CN114480923B - 一种溶解速度可控的可溶金属密封圈及其制备工艺 - Google Patents
一种溶解速度可控的可溶金属密封圈及其制备工艺 Download PDFInfo
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Abstract
本发明涉及一种溶解速度可控的可溶金属密封圈及其制备工艺,其结构包括圆环状的高塑性铝合金密封圈基体及其外表面包覆的标准电极电位高于‑0.3V的复合涂层;其制备工艺包括如下步骤:(1)制备高塑性铝合金;(2)机加工制备铝合金密封圈基体;(3)对密封圈铝合金基体退火处理;(4)按比例准备涂层原料并混匀;(5)在铝合金密封圈基体外表面制备复合涂层;(6)制备微孔。本发明所得可溶金属密封圈通过坐封后复合涂层与铝合金密封圈基体之间的电偶腐蚀现象来加速铝合金密封圈基体的溶解速率,解决了现有可溶密封圈产品中存在的良好密封性能与良好溶解性能难以兼得的问题,具有密封性能好、溶解速率可控、不会堵塞等优点。
Description
技术领域
本发明属于井下工具技术领域,具体为一种溶解速度可控的可溶金属密封圈及其制备工艺。
背景技术
可溶桥塞是一种应用在油气井中起临时封隔作用的井下工具,主要包括接头、卡瓦、锥体、密封圈等部分,其中密封圈是保证桥塞封堵效果的关键部件。使用时,将桥塞下放至井下套管内目标位置,然后通过一定手段施加压力,使桥塞中密封圈的直径增大,最终,密封圈的外表面紧贴在套管内壁上,从而将套管封堵。密封圈良好的密封性能是保证压裂作业成功的关键。根据压裂工况,通常要求密封圈的延伸率大于35%以上,且各方向的延伸率要基本相等,极差小于5%,以实现密封圈良好的密封性能。压裂作业后,需要包括密封圈在内的可溶桥塞整体在7-30天内完全溶解,目前可溶桥塞除密封圈外的其他部件常用可溶镁合金制备,可以在要求的时间内完全溶解。
目前国内外常用的可溶桥塞密封圈主要是可溶高分子材料密封圈,但可溶高分子材料密封圈耐温、耐压性能差,在压裂施工时易因地层温度高或承压不足导致密封失效;同时高分子材料密封圈在地下水中的溶解产物呈絮状,极易导致套管的堵塞。采用可溶金属密封圈代替可溶高分子材料密封圈,可有效解决可溶高分子材料密封圈承压不足、耐温性能差,溶解产物易堵塞的问题。目前常见的可溶金属主要是镁基合金和铝基合金,但是镁基合金的塑性变形能力较差,延伸率通常为10%-20%,不能满足密封圈的塑性要求;其次,镁基合金密封圈通常以镁合金挤压棒材为原料,采用机加工按照设定的厚度将挤压棒材切成片状,然后将切片后的棒材内部挖空形成密封圈,这种成形工艺导致镁基密封圈具有明显的各向异性,压裂时各方向受力变形不均匀,导致密封不严或局部缩颈断裂。
铝为面心立方结构,具有较好的塑性,通过调整合金成分,其延伸率可达到35%以上,但铝合金因其表面覆盖有致密氧化膜而导致溶解性能较差。因此本发明采用高塑性的铝合金制备密封圈基体,在铝合金密封圈基体表面设计了一层腐蚀电位极高的表面覆盖涂层,在桥塞坐封前,表面覆盖涂层具有良好的耐蚀性,可以保护密封圈不受腐蚀;坐封时,高塑性的铝合金密封圈基体产生极大的塑性变形,但铝合金密封圈基体表面的覆盖涂层变形能力差,会产生大量微裂纹,使表面覆盖涂层与大塑性变形后的铝合金基体之间形成大量“大阴极-小阳极”结构的电偶腐蚀,加速铝合金密封圈基体的腐蚀。
发明内容
针对现有技术的不足,本发明提供一种溶解速度可控的可溶金属密封圈及其制备工艺,该密封圈不但具有延伸率大且各方向延伸率几乎相等的特点,还可通过调整表面覆盖涂层的成分、孔隙率来调整密封圈的溶解速度,具有延伸率大、溶解速率可控、成本低等优点。
为实现上述目的,本发明通过以下技术方案予以实现:一种溶解速度可控的可溶金属密封圈及其制备工艺,其结构包括高塑性的铝合金密封圈基体及其外表面包覆的复合涂层。
