末颗粒的碾磨或低温碾磨。还可通过所需量的各种合金成分的纯金属粉末的机械合金化来形成颗粒芯部14。机械合金化涉及这些粉末成分的球磨(包括低温碾磨)以机械地包裹和混合成分并形成颗粒芯部14。除了产生如上所述的纳米结构以外,球磨(包括低温碾磨)可导致颗粒芯部14和芯部材料18的固溶强化,其进而可导致金属基体214和颗粒芯部材料218的固溶强化。固溶强化可源于机械混合比根据特定的合金成分相平衡为可能的更高浓度的固溶体中的间隙或置换溶质原子的能力,由此向颗粒内的位错移动提供阻挡体或充当限制,这进而提供了颗粒芯部14和金属基体214中的强化机制。还可通过包括例如惰性气体凝聚、化学蒸发凝聚、脉冲电子沉积、等离子体合成、非晶固体的结晶、电沉积和严重塑性变形的方法形成具有纳米结构(晶界227、229)的颗粒芯部14。纳米结构还可包括高位错密度,例如约1017m-2至1018m-2的位错密度,其可为比通过传统方法例如冷轧而变形的类似合金材料高两个或三个数量级。
通过多个具有多个粉末颗粒12的金属性涂层16的压实和烧结,例如通过冷等静压(CIP)、热等静压(HIP)或动态锻造,基本上连续的蜂窝纳米基体材料216(参见图3)和纳米基体材料220由金属性涂覆层16形成。由于与烧结相关的扩散效果,纳米基体材料220的化学组成可不同于涂层材料20的组成。金属复合材料200还包括多个颗粒,其构成包含颗粒芯部材料218的金属基体214。随着将金属性涂覆层16在一起烧结形成蜂窝纳米基体216,金属基体214和颗粒芯部材料218对应于并且由多个粉末颗粒12的多个颗粒芯部14和颗粒芯部材料218形成。由于与烧结相关的扩散效果,颗粒芯部材料218的化学组成还可不同于芯部材料18的化学组成。
如本文中使用的,术语蜂窝纳米基体216不意味着粉末压块的主要成分,而是意指一种或多种少数成分(无论以重量计还是以体积计)。这区别于其中基体以重量或体积计构成主要成分的大多数基体复合材料。术语基本上连续的蜂窝纳米基体的使用旨在描述金属复合材料200内纳米基体材料220的分布的大的、规则的、连续的和相互连接的属性。如本文中使用的,“基本上连续的”描述了纳米基体材料220在整个金属复合材料200中的延伸使得其在基本上所有的金属基体214之间延伸并且包封基本上所有的金属基体214。基本上连续的用于表明不需要围绕金属基体214的各个颗粒的蜂窝纳米基体220的完整连续性和规则级别。例如,一些粉末颗粒12上的颗粒芯部14上方的涂覆层16中的缺陷在金属复合材料200的烧结期间可引起颗粒芯部14的桥接,由此导致蜂窝纳米基体216内的局部不连续性,即使在粉末压块的其它部分中蜂窝纳米基体216是基本上连续的并且表现出如本文中描述的结构。相比之下,在金属基体214的大体狭长的颗粒的情况下(即非等轴形状),例如通过挤压形成的那些,“基本上不连续的”用于表明金属基体214的每个颗粒周围的纳米基体的不完全连续性和中断(例如开裂或分离),例如可在预定的挤压方向上出现。如本文中使用的,“蜂窝”用于表明纳米基体限定纳米基体材料220的整体上重复、相互连接的室或格的网络,所述室或格包括并且还与金属基体214相互连接。如本文中使用的,“纳米基体”用于描述基体的尺寸或级别,特别是金属基体214的相邻颗粒之间基体的厚度。在一起烧结形成纳米基体的金属性涂覆层自身是纳米级厚度涂覆层。因为除了金属基体214的多于两个颗粒的交切以外,大部分位置处的蜂窝纳米基体216通常包含两个涂覆层16从具有纳米级厚度的相邻粉末颗粒12的互扩散和结合,形成的蜂窝纳米基体216还具有纳米级厚度(例如如本文中描述的涂覆层厚度的约两倍)并且因此被描述为纳米基体。此外,术语金属基体214的使用不意味着金属复合材料200的少数成分,而是意指一种或多种多数成分(无论以重量计还是以体积计)。术语金属基体的使用旨在表达金属复合材料200内颗粒芯部材料218的不连续和离散的分布。
可通过任何合适的方式镶嵌该嵌入颗粒224,包括例如通过将硬颗粒与颗粒芯部材料18一起球磨或低温碾磨。沉淀颗粒226可包括可在金属基体214内沉淀的任何颗粒,包括与所关注的材料特别是金属合金的成分的相平衡和它们的相对量一致的沉淀颗粒226(例如可沉淀硬化的合金),并且包括由于非平衡条件可沉淀的那些,例如可在如在机械合金化期间已知发生的以高于其相平衡限制的量被迫使进入合金的固溶体中的合金成分被充分加热以激活能够沉淀的扩散机制时发生。弥散体颗粒228可包括源自颗粒芯部14的制造的元素的纳米级颗粒或簇,例如与球磨相关的那些,包括碾磨介质(例如球)或碾磨流体(例如液氮)的成分或颗粒芯部14自身的表面(例如金属性氧化物或氮化物)。弥散体颗粒228可包括元素例如Fe、Ni、Cr、Mn、N、O、C、H等。可将添加剂颗粒222布置在与颗粒芯部14和金属基体214连接的任何地方。在一个示例性实施方案中,如图2所说明的可将添加剂颗粒222布置在金属基体214的表面之内或之上。在另一个示例性实施方案中,将多个添加剂颗粒222布置在金属基体214的表面上并且如图2所说明的还可将其布置在蜂窝纳米基体216中。
类似地,分散的第二颗粒234可由涂覆或未涂覆的第二粉末颗粒32例如通过将第二粉末颗粒32与粉末颗粒12分散而形成。在一个示例性实施方案中,可用与粉末颗粒12的涂覆层16相同的涂覆层36来涂覆该涂覆的第二粉末颗粒32,使得涂覆层36也导致纳米基体216。在另一个示例性实施方案中,可不涂覆第二粉末颗粒232,使得分散的第二颗粒234嵌入纳米基体216内。可混合粉末10和额外的粉末30以形成分散颗粒214和分散的第二颗粒234的均匀分散体或形成这些颗粒的非均匀分散体。由于颗粒芯部34、或涂覆层36、或它们两者的组成差异,分散的第二颗粒234可由不同于粉末10的任何合适的额外粉末30形成,并且可包括本文中公开的用作第二粉末30的任何材料,该材料不同于被选择来形成粉末压块200的粉末10。
在一个实施方案中,金属复合材料任选包括强化剂。强化剂提高金属复合材料的材料强度。示例性的强化剂包括陶瓷、聚合物、金属、纳米颗粒、金属陶瓷等。特别地,强化剂可为二氧化硅、玻璃纤维、碳纤维、炭黑、碳纳米管、硼化物、氧化物、碳化物、氮化物、硅化物、硼化物、磷化物、硫化物、钴、镍、铁、钨、钼、钽、钛、铬、铌、硼、锆、钒、硅、钯、铪、铝、铜、或包含前述的至少一种的组合。根据一个实施方案,将陶瓷与金属组合以形成金属陶瓷,例如碳化钨、氮化钴等。示例性的强化剂特别地包括镁砂、莫来石、氧化钍、氧化铍、氧化铀、尖晶石、氧化锆、氧化铋、氧化铝、氧化镁、二氧化硅、钛酸钡、堇青石、氮化硼、碳化钨、碳化钽、碳化钛、碳化铌、碳化锆、碳化硼、碳化铪、碳化硅、硼碳化铌、氮化铝、氮化钛、氮化锆、氮化钽、氮化铪、氮化铌、氮化硼、氮化硅、硼化钛、硼化铬、硼化锆、硼化钽、硼化钼、硼化钨、硫化铈、硫化钛、硫化镁、硫化锆、或包含前述的至少一种的组合。强化剂聚合物的非限制性实例包括聚氨酯、聚酰亚胺、聚碳酸酯等。
