U.S. patent application number 15/531093 was filed with the patent office on 2017-12-14 for blending of water reactive powders.
The applicant listed for this patent is SCHLUMBERBER TECHNOLOGY CORPORATION. Invention is credited to Gregoire Jacob, Indranil Roy.
Application Number | 20170355016 15/531093 |
Document ID | / |
Family ID | 56074919 |
Filed Date | 2017-12-14 |
United States Patent
Application |
20170355016 |
Kind Code |
A1 |
Roy; Indranil ; et
al. |
December 14, 2017 |
BLENDING OF WATER REACTIVE POWDERS
Abstract
A method can include blending materials to form a blend where
the materials include a first particulate material and a second
particulate material and where the first particulate material is
water reactive and includes aluminum and one or more metals
selected from a group consisting of metals, alkaline earth metals,
group 12 transition metals, and basic having an atomic number equal
to or greater than 31; and forming a degradable object from the
blend.
Inventors: |
Roy; Indranil; (Missouri
City, TX) ; Jacob; Gregoire; (Rosharon, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SCHLUMBERBER TECHNOLOGY CORPORATION |
Sugar Land |
TX |
US |
|
|
Family ID: |
56074919 |
Appl. No.: |
15/531093 |
Filed: |
November 20, 2015 |
PCT Filed: |
November 20, 2015 |
PCT NO: |
PCT/US2015/061830 |
371 Date: |
May 26, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62085016 |
Nov 26, 2014 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E21B 33/12 20130101;
E21B 43/26 20130101; B22F 2999/00 20130101; B22F 3/02 20130101;
B22F 2998/10 20130101; B22F 1/0003 20130101; B22F 2998/10 20130101;
B22F 9/04 20130101; B22F 2202/03 20130101; B22F 2009/049 20130101;
B22F 5/00 20130101; E21B 43/14 20130101; B22F 9/04 20130101; B22F
3/14 20130101; B22F 1/0003 20130101; B22F 3/17 20130101; B22F 3/15
20130101; B22F 2999/00 20130101; E21B 33/1208 20130101; E21B 29/02
20130101; E21B 43/10 20130101 |
International
Class: |
B22F 1/00 20060101
B22F001/00; E21B 29/02 20060101 E21B029/02; E21B 33/12 20060101
E21B033/12; B22F 9/04 20060101 B22F009/04; B22F 3/02 20060101
B22F003/02 |
Claims
1. A method comprising: blending materials to form a blend wherein
the materials comprise a first particulate material and a second
particulate material and wherein the first particulate material is
water reactive and comprises aluminum and one or more metals
selected from a group consisting of alkali metals, alkaline earth
metals, group 12 transition metals, and basic metals having an
atomic number equal to or greater than 31; and forming a degradable
object from the blend.
2. The method of claim 1 comprising forming the second particulate
material at least in part via a severe plastic deformation
process.
3. The method of claim 1 wherein the second particulate material is
water reactive.
4. The method of claim 1 wherein the second particulate material is
a metal powder.
5. The method of claim 4 wherein the water reactivity of the first
particulate material exceeds water reactivity of the second
particulate material.
6. The method of claim 1 wherein the materials comprise at least
one non-metallic particulate material.
7. The method of claim 1 wherein the first particulate material
imparts degradability to the degradable object.
8. The method of claim 1 wherein the forming comprises
consolidating the blend.
9. The method of claim 1 wherein the forming comprises
consolidating the blend to form a consolidated near-net shape
object.
10. The method of claim 9 comprising machining the near-net shape
object to form the degradable objection wherein the degradable
object comprises a component of a borehole tool.
11. The method of claim 1 wherein the blending occurs before a
process that subjects the blend to severe plastic deformation.
12. The method of claim 1 wherein the blending occurs during a
process that subjects the blend to severe plastic deformation.
13. The method of claim 1 wherein the blending occurs after a
process that subjects at least one of the materials to severe
plastic deformation.
14. The method of claim 1 wherein at least one of the materials
comprises dispersoids.
15. The method of claim 14 wherein the dispersoids are formed via
cryomilling.
16. The method of claim 1 wherein the one or more metals selected
from the group comprises at least one basic metal having an atomic
number equal to or greater than 31.
17. The method of claim 16 wherein the at least one basic metal
having an atomic number equal to or greater than 31 comprises at
least approximately two percent by weight of the material.
18. The method of claim 1 wherein the one or more metals selected
from the group comprises gallium.
19. The method of claim 18 wherein the gallium comprises at least
approximately two percent by weight of the first particulate
material.
20. The method of claim 1 wherein the one or more metals selected
from the group comprises indium.
21. The method of claim 1 wherein the one or more metals selected
from the group comprises at least one member selected from a group
consisting of gallium, indium, tin, bismuth, zinc, mercury,
lithium, sodium and potassium.