进一步地,所述高塑性的铝合金主要成分为铝、铜、镁,其中铜的含量为0.03%-0.80%、镁的含量为0.03%-0.40%,硅含量为0.20%,铁含量为0.25%,锰含量为0.03%,锌含量为0.04%,钛含量为0.03%,其余为铝。
进一步地,所述铝合金密封圈基体在作为一个整体的基础上分为密封圈基体上层、密封圈基体中层和密封圈基体下层,内径相同,密封圈基体下层外直径最大,密封圈基体中层外直径最小。
进一步地,所述复合涂层的厚度为5-50μm,标准电极电位高于-0.3V,包含石墨组元及一种或一种以上标准电极电位高于-0.3V的金属组元。
进一步地,优选的复合涂层厚度在8-30μm之间。
进一步地,所述复合涂层的组元,可以是石墨和镍两种组元。
进一步地,所述包含镍和石墨两种组元且标准电极电位高于-0.3V的复合涂层中,石墨的体积分数为10%-35%,金属镍的体积分数为65%-90%。
进一步地,复合涂层上制备有若干数量的直径小于0.5mm的微孔。
本发明提供一种溶解速度可控的可溶金属密封圈及其制备工艺,其制备工艺包括如下步骤:
步骤一:根据高塑性铝合金的化学成分熔炼铝合金并浇注成铝合金锭,然后将铝合金锭均匀化处理后,轧制成板材。
步骤二:根据设计的几何尺寸,从铝合金轧制板材上下料,并用机加工的方式进一步加工出所需形状及尺寸的铝合金密封圈基体;
步骤三:对铝合金密封圈基体进行退火处理,退火温度为300-400℃,热处理时间为25-40min,以此消除铝合金密封圈基体因为铝合金原始板材内轧制织构带来的各向异性,使其各个方向的延伸率几乎相等;
步骤四:根据复合涂层组分要求,确定复合涂层原料的组分种类及百分含量,按照设计的比例混合均匀;
步骤五:对铝合金密封圈基体进行表面喷砂处理;
步骤六:采用火焰喷涂或等离子喷涂的方式,在铝合金密封圈基体外表面制备复合涂层并采用机械或化学方式在涂层表面加工若干个直径小于0.5mm的微孔。
进一步地,在所述步骤四中,复合涂层以镍包石墨粉末为原料,原料包含石墨和镍两种组分,其中石墨体积分数为10%-35%、金属镍的体积分数为65%-90%。
本发明的有益效果:
针对现有技术的缺陷以及压裂作业对可溶桥塞密封圈的密封性、溶解性及承压能力的要求,本发明结合合金成分设计、结构设计及电偶腐蚀原理,创造性地设计了一种溶解速度可控的可溶金属密封圈及其制备工艺。本发明以高塑性铝合金制备密封圈基体,并通过退火处理消除铝合金密封圈基体的各向异性,使其各方向的延伸率几乎相等,保证了密封圈的密封性能;通过将铝合金密封圈基体设计为内径相等,但密封圈基体下层外直径最大,密封圈基体中层外直径最小的几何结构保证了密封圈的承压能力;在此基础上,通过在铝合金密封圈基体外表面上包覆一层标准电极电位高于-0.3V的复合涂层,通过坐封时复合涂层表面产生的微裂纹或局部磨损与铝合金密封圈基体形成大量“大阴极-小阳极”结构的电偶腐蚀对来加速铝合金密封圈基体的溶解速率,通过调整涂层上预制的微孔数量来调控铝合金密封圈基体的溶解速度,从而解决了现有产品中存在的可溶密封圈良好密封性能与良好溶解性能难以兼得的问题。本发明所述的可溶金属密封圈具有密封性能好、承压能力强、耐温性能好、溶解速率可控、制备简单、成本低等优点,同时本发明所述的可溶金属密封圈溶解产物为溶于水的金属离子,铝合金密封圈基体表面的复合涂层在其依附的铝合金密封圈基体溶解后会分离成直径极小的微块,随返排液排出,不会造成堵塞现象。
附图说明
图1为本发明结构示意图。
图2为本发明结构剖面图。
图3为本发明实施例1中组装的可溶桥塞工装示意图。