在一个实施方案中,强化剂为具有约100微米或更少、特别是约10微米或更少、并且更特别是500nm或更少的尺寸的颗粒。在另一个实施方案中,纤维强化剂可与粒料强化剂组合。据认为强化剂的纳入可提高金属复合材料的强度和断裂韧性。不希望受理论所束缚,较细(即较小)尺寸的颗粒可产生与较大尺寸的颗粒相比更强的金属复合材料。此外,强化剂的形状可变化并且包括纤维、球、杆、管等。强化剂可以以0.01重量%(wt%)-20wt%、特别是0.01wt%-10wt%、并且更特别是0.01wt%-5wt%的量存在。
在一种用于制备包含金属复合材料的可分解的连接系统的部件(例如密封件、截头圆锥零件、套管、底部接头等)的方法中,该方法包括将金属基体粉末、分解剂、金属纳米基体材料和任选地强化剂组合以形成组合物;压实该组合物以形成压实组合物;烧结该压实组合物;和压制该烧结组合物以形成可分解系统的部件。可将该组合物的零件混合、碾磨、掺混等以形成例如如图4所示的粉末10。应理解金属纳米基体材料是布置在金属基体粉末上的涂层材料,其在被压实和烧结时形成蜂窝纳米基体。可通过在压力下压制(即压实)该组合物以形成生坯压块来形成压块。随后在约15,000ps i-约100,000ps i、特别是约20,000ps i-约80,000ps i、并且更特别是约30,000psi-约70,000psi的压力下在约250℃-约600℃、并且特别是约300℃-约450℃的温度下压制该生坯压块以形成粉末压块。压制以形成粉末压块可包括模具中的压缩。还可将粉末压块机加工以将粉末压块成型成有用的形状。或者,可将粉末压块压制成有用的形状。机加工包括使用例如碾磨机、台锯、车床、异型铣刀、放电机器等切削、锯切、烧蚀、碾磨、铣端面、车削、钻孔等。
金属基体200可具有任何所需的形状和尺寸,包括柱体棒、条、片、环或可机加工、成形或以其它方式用于形成有用的制造制品的其它形式,包括各种井眼工具和部件。由用于形成金属复合材料200的烧结和压制方法通过使粉末颗粒12(包括颗粒芯部14和涂覆层16)变形,使用压制来形成可分解的连接系统的部件(例如密封件、截头圆锥零件、套管、底部接头等),以提供金属复合材料200的全密度和所需的宏观形状和尺寸以及其显微结构。颗粒层的金属基体214和蜂窝纳米基体216的各个颗粒的形态(例如等轴或大体狭长的)源自于烧结和随着粉末颗粒12被压实并且互扩散和变形以填充金属基体214的颗粒间空间(图2)的变形。可选择烧结温度和压力以确保金属复合材料200的密度实现基本上完全的理论密度。
对于例如在井下环境中的使用,金属复合材料具有有益的性质。在一个实施方案中,由金属复合材料制得的可分解的连接系统的部件具有可在井下运行的初始形状,并且在密封件和套管的情况下,可随后在压力下变形。金属复合材料是强的和有延展性的,基于可分解的连接系统的部件的原始尺寸,具有约0.1%-约75%、特别是约0.1%-约50%、并且更特别是约0.1%-约25%的百分比延伸率。金属复合材料具有每平方英寸约15千磅(ksi)-约50ksi、并且特别是约15ksi-约45ksi的屈服强度。金属复合材料的压缩强度为约30ksi-约100ksi,并且特别是约40ksi-约80ksi。可分解的连接系统的部件可具有相同或不同的材料性质,例如百分比延伸率、压缩强度、拉伸强度等。
与弹性体材料不同,本文中的可分解的连接系统的部件包括具有最高至约1200℉、特别是最高至1000℉、并且更特别是约800℉的温度等级。可分解的连接系统是暂时的,因为该系统为可选择性和可调节地分解的以响应与井下流体的接触或条件(例如pH、温度、压力、时间等)的变化。此外,该可分解的连接系统的部件可具有相同或不同的分解速率或与井下流体的反应性。示例性的井下流体包括盐水、无机酸、有机酸、或包含前述的至少一种的组合。盐水例如可为海水、油层产出水、完井盐水、或其组合。盐水的性质可取决于盐水的特性和组分。作为一个实例,除了通常的含卤化物的盐以外,海水包含数种成分,例如硫酸盐、溴和痕量金属。另一方面,油层产出水可为从由地表制备的产油藏(例如油气藏)提取的水。油层产出水还称作油层盐水并且经常包含许多组分例如钡、锶和重金属。除了天然出现的盐水(盐水和油层产出水)以外,完井盐水可由新鲜水添加各种盐例如KCl、NaCl、ZnCl2、MgCl2、或CaCl2合成,以增加盐水的密度,例如CaCl2盐水的每加仑10.6磅。完井盐水通常提供优化以对抗井下储层压力的流体静压力。可改变上述盐水以包括额外的盐。在一个实施方案中,盐水中包括的额外盐为NaCl、KCl、NaBr、MgCl2、CaCl2、CaBr2、ZnBr2、NH4Cl、甲酸钠、甲酸铯等。基于该组合物的重量,该盐可以以约0.5wt.%-约50wt.%、特别是约1wt.%-约40wt.%、并且更特别是约1wt.%-约25wt.%的量存在于盐水中。
在另一个实施方案中,井下流体为无机酸,其可包括盐酸、硝酸、磷酸、硫酸、硼酸、氢氟酸、氢溴酸、高氯酸、或包含前述的至少一种的组合。在又一个实施方案中,井下流体为有机酸,其可包括羧酸、磺酸、或包含前述的至少一种的组合。示例性的羧酸可包括甲酸、乙酸、氯乙酸、二氯乙酸、三氯乙酸、四氟乙酸、丙酸、丁酸、草酸、苯甲酸、苯二甲酸(包括邻、间和对-异构体)等。示例性的磺酸包括烷基磺酸和芳基磺酸。烷基磺酸包括例如甲磺酸。芳基磺酸包括例如苯磺酸或甲苯磺酸。在一个实施方案中,烷基可为枝化或未枝化的并且可包含一个至约20个碳原子且可为取代或未取代的。芳基可为烷基取代的,即可为烷芳基,或可通过亚烷基与磺酸部分连接(即芳烷基)。在一个实施方案中,芳基可用杂原子进行取代。芳基可具有约3个碳原子-约20个碳原子并且包括多核环结构。
金属复合材料的分解速率(还称作溶解速率)为每小时每平方厘米约1毫克(mg/cm2/小时)-约10,000mg/cm2/小时、特别是约25mg/cm2/小时-约1000mg/cm2/小时、并且更特别是约50mg/cm2/小时-约500mg/cm2/小时。取决于用于形成本文中的金属复合材料的组合物和加工条件,分解速率是可变化的。