22. The method of claim 1 wherein the degradable object is
degradable in an aqueous environment.
23. The method of claim 1 wherein the degradable object comprises a
metal matrix composite.
24. The method of claim 1 wherein the degradable object comprises
at least a portion of a borehole tool.
Description
RELATED APPLICATION
[0001] This application claims the benefit of and priority to a
U.S. Provisional Patent Application having Ser. No. 62/085,016,
filed 26 Nov. 2014, which is incorporated by reference herein.
BACKGROUND
[0002] Various types of materials are used in equipment,
operations, etc. for exploration, development and production of
resources from geologic environments. For example, equipment may be
used in one or more of a sensing operation, a drilling operation, a
cementing operation, a fracturing operation, a production
operation, etc.
SUMMARY
[0003] A method can include blending materials to form a blend. The
materials may include a first particulate material and a second
particulate material. The first particulate material is water
reactive and includes aluminum and one or more metals selected from
a group including alkali metals, alkaline earth metals, group 12
transition metals, and basic metals having an atomic number equal
to or greater than 31. The method includes forming a degradable
object from the blend. Various other apparatuses, systems, methods,
etc., are also disclosed.
[0004] This summary is provided to introduce a selection of
concepts that are further described below in the detailed
description. This summary is not intended to identify key or
essential features of the claimed subject matter, nor is it
intended to be used as an aid in limiting the scope of the claimed
subject matter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] Features and advantages of the described implementations can
be more readily understood by reference to the following
description taken in conjunction with the accompanying
drawings.
[0006] FIGS. 1 and 2 illustrate an example of a method and examples
of equipment for fracturing a geologic environment;
[0007] FIG. 3 illustrates an example of equipment in various
example operational states;
[0008] FIG. 4 illustrates an example of a method;
[0009] FIG. 5 illustrates examples of materials;
[0010] FIG. 6 illustrates an example of a table as to examples of
powders and examples of processes;
[0011] FIG. 7 illustrates some examples of severe plastic
deformation processes;
[0012] FIG. 8 illustrates examples of plots of relationships;
[0013] FIG. 9 illustrates an example of a system;
[0014] FIG. 10 illustrates an example of a micrograph of an example
of particles;
[0015] FIG. 11 illustrates an example of a micrograph of an example
of a particle;
[0016] FIG. 12 illustrates an example of a micrograph of an example
of a particle;
[0017] FIG. 13 illustrates an example of a plot of a component
parameter versus degradation time and an example of a system;
[0018] FIG. 14 illustrates an example of a method;
[0019] FIG. 15 illustrates an example of a method;
[0020] FIG. 16 illustrates an example of a method;
[0021] FIG. 17 illustrates an example of an assembly;
[0022] FIG. 18 illustrates an example of equipment;
[0023] FIG. 19 illustrates an example of equipment and an example
of a surface mechanical attrition treatment process;
[0024] FIG. 20 illustrates examples of surface mechanical attrition
treatment processes; and
[0025] FIG. 21 illustrates example components of a system and a
networked system.
DETAILED DESCRIPTION
[0026] The following description includes the best mode presently
contemplated for practicing the described implementations. This
description is not to be taken in a limiting sense, but rather is
made merely for the purpose of describing the general principles of
the implementations. The scope of the described implementations
should be ascertained with reference to the issued claims.
[0027] As an example, a material or materials may be processed to
form processed material. In such an example, the processed material
may be machined, formed, etc. to produce a part or parts. As an
example, a part may be a component or a portion of a component. A
part may be included in equipment, which may be suitable for use in
an environment such as, for example, a downhole environment. As an
example, equipment may be drilling equipment, cementing equipment,
fracturing equipment, sampling equipment, or other type of
equipment. As an example, equipment may be borehole equipment. As
an example, a tool may be a borehole tool, for example, suitable to
perform a function or functions in a downhole environment in a
borehole.
[0028] As to cementing equipment, such equipment may be used in one
or more downhole cementing operations. As an example, cement may be
placed adjacent to a liner. As an example, a liner may be a string
of casing in which the top does not extend to the surface but
instead is suspended from inside another casing string. As an
example, a liner hanger may be used to attach or hang one or more
liners from an internal wall of another casing string.
[0029] As an example, a method may include operating one or more
components of a liner hanger system. As an example, a lower
completion may be a portion of a well that is at least in part in a
production zone or an injection zone. As an example, a liner hanger
system may be implemented to perform one or more operations
associated with a lower completion, for example, including setting
one or more components of a lower completion, etc. As an example, a
liner hanger system may anchor one or more components of a lower
completion to a production casing string.
[0030] As an example, equipment may include one or more plugs, one
or more seats that can receive a respective plug, etc. In such an
example, it may be desirable that a plug and/or a seat have
properties suited for one or more operation or operations.