附图标记1、中心轴;2、上接头;3、可溶卡瓦;4、卡瓦牙;5、可溶金属密封圈;6、可溶球座;7、下接头;8、铝合金密封圈基体;81、密封圈基体上层;82、密封圈基体中层;83、密封圈基体下层;9、复合涂层。
具体实施方式
为了使本发明的目的、技术方案以及优点更加清楚明白,下面结合附图及实施例,对本发明做进一步详细说明。需要强调,此处描述的具体实施例仅用于更好的阐述本发明,为本发明部分实施例,而非全部实施例,所以并不用作限定本发明。
如图1和图2所示,一种溶解速度可控的可溶金属密封圈及其制备工艺,其结构包括圆环状的铝合金密封圈基体8,所述铝合金密封圈基体8包括密封圈基体上层81、密封圈基体中层82和密封圈基体下层83,所述铝合金密封圈基体8外表面包覆有复合涂层9。
如图1和图2所示,铝合金密封圈基体8的主要成分为铝、铜、镁,其中铜的含量为0.28%、镁的含量为0.08%,硅含量为0.20%,铁含量为0.25%,锰含量为0.03%,锌含量为0.04%,钛含量为0.03%,其余为铝。
如图1和图2所示,铝合金密封圈基体8为一个整体,密封圈基体上层81、密封圈基体中层82和密封圈基体下层83,此三者内径相同;密封圈基体下层83外直径最大,密封圈基体中层82外直径最小,为密封圈基体下层83外直径的94%,密封圈基体上层81外直径居中,为密封圈基体下层83外直径的97%。该结构可以减少坐封时所需外力并提高密封圈的承压能力。
如图1和图2所示,复合涂层9标准电极电位高于-0.3V,包含石墨和镍两种组元,且复合涂层9中石墨的体积分数为20%,金属镍的体积分数为80%,复合涂层9的厚度为20μm。
如图1和图2所示,复合涂层9上均匀分布着100个直径为0.4mm的微孔。
本发明提供一种溶解速度可控的可溶金属密封圈及其制备工艺,其制备工艺包括如下步骤:
步骤一:根据高塑性铝合金的化学成分熔炼铝合金并浇注成铝合金锭,然后将铝合金锭均匀化处理后,轧制成板材;
步骤二:根据设计的几何尺寸,从铝合金轧制板材上下料,并用机加工的方式进一步加工出图1和图2所示形状的铝合金密封圈基体8。
步骤三:对铝合金密封圈基体8进行退火处理,退火温度为340℃,退火时间为30min,退火后铝合金密封圈基体8各个方向的延伸率几乎相等且均在35%以上;
步骤四:确定复合涂层9原料为镍包石墨粉,其中石墨体积分数为20%、金属镍的体积分数为80%,按照比例混合均匀;
步骤五:对铝合金密封圈基体进行表面喷砂处理;
步骤六:采用火焰喷涂或等离子喷涂的方式,在铝合金密封圈基体外表面制备复合涂层9并采用机械加工方式在复合涂层9表面加工100个直径为0.4mm的微孔。
下面结合具体实施例对本发明作进一步说明。
作为本发明的一个实施例:将所得可溶金属密封圈5安装在可溶桥塞工装上,其结构如图3所示。
如图3所示,一种溶解速度可控的可溶金属密封圈组装在可溶桥塞工装的示意图,包括中心轴1,所述中心轴1上安装有上接头2,所述上接头2下方安装有可溶卡瓦3,所述可溶卡瓦3上嵌有卡瓦牙4,所述可溶卡瓦3下方安装有可溶金属密封圈5,所述可溶金属密封圈5下方安装有可溶球座6,所述可溶球座1下方安装有下接头7。
如图3所示,此可溶桥塞工装中除卡瓦牙4和可溶金属密封圈5外,其他部分均由可溶镁合金制备,其中卡瓦牙4由高硬度陶瓷材料制备,可溶金属密封圈5包括铝合金密封圈基体8和复合涂层9。
如图3所示,此可溶桥塞工装为现有技术中的常见结构,在此主要对可可溶金属密封圈5的相关实施方式进行详细描述。
如图3所示,当坐封开始时,在可溶桥塞工装上施加20MPa的轴向压力,使可溶金属密封圈5受到轴向的压力并沿着可溶球座6滑动,使轴向压力转化为径向压力,进而使可溶金属密封圈5发生向外扩张的塑性变形,最后可溶金属密封圈5的外表面紧贴在套管内壁上,塑性变形后的可溶金属密封圈5填充了可溶金属密封圈5与套管内壁之间的空隙,达到密封的效果。