不希望受理论束缚,本文中的金属复合材料的出乎预料地高的分解速率是由通过金属基体和蜂窝纳米基体提供的显微结构所致。如上讨论的,通过使用涂覆粉末的粉末冶金加工(例如压实和烧结)来提供这样的显微结构,其中涂层产生纳米蜂窝基体并且粉末颗粒产生金属基体的颗粒芯部材料。据认为金属复合材料中蜂窝纳米基体与金属基体的颗粒芯部材料的紧密接近产生用于金属基体的快速且可调节地分解的电位点。这样的电解位点在缺少蜂窝纳米基体的单一金属和合金中是没有的。为了说明,图5A显示了由镁粉末形成的压块50。尽管压块50表现出被颗粒边界54包围的颗粒52,但是颗粒边界构成基本上一致的材料(颗粒52)之间的物理边界。然而,图5B显示了复合材料金属56(粉末压块)的示例性实施方案,该复合材料金属56包括具有布置在蜂窝纳米基体62中的颗粒芯部材料60的金属基体58。复合材料金属56由涂覆氧化铝的镁颗粒形成,其中在粉末冶金加工下,氧化铝涂层产生蜂窝纳米基体62,并且镁产生具有(镁的)颗粒芯部材料60的金属基体58。蜂窝纳米基体62不仅是作为图5A中的颗粒边界54的物理边界,而且还是插在金属基体58的邻近颗粒芯部材料60之间的化学边界。然而压块50(图5A)中的颗粒52和颗粒边界54不具有电位点,具有颗粒芯部材料60的金属基体58建立与蜂窝纳米基体62连接的多个电位点。电位点的反应性取决于金属基体58和蜂窝纳米基体62中使用的化合物(作为用于金属复合材料的金属基体和蜂窝纳米基体显微结构的加工条件的结果)。
此外,通过在粉末和涂层中使用的粉末冶金加工条件和化学材料的选择,本文中的金属复合材料的显微结构是可控制的。因此,如对于图6中各种组成的金属复合材料所说明的,分解速率是选择性地可调节的,图6显示了对于包括蜂窝纳米基体的各种金属复合材料的质量损失对时间的图表。具体地,图6显示了对于四种不同的金属复合材料(金属复合材料A 80、金属复合材料B 82、金属复合材料C 84、和金属复合材料D 86)的分解速率曲线。每条曲线的每个部分(由图6中的黑点分隔)的斜率提供了该曲线的特定部分的分解速率。金属复合材料A 80具有两种不同的分解速率(802、806)。金属复合材料B 82具有三种不同的分解速率(808、812、816)。金属复合材料C 84具有两种不同的分解速率(818、822),并且金属复合材料D 86具有四种不同的分解速率(824、828、832和836)。在由点804、810、814、820、826、830和834表示的时间处,由于变化的条件(例如如上讨论的pH、温度、时间、压力),金属复合材料(80、82、84、86)的分解速率改变。沿着相同的分离曲线,该速率可增加(例如从速率818到速率822)或减小(例如从速率802到806)。此外,基于金属性复合材料的显微结构和部件,分解速率曲线可具有多于两种速率、多于三种速率、多于四种速率等。以这种方式,分解速率曲线是选择性地可调节的并且可区别于缺少本文中描述的金属复合材料的显微结构(即金属基体和蜂窝纳米基体)的仅金属合金和纯金属。
金属复合材料的显微结构不仅控制金属复合材料的分解速率行为,而且还影响金属复合材料的强度。因此,本文中的金属复合材料还具有选择性地可调节的材料强度屈服(和其它材料性质),其中由于用于制备金属复合材料的加工条件和材料,该材料强度屈服改变。为了说明,图7A显示了由纯Mg粉末形成的压块的断裂表面的电子显微照片,并且图7B显示了具有如本文中描述的蜂窝纳米基体的金属复合材料的示例性实施方案的断裂表面的电子显微照片。基本上连续的蜂窝纳米基体(可选择来提供强化相材料)与金属基体(具有颗粒芯部材料)的显微结构形态提供本文中具有增强的机械性质(包括压缩强度和剪切强度)的金属复合材料,因为可通过类似于传统强化机制的方法例如晶粒尺寸减少、通过使用杂原子的固溶硬化、沉淀或时效硬化和应变/加工硬化机制来操纵蜂窝纳米基体/金属基体的所得形态以提供强化。蜂窝纳米基体/金属基体结构倾向于通过如本文中描述的数个颗粒纳米基体界面以及蜂窝纳米基体材料内的离散层之间的界面来限制位错移动。这在如图7A和图7B中说明的这些材料的断裂行为中得到例证。在图7A中,使用未涂覆的纯Mg粉末制得并且经受足以诱发失效的剪切应力的压块说明了晶间断裂。相比之下,在图7B中,使用由具有纯Mg粉末颗粒芯部以形成金属基体和包括Al的金属性涂覆层以形成蜂窝纳米基体的粉末颗粒制得并且经受足以诱发失效的剪切应力的金属复合材料说明了穿晶断裂和如本文中描述的显著较高的断裂应力。因为这些材料具有高强度特性,所以可选择芯部材料和涂层材料以利用低密度材料或不会以其它方式提供用于所需应用(包括钻孔工具和部件)的必要强度特性的其它低密度材料,例如低密度金属、陶瓷、玻璃或碳。
为了进一步说明具有蜂窝纳米基体的金属复合材料的选择性地可调节的材料性质,图8显示了具有蜂窝纳米基体的金属复合材料的压缩强度对蜂窝纳米基体的成分(Al2O3)的重量百分比的图表。图8清楚地显示改变氧化铝涂层的重量百分比(wt%)即厚度对金属复合材料的室温压缩强度的影响,该金属复合材料具有由包括在纯Mg颗粒芯部上的多层(Al/Al2O3/Al)金属性涂覆层的涂覆粉末颗粒形成的蜂窝纳米基体。在该实例中,以4%的氧化铝实现了优化的强度,这代表与0wt%氧化铝相比21%的增加。
因此,可将本文中的金属复合材料配置成提供宽范围的可选择和可控制的腐蚀或分解行为,从非常低的腐蚀速率到极高的腐蚀速率、特别是比没有纳入蜂窝纳米基体的粉末压块、例如由纯Mg粉末通过与在本文中描述的各种蜂窝纳米基体中包括纯Mg分散的颗粒相比相同的压实和烧结方法形成的压块更低和更高的腐蚀速率。还可将这些金属复合材料200配置成提供与由不包括本文中描述的纳米级涂层的纯金属(例如纯Mg)颗粒形成的压块相比显著增强的性质。此外,没有蜂窝纳米基体的金属合金(通过例如由熔体浇注形成或通过冶金加工粉末形成)也不具有如本文中的金属复合材料的选择性地可调节的材料和化学性质。
如上所提及的,金属复合材料用于制备可在例如井下环境中用作工具或器具的制品。在一个特别的实施方案中,该制品为密封件、截头圆锥零件、套管、或底部接头。在另一个实施方案中,制品的组合一起用作可分解的管状连接系统。
参考图9A和9B,以510说明了本文中公开的可分解的管状连接系统的实施方案。密封系统510包括截头圆锥零件514(也称作圆锥体并且在图10中单独显示),其具有在彼此相对的轴向方向上成锥形的第一截头圆锥部分516和第二截头圆锥部分520。将底部截头570(在图11中单独显示)布置在可分解的系统510的端部处。套管524(在图12中单独显示)是可径向膨胀的,以响应使其轴向移动抵抗第一截头圆锥部分516。类似地,密封件528(在图13A和13B中单独显示)是可径向膨胀的,以响应使其轴向移动抵抗第二截头圆锥部分520。一种相对于截头圆锥部分516、620移动套管524和密封件528的方法是用安装工具558轴向压缩该完整的组件。密封件528包括具有表面536(在该实施方案中成锥形)的基座532并且能容纳塞子578,该塞子578可密封地接合密封件528的表面536。