Properties may include mechanical properties and may include one or
more other types of properties (e.g., chemical, electrical, etc.).
As an example, it may be desirable that a plug and/or a seat
degrade. For example, a plug and/or a seat may be manufactured with
properties such that the plug and/or the seat degrade when exposed
to one or more conditions. In such an example, where the plug acts
to block a passage, upon degradation, the passage may become
unblocked. As an example, a component (e.g., a plug, a seat, etc.)
may degrade in a manner that facilitates one or more operations. As
an example, a component or a portion of a component may degrade in
stages. For example, consider a plug that degrades from a first
size to a second smaller size. In such an example, the second
smaller size may allow the plug to move (e.g., from a first seat to
a second seat, etc.). As an example, a plug tool may be a
degradable tool. As an example, a plug tool may be degradable in
part. For example, consider a plug tool with a degradable seat or
degradable seats. In such an example, a plug may be seated in a
degradable seat that upon degradation of the seat, the plug may
pass through the seat (e.g., become unplugged with respect to that
seat). As an example, a system can include a plug tool that is
degradable at least in part and can also include one or more
degradable plugs (e.g., balls, cylinders, etc.).
[0031] As an example, at least a portion of a borehole tool may be
broken via interaction with a tool where at least some of resulting
pieces are degradable. For example, a tool may apply force (e.g.,
drilling force or other force) to a plug, a plug tool, etc. such
that the applied forces causes breaking into pieces of at least a
portion of the plug, at least a portion of the plug tool, etc. In
such an example, the pieces may be relatively large and degrade to
relatively small pieces (e.g., which may pass through one or more
openings, etc.).
[0032] As mentioned, equipment may include fracturing equipment
where such equipment may be employed to generate one or more
fractures in a geologic environment. As an example, a method to
generate fractures can include a delivery block for delivering
fluid to a subterranean environment, a monitor block for monitoring
fluid pressure and a generation block for generating fractures via
fluid pressure. As an example, the generation block may include
activating one or more fractures. As an example, the generation
block may include generating and activating fractures. As an
example, activation may occur with respect to a pre-existing
feature such as a fault or a fracture. As an example, a
pre-existing fracture network may be at least in part activated via
a method that includes applying fluid pressure in a subterranean
environment. The foregoing method may be referred to as a treatment
method or a "treatment". Such a method may include pumping an
engineered fluid (e.g., a treatment fluid) at high pressure and
rate into a reservoir via one or more bores, for example, to one or
more intervals to be treated, which may cause a fracture or
fractures to open (e.g., new, pre-existing, etc.).
[0033] As an example, a fracture may be defined as including
"wings" that extend outwardly from a bore. Such wings may extend
away from a bore in opposing directions, for example, according in
part to natural stresses within a formation. As an example,
proppant may be mixed with a treatment fluid to keep a fracture (or
fractures) open when a treatment is complete. Hydraulic fracturing
may create high-conductivity communication with an area of a
formation and, for example, may bypass damage that may exist in a
near-wellbore area. As an example, stimulation treatment may occur
in stages. For example, after completing a first stage, data may be
acquired and analyzed for planning and/or performance of a
subsequent stage.
[0034] Size and orientation of a fracture, and the magnitude of the
pressure to create it, may be dictated at least in part by a
formation's in situ stress field. As an example, a stress field may
be defined by three principal compressive stresses, which are
oriented perpendicular to each other. The magnitudes and
orientations of these three principal stresses may be determined by
the tectonic regime in the region and by depth, pore pressure and
rock properties, which determine how stress is transmitted and
distributed among formations.
[0035] Where fluid pressure is monitored, a sudden drop in pressure
can indicate fracture initiation of a stimulation treatment, as
fluid flows into the fractured formation. As an example, to break
rock in a target interval, fracture initiation pressure exceeds a
sum of the minimum principal stress plus the tensile strength of
the rock. To determine fracture closure pressure, a process may
allow pressure to subside until it indicates that a fracture has
closed. A fracture reopening pressure may be determined by
pressurizing a zone until a leveling of pressure indicates the
fracture has reopened. The closure and reopening pressures tend to
be controlled by the minimum principal compressive stress (e.g.,
where induced downhole pressures exceed minimum principal stress to
extend fracture length).
[0036] After performing fracture initiation, a zone may be
pressurized for furthering stimulation treatment. As an example, a
zone may be pressurized to a fracture propagation pressure, which
is greater than a fracture closure pressure. The difference may be
referred to as the net pressure, which represents a sum of
frictional pressure drop and fracture-tip resistance to propagation
(e.g., further propagation).