如图3所示,可溶金属密封圈5受到外力作用时,主要由铝合金密封圈基体8发生塑性变形,其中密封圈基体下层83优先发生变形,进而带动密封圈基体中层82和密封圈基体上层81发生变形,使得铝合金密封圈基体8沿着可溶球座6滑动而向外部扩张,铝合金密封圈基体8外直径不断变大,直到可溶金属密封圈5外表面抵住套管内壁,完成坐封。
如图3所示,铝合金密封圈基体8外表面的复合涂层9延伸率较低,在坐封过程中密封圈铝合金基体8发生大塑性变形,导致铝合金密封圈基体8外表面的复合涂层9产生大量微裂纹;同时大塑性变形的铝合金密封圈基体8外侧与套管接触,发生摩擦,铝合金密封圈基体8外侧表面的复合涂层9局部位置发生磨损。复合涂层9表面的微裂纹、局部磨损及预制的微孔处裸露的铝合金标准电极电位低、面积小,其周围涂层中的镍、石墨标准电极电位高、面积大,在井下含有氯离子的地层水以及地层温度条件下,形成“大阴极-小阳极”结构的电偶腐蚀,加速铝合金密封圈基体8的溶解,溶解产物随返排液排出。
在井下含有氯离子的地层水以及地层温度条件下,由于复合涂层9厚度仅20μm,且分布着100个微孔及大量微裂纹,因此当铝合金密封圈基体8溶解后,依附在铝合金密封圈基体8表面的复合涂层9会分离成小块,随着返排液排出,不会造成堵塞现象。
在本发明的描述中,需要说明的是,术语、“下方”、“向外”、“轴向”、“径向”等指示的方位或位置关系为基于附图所示的方位或位置关系,仅是为了便于描述本发明和简化描述,而不是指示或暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和操作,因此不能理解为对本发明的限制;上述术语在本发明中的具体含义对于本领域的普通技术人员而言,可以具体情况理解。
尽管已经示出和描述了本发明的实施例,对于本领域的普通技术人员而言,可以理解在不脱离本发明的原理和精神的情况下可以对这些实施例进行多种化、修改、替换和变型,本发明的范围由所附权利要求及其等同物限定。
Claims (4)
1.一种溶解速度可控的可溶金属密封圈,其特征在于,所述可溶金属密封圈(5)包括高塑性的铝合金密封圈基体(8)及其外表面包覆的复合涂层(9),所述铝合金密封圈基体(8)所用材料为在300-400℃下退火25-40分钟的铝合金;所述复合涂层(9)厚度为5-50μm、由石墨及一种或一种以上标准电极电位高于-0.3V的金属组元组成;
所述铝合金的成分为:铜的含量为0.03%-0.80%、镁的含量为0.03%-0.40%,硅含量为0.20%,铁含量为0.25%,锰含量为0.03%,锌含量为0.04%,钛含量为0.03%,其余为铝;
所述铝合金密封圈基体(8)包括密封圈基体上层(81)、密封圈基体中层(82)和密封圈基体下层(83),所述密封圈基体上层(81)、密封圈基体中层(82)和密封圈基体下层(83)为一个整体,内径相同,密封圈基体下层(83)外直径最大,密封圈基体中层(82)外直径最小,为密封圈基体下层(83)直径的94%,密封圈基体上层(81)外直径为密封圈基体下层(83)直径的97%。
2.根据权利要求1所述的一种溶解速度可控的可溶金属密封圈,其特征在于,所述复合涂层(9)为石墨和镍两种组元,其中石墨的体积分数为10%-35%,金属镍的体积分数为65%-90%。
3.根据权利要求1所述的一种溶解速度可控的可溶金属密封圈,其特征在于,所述复合涂层(9)表面有用机械或化学方式加工的若干个直径小于0.5mm的微孔。
4.根据权利要求1所述的一种溶解速度可控的可溶金属密封圈,其特征在于,所述复合涂层(9)采用火焰喷涂或等离子喷涂的方式制备。
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