密封件528的基座532还包括箍544,该箍544位于密封件528与第二截头圆锥部分520之间。箍544具有壁548,由于其上径向向内面向的截头圆锥表面552,其厚度逐渐减小。壁548变化的厚度使较薄部分比较厚部分更容易变形。出于至少两个原因,这可为有益的。首先,当使箍544相对于第二截头圆锥部分520移动时较薄壁部分549可变形,以便密封件528径向膨胀进入与结构540的密封接合中。其次,例如当在处理操作期间加压抵抗位于基座532处的塞子(例如塞子578)时,较厚壁部分550应抵抗因产生的穿过其中的压力差所致的变形。可选择截头圆锥表面552的锥角以匹配第二截头圆锥部分520的锥角,由此使第二截头圆锥部分520向箍544至少在它们彼此接触的区域中提供径向支撑。
将可分解的管状连接系统510配置成安装(即连接)和密封一种结构540例如(例如在烃回收和二氧化碳固定应用中可利用的)衬里、壳体或地层(earth formation)钻井中的封闭或安装孔。与结构540的密封和连接使抵抗位于那里的塞子578的压力增加,用于例如在压裂和酸处理期间完成的地形成物的处理。此外,基座532位于密封件528中,使得抵抗位于基座532上的塞子而施加的压力推动密封件528朝向套管524,由此增加密封件528与结构540和截头圆锥零件514两者的密封接合以及增加套管524与结构540的连接接合。
可配置密封系统510使得在密封件528与结构540密封接合之前,将套管524与结构540连接(按位置固定),或者使得在套管524与结构540连接之前将密封件528与结构540密封接合。可通过在密封件528的安装中涉及的部件与在套管524的安装中涉及的部件相比的材料性质关系(例如相对压缩强度)或尺度关系,选择控制密封件528和套管524中哪一个首先与结构540接合。无论套管524或密封件528哪一个首先与结构540接合,可安装其以响应安装可分解的管状连接系统510的安装工具的部分的方向。通过减少或消除在密封件528与结构540接合之后密封件528与结构540之间的相对移动,可使密封件528的损坏最小化。在该实施方案中,在使套管524与结构540接合之前使密封件528与结构540接合可实现该目标。
基座532的表面536位于套管524的轴向上游(如由推动塞子抵抗基座532的流体流限定)。此外,密封件的基座536可位于密封件528的箍544的轴向上游。这种相对定位使由抵抗塞子(位于抵抗接触面(land)536)的压力产生的力进一步推动密封件528进入与结构540的密封接合中。箍544变形的部分充分贴合第二截头圆锥部分520,由此被径向支撑,而无论锥角是否匹配。第二截头圆锥部分520可具有约1°-约30°、特别是约2°-约20°的锥角以便于箍544的径向膨胀并且允许箍544与第二截头圆锥部分520之间的摩擦力在移除引起其间移动的轴向力之后维持其间的位置关系。出于与第二截头圆锥部分520相同的原因,第一截头圆锥部分516还可具有约10°-约30°、特别是约14°-约20°的锥角。截头圆锥表面552和第二截头圆锥部分520之一或两者可包括多于一个锥角,如本文中对第二截头圆锥部分520进行说明的,其中突出部556具有比远离突出部556的表面520更大的锥角。具有多个锥角可向操作人员提供对箍544与截头圆锥零件514之间的每单位轴向移动的箍544(和随后密封件528)的径向膨胀量的较大控制。除了其它变量以外,锥角还提供对相对于截头圆锥零件514移动箍544所需的轴向力的额外控制。这样的控制可允许可分解的管状连接系统510使密封件528的箍544膨胀以在膨胀和安装套管224之前安装密封件528。
在一个实施方案中,沿着系统510从底部接头570到密封件528的长度布置安装工具558。安装工具558可产生引起截头圆锥零件514相对于套管524移动所需的载荷。安装工具558可具有主轴560,其具有通过力失效零件566例如多个剪切螺钉与一端564连接的挡板562。布置挡板562来接触底部接头570。布置来接触密封件528在朝向底部接头570处的挡板562的方向上沿着主轴560可导向移动(在本文中未示出)的板568,可轴向推动截头圆锥零件514朝向套管524。可设置使力失效元件566失效的载荷仅在通过截头圆锥零件514已经径向改变套管524所选择的量之后出现。在力失效零件566的失效之后,挡板562可从主轴560分离,由此允许主轴560和板568例如回到表面。
根据一个实施方案,套管524的表面572包括突起574,其可称作齿,被配置来与结构540的壁576咬入接合,当表面572处于径向改变(即膨胀)的配置时,在该结构540内可分解的系统510是可利用的。该咬入接合起到连接可分解的系统510与结构540的作用,以防止其间的相对移动。尽管在该实施方案中公开的结构540为管状的,例如钻井中的衬里或壳体,但是其还可为例如地形成物中的安装孔。
图9B显示了在继安装可分解的系统510后从结构540移除安装工具558之后的可分解的系统510。这里,套管524的突起574咬入接合结构540的壁576以将可分解系统510连接到那里。此外,由于其通过安装工具558的压缩,已使密封件528径向膨胀以在密封件528的外表面上接触结构540的壁576。密封件528变形,使得随着在截头圆锥零件514与结构540的壁576之间的密封件528的压缩期间厚度548减小,密封件528的长度增加。以这种方式,密封件528形成抵抗截头圆锥零件514的金属至金属密封和抵抗壁576的金属至金属密封。或者,密封件528可变形以补全壁576的地形特征,例如孔隙、缝隙、突起等。类似地,密封件528的延展性和拉伸强度允许密封件528变形以补全截头圆锥零件514的地形特征。
在安装具有套管514的突起574的可分解的系统510之后,可在基座532的表面536上布置塞子578。一旦塞子578与基座536密封接合,在其上游压力就可增加以进行工作例如压裂地形成物或驱动井下工具(例如在烃类回收应用中使用时)。