[0037] As an example, a method may include seismic monitoring
during a treatment operation (e.g., to monitor fracture initiation,
growth, etc.). For example, as fracturing fluid forces rock to
crack and fractures to grow, small fragments of rock break, causing
tiny seismic emissions, called microseisms. Equipment may be
positioned in a field, in a bore, etc. to sense such emissions and
to process acquired data, for example, to locate microseisms in the
subsurface (e.g., to locate hypocenters). Information as to
direction of fracture growth may allow for actions that can "steer"
a fracture into a desired zone(s) or, for example, to halt a
treatment before a fracture grows out of an intended zone. Seismic
information (e.g., information associated with microseisms) may be
used to plan one or more stages of fracturing operations (e.g.,
location, pressure, etc.).
[0038] FIGS. 1 and 2 show an example of a method 100 that includes
generating fractures. As shown, the method 100 can include various
operational blocks such as one or more of the blocks 101, 102, 103,
104, 105 and 106. The block 101 may be a drilling block that
includes drilling into a formation 110 that includes layers 112,
114 and 116 to form a bore 130 with a kickoff 132 to a portion
defined by a heel 134 and a toe 136, for example, within the layer
114.
[0039] As illustrated with respect to the block 102, the bore 130
may be at least partially cased with casing 140 into which a string
or line 150 may be introduced that carries a perforator 160. As
shown, the perforator 160 can include a distal end 162 and charge
positions 165 associated with activatable charges that can
perforate the casing 140 and form channels 115-1 in the layer 114.
Next, per the block 103, fluid may be introduced into the bore 130
between the heel 134 and the toe 136 where the fluid passes through
the perforations in the casing 140 and into the channels 115-1.
Where such fluid is under pressure, the pressure may be sufficient
to fracture the layer 114, for example, to form fractures 117-1. In
the block 103, the fractures 117-1 may be first stage fractures,
for example, of a multistage fracturing operation.
[0040] Per the block 104, additional operations are performed for
further fracturing of the layer 114. For example, a plug 170 may be
introduced into the bore 130 between the heel 134 and the toe 136
and positioned, for example, in a region between first stage
perforations of the casing 140 and the heel 134. Per the block 105,
the perforator 160 may be activated to form additional perforations
in the casing 140 (e.g., second stage perforations) as well as
channels 115-2 in the layer 114 (e.g., second stage channels). Per
the block 106, fluid may be introduced while the plug 170 is
disposed in the bore 130, for example, to isolate a portion of the
bore 130 such that fluid pressure may build to a level sufficient
to form fractures 117-2 in the layer 114 (e.g., second stage
fractures).
[0041] In a method such as the method 100 of FIGS. 1 and 2, it may
be desirable that a plug (e.g., the plug 170) includes properties
suited to one or more operations. Properties of a plug may include
mechanical properties (e.g., sufficient strength to withstand
pressure associated with fracture generation, etc.) and may include
one or more other types of properties (e.g., chemical, electrical,
etc.). As an example, it may be desirable that a plug degrades,
that a plug seat degrades, that at least a portion of a borehole
tool degrades, etc. For example, a plug may be manufactured with
properties such that the plug withstands, for a period of time,
conditions associated with an operation and then degrades (e.g.,
when exposed to one or more conditions). In such an example, where
the plug acts to block a passage for an operation, upon
degradation, the passage may become unblocked, which may allow for
one or more subsequent operations.
[0042] As an example, a component may be degradable upon contact
with a fluid such as an aqueous ionic fluid (e.g., saline fluid,
etc.). As an example, a component may be degradable upon contact
with well fluid that includes water (e.g., consider well fluid that
includes oil and water, etc.). As an example, a component may be
degradable upon contact with a fracturing fluid (e.g., a hydraulic
fracturing fluid). FIG. 13 shows an example plot 1300 of
degradation time versus a component dimension for various
temperatures where a component is in contact with a fluid that is
at least in part aqueous (e.g., include water as a medium, a
solvent, a phase, etc.).
[0043] FIG. 3 shows an example of equipment in various states 301,
302 and 303. As shown, the equipment can include a casing 340 that
include various components 341, 342, 343 and 345. For example, the
component 342 may define a bore 346 and the component 345 may
define a bore 348 where the component 343 includes features (e.g.,
reduced diameter, conical shape, receptacle, etc.) that can catch a
ring component 370 that is operatively coupled to a plug component
360 where the ring component 370 and the plug component 360 may
position and seat a plug 350 in the casing 340. As an example, a
seal may be formed by the plug 350 with respect to the plug
component 360 and/or the ring component 370 and, for example, a
seal may be formed by the ring component 370 with respect to the
component 343. In such an approach, the seals may be formed in part
via fluid pressure in a manner where increased pressure acts to
increase seal integrity (e.g., reduce clearances that may be
subject to leakage). As an example, the ring component 370 may be
an upper component (e.g., a proximal component) of a plug seat and
the plug component 360 may be a lower component (e.g., a distal
component) of the plug seat.