在一个实施方案中,如图9B所示,塞子578例如球与密封件528的基座532接合。例如向塞子578例如液压地施加压力以使密封件528的箍544变形。箍544的变形导致壁材料548伸长并且与结构540(例如钻井壳体)密封接合以形成与截头圆锥零件514的第一截头圆锥部分516的金属至金属密封并且形成与结构576的另一金属至金属密封。这里,金属复合材料的延展性允许密封件528填充结构540与截头圆锥零件514之间的空间。可在该时刻进行井下操作,并且在该操作之后随后移除塞子578。塞子578从基座532的移除可通过以下方法发生:产生跨过塞子578的压力差,使得塞子578离开基座532并且移动离开密封件528和截头圆锥零件514。此后,可通过与井下流体接合将任何密封件528、截头圆锥零件514、套管524或底部接头570分解。或者,在将塞子578从基座532移除之前,井下流体可接触和分解密封件528,并且随后可从可分解的系统510的任何残留部件移除塞子578。密封件528、截头圆锥零件514、套管524、或底部接头570的分解是有益的,这至少部分是因为恢复了钻井的流动通道而没有机械移除可分解的系统510的部件(例如通过钻孔或碾磨)或将碎片排出钻井。应理解可分解的系统510的部件的分解速率是如上讨论的独立地选择性地可调节的,并且密封件528、截头圆锥零件514、套管524、或底部接头570具有独立地选择性地可调节的材料性质例如屈服强度和压缩强度。
根据另一个实施方案,将可分解的管状连接系统510配置成有通孔580,其具有由当安装在结构540中时可分解的系统510的最大径向尺度限定的内径向尺寸582和外径向尺寸584。在一个实施方案中,内径向尺寸582可为足够大,用于安装工具558的主轴560适合通过系统510。在安装可分解的系统510和移除主轴560之后,安装工具558的挡板562可留在结构540中。在将系统510至少分解到其中挡板562可通过内径向尺度582的点之后,可将挡板562从结构540中取出。因此,可分解的系统510的部件可为基本上实心的。通过在可分解的系统510中纳入通孔580,可从结构540中下游或上游方向使流体循环通过可分解的系统510,以导致部件(例如套管)的分解。
在另一个实施方案中,配置可分解的管状连接系统510具有内径向尺度582,其与外径向尺度584比较为大的。根据一个实施方案,内径向尺度582大于外径向尺度584的50%,特别是大于60%,并且更特别是大于70%。
密封件、截头圆锥零件、套管、和底部接头可具有例如用于井下环境的组合或单独的有益性质。这些部件是可分解的并且可为本文中完全可分解的连接系统的一部分。此外,所述部件具有本文中描述的金属复合材料的机械和化学性质。因此所述部件有益地为选择性和可调节地可分解的,以响应与流体的接触或条件(例如pH、温度、压力、时间等)的变化。示例性的流体包括盐水、无机酸、有机酸、或包含前述的至少一种的组合。
在图10中显示了截头圆锥零件的一个实施方案的横截面视图。如上所述,截头圆锥零件514具有第一截头圆锥部分516、第二截头圆锥部分520和突出部556。截头圆锥零件514的锥角可沿着外表面584而变化,使得截头圆锥零件514具有不同的横截面形状,包括所示的截头双锥形状。壁厚度586因此可沿着截头圆锥零件514的长度而变化,并且可基于特定的应用来选择截头圆锥零件514的内径。截头圆锥零件514可用于各种应用例如本文中的可分解的管状连接系统以及其中强的或可分解的截头圆锥形状为有用的情况。示例性的应用包括轴承、扩口截头、阀杆、密封环等。
在图11中显示了底部接头的横截面视图。底部截头700具有第一端部702、第二端部704、任选的螺纹706、任选的通孔708、内径710和外径712。在一个实施方案中,底部接头700是工具(例如可分解的系统510)的末端。在另一个实施方案中,在线状物(string)的端部处布置底部接头700。在某些实施方案中,使用底部接头700将工具与线状物连接。或者,底部接头700可用于各工具或线状物之间,并且可为接头或连接器的一部分。底部接头700可与线状物和制品例如桥塞、压裂塞、井下马达、包装机、斜向器等一起使用。在一个非限制性的实施方案中,第一端部702提供与例如截头圆锥零件514和套管524的界面。第二端部704接合安装工具558的挡板562。螺纹576(当存在时)可用于固定底部接头700与制品。在一个实施方案中,截头圆锥零件514具有与螺纹706配合的螺纹部分。在一些实施方案中,螺纹706是不存在的,并且内径710可为直孔或可具有其成锥形的部分。通孔708可传送流体例如盐水以分解底部接头700或可分解的系统510的其它部件。通孔还可为用于力失效零件566的连接点,该力失效零件566与安装工具558或类似的设备结合使用。设想了底部接头700可具有不用于图11中所示的另一种横截面形状。示例性形状包括圆锥、椭圆、圆环、球、圆柱、它们的截断形状、非对称形状、包括前述的组合等。此外,底部接头700可为实心物品并且可具有的内径为外径尺寸的至少10%、特别是至少50%、并且更特别是至少70%。
在图12A、12B和12C中分别显示了套管的透视图、横截面视图和俯视图。套管524包括外表面572、布置在外表面572上的突起574、和内表面571。随着套管524径向膨胀以响应内表面571的第一部分573接合配合表面(例如图10中的第一截头圆锥部分516),套管524充当具有突起574的滑动环,突起574作为咬入接合表面例如壳体或安装孔的壁的滑动面(slip)。突起574可圆周地围绕整个套管524。或者如图12C的俯视图所示,可以对称或非对称地将突起574间隔开。套管524的形状不限于图12中显示的。套管,除了为图9中说明的可分解的管状连接系统中的滑动环以外,还可用于安装多种工具,包括包装机、桥塞、压裂塞,或可布置在任何环境中,其中制品的抗滑动可通过使套管的突起与配合表面接合来完成。
参考图13A和13B,密封件400包括内密封表面402、外密封表404、基座406、和基座406的表面408。将表面408配置(成形)成接受零件(例如塞子)以提供对密封件400的力以便使密封件变形,使得内密封表面402和外密封表面404分别形成与配合表面(未在图13A和13B中示出)的金属至金属密封。或者,通过布置在如图9A的密封件400的相对端处的截头圆锥零件和安装工具,对密封件400施加压缩力。在一个实施方案中,密封件400在井下环境中作为可贴合、可变形、非常有延展性和可分解的密封件是有用的。在一个实施方案中,密封件400是桥塞、垫圈、瓣阀等。
除了为选择性地可腐蚀的以外,本文中的密封件还原位变形以贴合一定空间(在其中布置该密封件)以响应施加的安装压力,该安装压力是大得足以使密封件径向膨胀或通过增加密封件的长度来降低密封件的壁厚度的压力。与许多密封件例如弹性体密封件不同,本文中的密封件以一定形状制备,该形状对应于待密封的配合表面,例如井下工具的壳体或截头圆锥形状。在一个实施方案中,该密封件是暂时密封件并且具有可在井下运行的初始形状且随后在压力下变形以形成金属至金属密封,该金属至金属密封变形至该密封件接触的表面并且填充配合表面中的空间(例如空隙)。为了实现密封性质,基于密封件的原始尺寸,该密封件具有约10%-约75%、特别是约15%-约50%、并且更特别是约15%-约25%的百分比延伸率。该密封件具有每平方英寸约15千磅(ksi)-约50ksi、并且特别是约15ksi-约45ksi的屈服强度。密封件的压缩强度为约30ksi-约100ksi、并且特别是约40ksi-约80ksi。为了使密封件变形,可向密封件施加最高至约10,000psi、并且特别是约9,000psi的压力。
与弹性体密封件不同,本文中包括金属复合材料的密封件具有最高至约1200℉、特别是最高至约1000℉、并且更特别是最高至约800℉的温度等级。密封件是暂时的,因为该密封件是选择性和可调节地可分解的,以响应与井下流体的接触或条件(例如pH、温度、压力、时间等)的变化。示例性的井下流体包括盐水、无机酸、有机酸、或包含前述的至少一种的组合。
由于密封件与例如本文中的可分解的管状连接系统中的其它部件例如截头圆锥零件、套管、或底部接头相互作用,因而对于合适的相对选择性地可调节的材料和化学性质,选择每个部件的性质。这些性质是金属复合材料和形成用于制备这样的制品即部件的金属复合材料的加工条件的特性。因此,在一个实施方案中,一个部件的金属复合材料将不同于可分解的系统的另一个部件。以这种方式,部件将具有独立的选择性地可调节的机械和化学性质。
根据一个实施方案,套管和密封件在由截头圆锥零件和底部接头给予的力下变形。为了实现该结果,套管和密封件具有的压缩强度小于底部接头或截头圆锥零件。在另一个实施方案中,在密封件变形之前、之后或同时套管变形。在某些实施方案中设想了底部接头或截头圆锥零件变形。在一个实施方案中,一个部件具有不同于另一个部件的量的强化剂,例如其中较高强度部件具有比较低强度的部件更大的量的强化剂。在一个特定的实施方案中,截头圆锥零件具有比密封件更大量的强化剂。在另一个实施方案中,截头圆锥零件具有比套管更大量的强化剂。类似地,底部接头可具有比密封件或套管更大量的强化剂。在一个特别的实施方案中,截头圆锥零件具有的压缩强度比密封件或套管更大。在又一个实施方案中,截头圆锥零件具有的压缩强度比密封件或套管更大。在一个实施方案中,截头圆锥零件具有40ksi-100ksi、特别是50ksi-100ksi的压缩强度。在另一个实施方案中,底部接头具有40ksi-100ksi、特别是50ksi-100ksi的压缩强度。在又一个实施方案中,密封件具有30ksi-70ksi、特别是30ksi-60ksi的压缩强度。在另一个实施方案中,套管具有30ksi-80ksi、特别是30ksi-70ksi的压缩强度。因此,在压缩力下密封件或套管将在底部接头或截头圆锥零件的变形之前变形。
可影响部件的相对强度的其它因素包括每个部件中强化剂的类型和尺寸。在一个实施方案中,截头圆锥零件包括比密封件或套管中的强化剂更小尺寸的强化。在又一个实施方案中,底部接头包括比密封件或套管中的强化剂更小尺寸的强化剂。在一个实施方案中,截头圆锥零件包括强化剂例如陶瓷、金属、金属陶瓷、或其组合,其中强化剂的尺寸为10nm-200μm、特别是100nm-100μm。
影响部件的相对选择性地可调节的材料和化学性质的又一个因素为金属复合材料的成分,即蜂窝纳米基体的金属性纳米基体、布置在蜂窝纳米基体中的金属基体、或分解剂。压缩和拉伸强度以及分解速率由这些成分的化学特性和相对量确定。因此,可通过金属复合材料的成分调整这些性质。根据一个实施方案,一个部件(例如密封件、截头圆锥零件、套管、或底部接头)具有包括纯金属的金属复合材料的金属基体,并且另一个部件具有包括合金的金属基体。在另一个实施方案中,密封件具有包括纯金属的金属基体,并且截头圆锥零件具有包括合金的金属基体。在又一个实施方案中,套管具有为纯金属的金属基体。设想了可对部件进行功能评级:金属复合材料的金属基体可包含纯金属和合金两者,其具有在部件中布置的金属基体中纯金属或合金的相对量的梯度。因此,选择性地可调节的性质的值相对于沿着部件的位置而变化。
在一个特别的实施方案中,一个部件(例如密封件、截头圆锥零件、套管、或底部接头)的分解速率具有比另一个部件更大的值。或者,每个部件可具有基本上相同的分解速率。在另一个实施方案中,套管具有比另一个部件例如截头圆锥零件更大的分解速率。在另一个实施方案中,一个部件(例如密封件、截头圆锥零件、套管、或底部接头)的分解剂的量以比另一个部件更大的量存在。在另一个实施方案中,套管中存在的分解剂的量大于另一个部件。在一个实施方案中,密封件中分解剂的量大于另一个部件。
参考图14和15,以1110说明了可分解的管状连接系统的一个替代性的实施方案。可分解的系统1110包括截头圆锥零件1114、具有表面1122的套管1118、具有表面1130的密封件1126和基座1134,其中每个部件由金属复合材料制得并且具有本文中的选择性地可调节的机械和化学性质。系统510(图9)与系统1110之间的主要区别是密封件和截头圆锥零件之间的初始相对位置。
通过迫使截头圆锥零件1114进入套管1118中多远来控制套管1118的表面1122经历的径向变化量。截头圆锥零件1114上的截头圆锥表面1144可与套管1118上的截头圆锥表面1148楔入接合。因此,使截头圆锥零件1114相对于套管1118移动越远,套管1118的径向变化越大。类似地,密封件1126放置于截头圆锥表面1144径向上并且相对于套管1118轴向固定,因此截头圆锥零件1114相对于套管1118和密封件1126移动越远,密封件1126和表面1130的径向变化越大。前述的结构允许操作人员在将系统1110放置在结构1150内之后确定表面1122、1130的径向变化量。
任选地,系统1110可包括径向放置在密封件1126与截头圆锥零件1114之间的箍1154,使得还通过截头圆锥零件1114改变箍1154的径向尺度以响应相对其的移动。箍1154可具有截头圆锥表面1158,其与截头圆锥表面1144互补,使得在截头圆锥零件1114移动时,同时径向改变箍1154的基本上完全轴向的程度。箍1154可由不同于密封件1126或截头圆锥零件1114的金属复合材料制得。因此,箍1154可保持密封件1126在变化的径向尺度下,即使截头圆锥表面1144随后移出与截头圆锥表面1158的接合,由此保持密封件1126与结构1150的壁1162的密封接合。这可通过选择箍1154的金属复合材料具有比密封件1136更高的压缩强度来实现。