[0044] As shown in the state 301, the plug 350 may be seated such
that the bore 346 (e.g., of a first zone) is separated (e.g.,
isolated) from the bore 348 (e.g., of a second zone) such that
fluid pressure in the bore 346 (see, e.g., P.sub.2) may be
increased to a level beyond fluid pressure in the bore 348 (see,
e.g., P.sub.1). Where the plug 350 and the plug component 360 are
degradable, for example, upon contact with fluid that may
pressurize the bore 348, degradation of the plug 350 and the plug
component 360 may transition the equipment from the state 301 to
the state 302. As shown in the state 302, fluid may pass from the
bore 346 to the bore 348, for example, via an opening of the ring
component 370. Where the ring component 370 is degradable, for
example, upon contact with fluid in the bore 346, degradation of
the ring component 370 may transition the equipment from the state
302 to the state 303. In the state 303, the casing 340 may be the
remaining equipment of the state 301 (e.g., the plug 350, the plug
component 360 and the ring component 370 are at least in part
degraded).
[0045] As an example, the plug 350, the plug component 360 and the
ring component 370 may be components of a dissolvable plug and
perforation system that may be used to isolate zones during
stimulation (see, e.g., the method 100 of FIGS. 1 and 2). Such
equipment may be implemented in, for example, cemented, uncemented,
vertical, deviated, or horizontal bores (e.g., in shale, sandstone,
dolomite, etc.).
[0046] As an example, the plug component 360 and the ring component
370 may be conveyed in a bore via a pump down operation (e.g.,
which may move the components 360 and 370 along a bore axis
direction). As an example, a component or components may include
adjustable features, for example, that allow a change in diameter
to facilitate seating in a receptacle disposed in a bore. For
example, a tool may interact with a component or components to
cause a change in diameter or diameters (e.g., a change in form of
one or more components). In the changed state, the component or
components may catch and seat in a receptacle disposed in a bore
(e.g., seat in a shoulder of a receptacle component).
[0047] As an example, the plug component 360 and the ring component
370 may be seated in a receptacle by a tool that may include one or
more perforators. Once seated, the tool may be repositioned to
perforate casing and form channels (e.g., in a layer or layers of
rock). As an example, repositioning may occur multiple times, for
example, to form multiple sets of perforations and multiple sets of
channels. As an example, after perforating and channel formation,
the plug 350 may be pumped down to contact the plug component 360
and/or the ring component 370, for example, to form a seal that can
isolate one zone from another zone (e.g., one interval from another
interval). Fluid pressure may be increased in an isolated zone as
defined by the plug 350, the plug component 360 and the ring
component 370 as positioned in a receptacle disposed in a bore such
that the fluid enters channels via perforations of the isolated
zone and generates fractures (e.g., new fractures, reactivated
fractures, etc.).
[0048] In the example of FIG. 3, the plug 350 may degrade in a
period of time measured in days, for example, from about 1 day to
about 10 days. In such an example, degradation of the plug 350 can
increase flow area for flow in a conduit (e.g., a casing). As an
example, another component may degrade slower, for example, where
such a component does not itself plug flow, it may degrade in a
period of time measured in weeks or months. For example, the ring
component 370 may degrade more slowly than the plug 350. As an
example, the ring component 370 may degrade in a period of time
measured in months, for example, from about 1 month to about 5
months. As an example, the plug 350 and the ring component 370 can
be formed differently such that one or more characteristics of the
material forming the plug 350 and the material forming the ring
component 370 differ. While the plug 350 and the ring component 370
are mentioned, the plug component 360 may be formed differently
from the plug 350 and/or the ring component 370.
[0049] FIG. 4 shows an example of a method 400 that includes a
provision block 410 for providing one or more particulate
materials, a process block 420 for processing material to form one
or more components and a deployment block 430 for deploying one or
more components, for example, as formed per the process block 420
and optionally one or more additional components. As an example, a
component formed via the method 400 may be a component of a
downhole tool. For example, the method 400 may be utilized to form
one or more of the components illustrated with respect to FIG. 3
(e.g., a plug, a plug component, a ring component, etc.).
[0050] As shown in FIG. 4, the provision block 410 can include
providing one or more different types of particulate materials
where at least one of the particulate materials is reactive in that
it can degrade (e.g., degrade in an aqueous solution). As an
example, one or more of the particulate materials may be produced
by and/or subjected to one or more severe plastic deformation (SPD)
processes. As an example, a material may be processed via
cryomilling as an SPD process.