可分解的系统1110还包括截头圆锥零件1114上的接触面1136,其与塞子1138可密封接合。在可分解的系统中还包括容纳指状物1174上的肩部1170的套管1118的槽1166(在壁1058内),一旦安装工具558以与如图9所示用安装工具558可分解的系统510是可安装的类似方法压缩该可分解的系统1110,这些构造在一起是可接合的。
参考图16,以1310说明了可分解的管状连接系统的另一个替代性的实施方案。可分解的系统1310包括第一截头圆锥零件1314、放置和配置为径向膨胀进入与结构1322(在本文中说明为地形成物1326中的钻井)的连接接合中的套管1318,以响应被推动抵抗第一截头圆锥零件1314的截头圆锥表面1330。箍1334可径向膨胀进入与结构1322的密封接合中,以响应相对于第二截头圆锥零件1338轴向被推动,并且具有基座1342,该基座1342具有可密封容纳可相反运行的塞子1350(用虚线显示)的表面1346。基座1342置于如由推动塞子1350抵抗基座1342的流体限定的箍1334的下游方向上。通过使由于在塞子1350塞入时跨过基座1342的压力差所致的径向力最小化,表面1346相对于箍1334的这种配置和位置协助保持箍1334处于径向膨胀的配置中(在已经膨胀后)。
为了清楚起见,如果将表面1346放置在甚至箍1334的轴向延伸的一部分的上游方向上(其不是),那么跨过抵抗表面1346而安放的塞子积累的压力将径向跨过在表面1346的下游方向上放置的箍1334的部分产生压力差。该压力差将由箍1334的径向向外超过箍1334的径向向内的较大压力限定,由此产生箍1334上径向向内的力。这些径向向内的力,如果足够大,那么可导致箍1334径向向内变形,从而潜在地损害在过程中箍1334与结构1322之间的密封整体性。通过相对于箍1334放置表面1346,特别地避免这种状况。
任选地,可分解的管状连接系统1310包括箍1334的径向上放置的密封件1354,其被配置成便于箍1334与结构1322的密封(通过当使箍1334径向膨胀时在其间被径向压缩)。密封件1354由具有比第一截头圆锥零件1314更低的压缩强度的金属复合材料制得,以增强密封件1354与箍1334和结构1322两者的密封。在一个实施方案中,密封件1354具有比箍1334更低的压缩强度。
因此在该实施方案中,可分解的系统1310可包括第一截头圆锥零件1314、套管1318和任选的密封件1354。在密封件1354不存在时的情况下,第一截头圆锥零件1314的箍1334可形成与壳体或衬里的金属至金属密封或与安装孔表面贴合。在一些实施方案中,第一截头圆锥零件1314包含功能梯度金属复合材料,使得箍1334具有比第一截头圆锥零件1314的其余部分更低的压缩强度值。在另一个实施方案中,箍1334具有比第二截头圆锥零件1338更低的压缩强度。在又一个实施方案中,第二截头圆锥零件1338具有比密封件1354更大的压缩强度。
可用各种材料加强本文中的部件。在一个实施方案中,密封件、例如密封件528可包括辅助密封件,例如图17所示的弹性体材料602。弹性体材料可为例如布置在密封件528的表面上的压盖604中的O形环。弹性体材料包括但不限于例如丁二烯橡胶(BR)、丁基橡胶(IIR)、氯磺化聚乙烯(CSM)、环氧氯丙烷橡胶(ECH、ECO)、三元乙丙橡胶(EPDM)、二元乙丙橡胶(EPR)、氟橡胶(FKM)、丁腈橡胶(NBR、HNBR、HSN)、全氟橡胶(FFKM)、聚丙烯酸酯橡胶(ACM)、聚氯丁二烯(氯丁橡胶)(CR)、聚异戊二烯(IR)、聚硫橡胶(PSR)、sanifluor、硅橡胶(SiR)、丁苯橡胶(SBR)、或包含前述的至少一种的组合。
如本文所述,部件例如密封件可用于井下环境,例如以提供金属至金属密封。在一个实施方案中,用于暂时密封井下元件的方法包括在井下布置部件并且施加压力以使该部件变形。该部件可包括密封件、截头圆锥零件、套管、底部、或包含前述至少一种的组合。该方法还包括使密封贴合一定空间以形成暂时密封,压缩套管以接合表面,并且此后使该部件与井下流体接触以分解该部件。该部件包括本文中具有金属基体、分解剂、蜂窝纳米基体、和任选地强化剂的金属复合材料。密封件的金属复合材料形成内密封表面和离开密封件的内密封表面径向布置的外密封表面。
根据一个实施方案,隔离一种结构的方法包括在一种结构(例如管状、筒、管、钻井(封闭或开放)等)中布置本文中可分解的管状连接系统,径向改变套管以接合该结构的表面,和径向改变密封件以隔离该结构。可使可分解的管状连接系统与流体接触以分解例如密封件、截头圆锥零件、套管、底部截头、或包含前述的至少一种的组合。该方法还可包括用安装工具安装可分解的连接系统。此外,可将塞子布置在密封件上。隔离该结构可为完全或基本上阻碍流体流动通过该结构。
此外,该密封件可具有除了图9和13-16中显示的特别设置以外的各种形状和密封表面。在另一个实施方案中,参考图18A和18B,以100说明了本文中公开的密封件的实施方案。密封件100包括金属复合材料、第一密封表面102、和与第一密封表面102相对布置的第二密封表面104。该金属复合材料包括布置在蜂窝纳米基体中的金属基体、分解剂、和任选地强化剂。密封件100可为任何形状并且在压力下与表面原位贴合以形成暂时密封,该密封可选择性分解以响应与流体的接触。在该实施方案中,密封件100是环状形状,其具有外径106和内径108。在一些实施方案中,第一表面102、第二表面104、外径106、内径108、或包含前述的至少一种的组合可为密封表面。
尽管已经描述了包括几种部件一起的可分解的管状连接系统的变体,但是设想每个部件为单独且独立地用作制品。此外,可以将部件的任何组合一起使用。此外,部件可用于表面或井下环境中。
虽然显示和描述了一个或多个实施方案,但是可由此作出改变或替换而不偏离本发明的精神和范围。因此,要理解的是通过说明而不是限制的方式描述了本发明。本文中的实施方案可独立地使用或可进行组合。
本文中公开的所有范围是包括端点的,并且端点是彼此可独立地组合的。如本文中使用的前缀“(一个或多个)”旨在包括其修饰的术语的单数和复数两者,由此包括至少一个该术语(例如(一种或多种)着色剂包括至少一种着色剂)。“任选的”或“任选地”意味着随后描述的事件或情况可以或可以不发生,并且该描述包括其中该事件发生的情况和其中该事件不发生的情况。如本文中使用的,“组合”是包括掺混物、混合物、合金、反应产物等的。通过引用将所有参考文献并入本文。
在描述本发明的上下文中(特别是在以下权利要求的上下文中)术语“一个(a)”和“一种(an)”和“这个(the)”及类似名词的使用应视为包括单数和复数两者,除非在本文中以其它方式说明或通过上下文清楚地被否定。“或”意指“和/或”。此外,还应注意本文中的术语“第一”、“第二”等不表示任何顺序、数量(使得多于一种、两种或多于两个的元件可存在)、重要性,而是用于区别一个元件与另一个。用于连接数量的修饰语“约”是包括所述值的并且具有通过上下文表明的含义(例如其包括与特别数量的测量相关的误差程度)。