[0051] As shown in FIG. 4, the process block 420 can include one or
more processes. For example, consider a casting process, an ageing
process, an SPD process and/or one or more other processes. As an
example, ageing of one or more components can include, for example,
ageing of one or more stock materials from which a component or
components may be formed. As an example, ageing can include heat
treating.
[0052] In the example of FIG. 4, the process block 420 can include
providing one or more particulate materials and introducing such
one or more particulate materials before, during and/or after a
process of the process block 420. In the example of FIG. 4, the one
or more particulate materials may include a particulate material
that is reactive in that it can degrade (e.g., degrade in an
aqueous solution) or, for example, the one or more particulate
materials may not include such a reactive particulate material.
[0053] As shown in FIG. 4, the deployment block 430 can include
disposing one or more components in a downhole environment and
degrading at least one of the one or more components in the
downhole environment. As an example, the deployment block 430 may
also include ageing of one or more components in an environment or
environments in which a component or components may be deployed. As
an example, ageing can include heat treating.
[0054] As an example, a component may be treated by a process that
effectively treats the entire component, such a process may include
one or more of the following: solution heat treatment (e.g., for
dissolution of soluble phases), quenching (e.g., for development of
supersaturation), and age hardening (e.g., precipitation of solute
atoms either at room temperature, often referred to as natural
aging, or at elevated temperature, often referred to as artificial
aging or precipitation heat treatment).
[0055] As an example, heat treating can include any of a variety of
heating operations or cooling operations performed for purposes of
changing mechanical properties, metallurgical structure, or
residual stress state of a metal or alloy component. As to aluminum
alloys, heat treating may include one or more operations performed
to increase strength and hardness of precipitation-hardenable
alloys.
[0056] An aluminum alloy that can be precipitation hardened, may be
referred to as a "heat-treatable" alloy; noting that some aluminum
alloys demonstrate no significant strengthening by heating or
cooling and may be referred to as "non-heat-treatable" alloys,
which may depend primarily on cold work to increase strength. In
general, heating to decrease strength and increase ductility (e.g.,
via annealing) may be used with heat-treatable or
non-heat-treatable aluminum alloys.
[0057] An attribute of a precipitation-hardening alloy can be
temperature-dependent equilibrium solid solubility, characterized
by increasing solubility with increasing temperature. A general
requirement for precipitation strengthening of supersaturated solid
solutions involves formation of finely dispersed precipitates
during aging heat treatment (which may include natural ageing
and/or artificial ageing). Many heat-treatable alloys are based on
ternary or quaternary systems with respect to solutes involved in
developing strength by precipitation.
[0058] As an example, the method 400 of FIG. 4 may employ one or
more of natural ageing and artificial ageing. As an example, ageing
of a component deployed in a downhole environment may be referred
to as natural ageing, for example, natural ageing of a component
during deployment and/or in a deployed state.
[0059] As an example, the method 400 may employ solution annealing
as an ageing process. Solution annealing may aim to put coarse
grains into solution while retaining finer grains from going into
solution. In such an example, the finer grains may be thermally
stable cryomilled nano grains. As an example, solution annealing
may be performed via one or more temperature thermal cycles.
[0060] As an example, the method may employ ageing to induce
precipitate hardening of solution annealed coarse grain
counterparts while promoting slight grain growth of finer grains.
In such an example, the finer grains may be thermally stable
cryomilled nano grains. As an example, ageing may be employed to
abet overall ductility of a solid consolidated from particulate
material, which may be a blend of particulate materials. As an
example, ageing may be performed via one or more temperature
thermal cycles.
[0061] As an example, one or more thermal processes (e.g., ageing
processes) may be performed to achieve one or more of increased
strength, retained and/or improved ductility or elongation to
failure, promotion of distinct plastic deformation after thermal
treatment, strain hardening through dislocation strengthening,
increased stiffness of a consolidated bulk solid, promotion of
resistance to initiation of a crack by blunting of crack tips, and
improved thermal stability of a solid.
[0062] As an example, various factors can effect degradation of a
component such as, for example, one or more of temperature,
pressure, fluid properties, dimensions of the component,
environmental history of a component, etc., may effect degradation.
As an example, as pressure increases, degradation rate may increase
for a component. As an example, as temperature increases,
degradation rate may increase for a component. As an example, a
component may interact with fluid and generate gas during
degradation. As an example, generation of gas may be visible as
bubbles during degradation of a component in a fluid.
[0063] As an example, a component may degrade in water where the
temperature of the water may be about 10 degrees C. or more where a
higher temperature may provide for a faster degradation rate. As an
example, a pressure and temperature plot for a particular fluid may
provide rates, times, etc., for degradation of a component (e.g.,
of a particular composition, size, shape, etc.).