Claims (35)
1.一种密封件,其包含:
金属复合材料,其包括:
包含金属性纳米基体材料的蜂窝纳米基体;
布置在该蜂窝纳米基体中的金属基体;和
分解剂;
第一密封表面;和
与第一密封表面相对布置的第二密封表面。
2.权利要求1的密封件,其中将第一密封表面布置在密封件的内部上,并且将第二密封表面径向布置在密封件的外部上离开第一密封表面。
3.权利要求1的密封件,其中将分解剂布置在金属基体外的蜂窝纳米基体中。
4.权利要求1的密封件,其中将分解剂布置在金属基体中。
5.权利要求1的密封件,其中金属基体包含铝、铁、镁、锰、锌、或包含前述的至少一种的组合。
6.权利要求1的密封件,其中分解剂包含钴、铜、铁、镍、钨、锌、或包含前述的至少一种的组合。
7.权利要求1的密封件,其中金属性纳米基体材料包含铝、钴、铜、铁、镁、镍、硅、钨、锌、其氧化物、其氮化物、其碳化物、其金属间化合物、其金属陶瓷、或包含前述的至少一种的组合。
8.权利要求1的密封件,其中基于密封件的重量,金属基体的量为约50wt%-约95wt%。
9.权利要求1的密封件,其中基于密封件的重量,分解剂的量为约0.25wt%-约15wt%。
10.权利要求1的密封件,其中基于密封件的重量,金属纳米基体材料的量为约10wt%-约50wt%。
11.权利要求1的密封件,其还包含添加剂颗粒,该添加剂颗粒包括金属、碳、金属氧化物、金属氮化物、金属碳化物、金属间化合物、金属陶瓷、或包含前述的至少一种的组合。
12.权利要求11的密封件,其中基于密封剂的重量,添加剂颗粒的量为约0.5wt%-约25wt%。
13.权利要求1的密封件,其还包含外密封表面中的压盖。
14.权利要求13的密封件,其还包含布置在压盖中的弹性体。
15.权利要求14的密封件,其中该弹性体包括丁二烯橡胶、丁基橡胶、氯磺化聚乙烯、环氧氯丙烷橡胶、三元乙丙橡胶、二元乙丙橡胶、氟橡胶、丁腈橡胶、全氟橡胶、聚丙烯酸酯橡胶、聚氯丁二烯、聚异戊二烯、聚硫橡胶、sanifluor、硅橡胶、丁苯橡胶、或包含前述的至少一种的组合。
16.权利要求1的密封件,其中该密封件是暂时密封件。
17.权利要求1的密封件,其中该密封件具有约10%-约75%的百分比延伸率。
18.权利要求1的密封件,其中该密封件具有约15ksi-约50ksi的屈服强度。
19.权利要求1的密封件,其中该密封件具有约30ksi-约80ksi的压缩强度。
20.权利要求1的密封件,其中该密封件具有最高至1000℉的温度等级。
21.权利要求1的密封件,其中该密封件是可分解的,以响应与流体的接触。
22.权利要求1的密封件,其中该流体包含盐水、无机酸、有机酸、或包含前述的至少一种的组合。
23.权利要求1的密封件,该密封件具有约1mg/cm2/小时-约10,000mg/cm2/小时的分解速率。
24.一种制品,其包含权利要求1的密封件,其中该制品是压裂塞、桥塞、垫圈或瓣阀。
25.权利要求24的制品,其中将该密封件配置成形成金属至金属密封以响应压缩力的施加。
26.一种用于制备密封件的方法,该方法包括:
将金属基体粉末、分解剂、和金属纳米基体材料组合以形成组合物;
将该组合物压实以形成压实组合物;
烧结该压实组合物;和
压制该烧结组合物以形成密封件。
27.一种用于暂时密封元件的方法,该方法包括:
施加压力以使权利要求1的密封件变形;
使密封件贴合一定的空间以形成暂时密封;和
使暂时密封与流体接触以分解暂时密封。
28.权利要求27的方法,其中该暂时密封为金属至金属密封。
29.权利要求27的方法,其中第一密封表面为内密封表面,并且第二密封表面为离开内密封表面径向布置的外密封表面。
30.一种分解剂,其包含:
在受控的电解材料当中布置的金属、脂肪酸、陶瓷颗粒、或包含前述的至少一种的组合,
其中分解剂改变受控的电解材料的分解速率。
31.权利要求30的分解剂,其中受控的电解材料包含:
包含金属性纳米基体材料的蜂窝纳米基体;和
布置在蜂窝纳米基体中的金属基体。
32.权利要求31的分解剂,其中将该分解剂布置在金属基体外的蜂窝纳米基体中。
33.权利要求30的分解剂,其中该金属包含钴、铜、铁、镍、钨、锌、或包含前述的至少一种的组合。
34.权利要求30的分离剂,其中脂肪酸包含油酸、硬脂酸、月桂酸、羟基硬脂酸、二十二烷酸、花生四烯酸、亚油酸、亚麻酸、蓖麻油酸、棕榈酸、褐煤酸、或包含前述的至少一种的组合。
35.权利要求30的分解剂,其中该陶瓷颗粒包含氮化硼、碳化钨、碳化钽、碳化钛、碳化铌、碳化锆、碳化硼、碳化铪、碳化硅、硼碳化铌、氮化铝、氮化钛、氮化锆、氮化钽、或包含前述的至少一种的组合。
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RU2627779C2 (ru) | 2017-08-11 |
AU2017201833B2 (en) | 2017-11-23 |
CA2872404C (en) | 2017-03-21 |
AU2013260077A1 (en) | 2014-10-30 |
WO2013169418A1 (en) | 2013-11-14 |
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PL237181B1 (pl) | 2021-03-22 |
AU2013260077B2 (en) | 2017-04-06 |
MX2014013544A (es) | 2015-01-16 |
RU2014149137A (ru) | 2016-06-27 |
PL410368A1 (pl) | 2015-11-09 |
CO7111254A2 (es) | 2014-11-10 |
US20130300066A1 (en) | 2013-11-14 |
CN104285032B (zh) | 2018-02-06 |
US20170138479A1 (en) | 2017-05-18 |
CA2872404A1 (en) | 2013-11-14 |
US10612659B2 (en) | 2020-04-07 |
CA2953874A1 (en) | 2013-11-14 |
CA2953874C (en) | 2018-11-06 |
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