[0064] As an example, a component (e.g., consider an aluminum alloy
with a melting point of around 650 degrees C. or 923 K), when
deployed downhole, can undergo degradation of its mechanical
properties where downhole temperatures are in a range of about 150
degrees C. or 423 K to about 200 degrees C. or 473 K. Such changes
can proceed over time, noting that temperature may vary with
respect to time.
[0065] As an example, a parameter may be defined as a ratio of a
downhole environment temperature (e.g., a wellbore temperature) to
a melting point temperature (e.g., average melting point
temperature) of a material such as, for example, an alloy. Such a
ratio may be given as T.sub.d/T.sub.m, where the temperatures are
provided in Kelvin. As an example, consider parameter values of
about 0.46 to 0.51; noting that a parameter value greater than
about 0.4 can be an indicator of susceptibility to creep under
load.
[0066] As an example, mechanical properties of a deployed component
may be temperature de-rated. As an example, depending on function
of a component, temperature may be an enabler, rather a detriment,
for example, where temperature helps to naturally age a deployed
structural part.
[0067] As an example, while under load, a part may be cooled down
by fluid pumped downhole. In such an example, the part may be less
affected by temperature of a downhole environment. However, where
flow of such an injection fluid stops, heating may occur due to
heat energy of the downhole environment.
[0068] As an example, in the method 400, the deployment block 430
may include adjusting temperature of an environment in which a
component is disposed. For example, an injection fluid may be at a
first temperature and act to maintain a component at or near that
first temperature while production fluid may be at a second
temperature and act to maintain a component at or near the second
temperature. As another example, a component may exist in an
environment at an environmental temperature where there is
substantially no flow of fluid. In such an example, a component may
be at or settle to a temperature that is substantially the same as
the environmental temperature.
[0069] As an example, the method 400 can include selecting
materials and processing materials in a manner such that a
component formed from such materials can respond to natural ageing.
In such an example, natural ageing may improve mechanical
properties of the component when deployed downhole.
[0070] As an example, an environment may be a harsh environment,
for example, an environment that may be classified as being a
high-pressure and high-temperature environment (HPHT). A so-called
HPHT environment may include pressures up to about 138 MPa (e.g.,
about 20,000 psi) and temperatures up to about 205 degrees C.
(e.g., about 400 degrees F. and about 480 K), a so-called
ultra-HPHT environment may include pressures up to about 241 MPa
(e.g., about 35,000 psi) and temperatures up to about 260 degrees
C. (e.g., about 500 degrees F. and about 530 K) and a so-called
HPHT-hc environment may include pressures greater than about 241
MPa (e.g., about 35,000 psi) and temperatures greater than about
260 degrees C. (e.g., about 500 degrees F. and about 530 K). As an
example, an environment may be classified based in one of the
aforementioned classes based on pressure or temperature alone. As
an example, an environment may have its pressure and/or temperature
elevated, for example, through use of equipment, techniques, etc.
For example, a SAGD operation may elevate temperature of an
environment (e.g., by 100 degrees C. or more; about 370 K or
more).
[0071] As an example, a particulate material may be a powder. As an
example, a powder may be defined as a dry, bulk solid composed of a
number of particles that may, for example, flow relatively freely
when shaken, tilted, etc. As an example, a powder may be a
sub-class of a granular material. As an example, a particulate
material may be a flowable material (e.g., flow relatively freely
when shaken, tilted, etc.).
[0072] As an example, a particulate material such as, for example,
a powder, may be characterized by one or more properties,
parameters, dimensions, etc. As an example, a particulate material
may be characterized by one or more particle sizes. Where a
particle is spherical, the particle may be quantitatively defined
by its diameter (e.g., or radius). Where a particle has an
irregular shape that is not-spherical, a dimension may be defined
by a diameter corresponding to the volume of the particle as
equated to the volume of a sphere. As an example, a particle may be
ellipsoidal and, for example, defined by a major axis length and/or
a minor axis length.
[0073] As an example, a particle may include a shape other than
spherical, ellipsoidal, etc. As an example, consider needle or rod
shaped particles that may be characterized at least in part by an
aspect ratio of a longest dimension to a shortest dimension (e.g.,
consider an aspect ratio of about 5 to 1 or more). As another
example, consider plate or platelet shape particles, which may be
characterized at least in part by planar dimensions and a thickness
dimension.
[0074] As an example, particulate matter may be characterized at
least in part by one or more of a particle population mean as an
average size of a population of particles, a particle population
median as a size where approximately 50 percent of the population
is below and approximately 50 percent is above, and a particle
population mode or modes, for example, a size with highest
frequency.
[0075] As an example, particulate material may include particles
that are substantially spherical in shape (e.g., optionally
characterized by sphericity). In such an example, a particle may be
characterized by a particle size that corresponds to a diameter
(e.g., assuming spherical shape). As an example, a powder may
include particles with corresponding particle sizes that are within
a range of less than about 100 microns and greater than about 10
microns.
[0076] As an example, particles may include crystalline structures,
for example, a particle may be greater than about 80 weight percent
crystalline. In such an example, a particle may include an
amorphous structure, for example, a particle may be less than about
20 weight percent amorphous and greater than about 80 weight
percent crystalline.
[0077] Crystals tend to have relatively sharp, melting points as
component atoms, molecules, or ions tend to be ordered with
regularity (e.g., with respect to neighbors). An amorphous solid
can exhibit particular characteristics, for example, upon cleaving
or breaking, an amorphous solid tends to produce fragments with
irregular surfaces and an amorphous solid tends to exhibit poorly
defined patterns in X-ray imaging. An amorphous, translucent solid
may be referred to as a glass.
[0078] Various types of materials may solidify into an amorphous
form where, for example, a liquid phase is cooled with sufficient
rapidity. Various solids may be intrinsically amorphous, for
example, because atoms do not fit together with sufficient
regularity to form a crystalline lattice or because impurities
disrupt formation of a crystalline lattice. For example, although
the chemical composition and the basic structural units of a quartz
crystal and quartz glass are the same (e.g., SiO.sub.2 and linked
SiO.sub.4 tetrahedra), arrangements of atoms in space are not.
Crystalline quartz includes an ordered arrangement of silicon and
oxygen atoms; whereas, in quartz glass, atoms are arranged
relatively randomly. As an example, when molten SiO.sub.2 is cooled
rapidly (e.g., at a rate of about 4 K/min), it can form quartz
glass; whereas, large quartz crystals (e.g., of the order of a
centimeter or more) may have had cooling times of the order of
years (e.g., thousands of years).
[0079] Aluminum crystallizes relatively rapidly; whereas, amorphous
aluminum may form when liquid aluminum is cooled at a rate of, for
example, about 4.times.10.sup.13 K/s. Thus, cooling rate of
aluminum can determine how atoms arrange themselves (e.g.,
regularly or irregularly).
[0080] As an example, a particle may be polycrystalline, for
example, composed of crystallites (e.g., grains) that can vary in
size and orientation. As an example, grain size may be determined
using a technique such as X-ray diffraction, transmission electron
microscopy, etc.
[0081] A grain boundary may be defined as the interface between two
grains in a polycrystalline material. Grain boundaries, defects in
crystal structure, tend to decrease electrical and thermal
conductivity of material. Grain boundaries may be sites for
precipitation of one or more phases, which may be referred to as
grain boundary material. Grain boundaries may disrupt motion of
dislocations through a material. As an example, reduction of grain
size may improve strength, for example, as described by the
Hall-Petch relationship.
[0082] As an example, grain boundaries may meet at a so-called
grain boundary triple point (GBTP). At a GBTP (e.g., a volumetric
space), a phase or phases (e.g., of grain boundary material) may
exist that differ from that of crystalline material in a grain.
[0083] As an example, a powder may include particles that include
grain sizes of less than about 2 microns. As an example, grain
sizes may be less than about 1 micron. As an example, average grain
sizes may be less than about 0.5 microns (e.g., less than about 500
nm). As an example, average grain sizes may be less than about 200
nm. As an example, material that exists between grains may be of a
dimension of an order of tens of nanometers to an order of hundreds
of nanometers. As an example, material that exists between grains
may be of a dimension that is less than an average grain size. For
example, consider grains with an average grain size of the order of
hundreds of nanometers and grain boundary material with an
inter-grain spacing dimension of the order of tens of
nanometers.
[0084] As an example, a powder particle may include grains that
include one or more materials at their boundaries. For example, a
grain may be bound by a select material at its boundaries. As an
example, a grain boundary material may coat a grain such that the
grain is substantially encapsulated by the grain boundary material.
As an example, a grain boundary material may be described as
"wetting" a grain, for example, a grain boundary material may be
continuous and wet an entire surface (e.g., boundary) of a grain.
As an example, a particle can include grains that are in a
continuum of a grain boundary material. In such an example, the
grains may be spaced from each other by the grain boundary
material. As an example, a size of the boundary (or the spacing
between grains) may be of the order of tens of nanometers to
hundreds of nanometers. The spacing between grains (e.g., the size
of the grain boundary) may be determined at least in part based on
the surface tension of the grain boundary material and the grain.
Thus, for example, spacing may vary depending on the material in
the grain boundary and the material of the grain. As an example,
strength of a powder particle may be approximated at least in part
by a relationship such as, for example: .varies.1/ d, where d is
the average grain size and .sigma. is the energy of the grain
boundary.
[0085] As an example, to form a continuous grain boundary, a
boundary forming component of a melt may be greater than about two
percent by weight. For example, consider a melt of an aluminum
alloy and gallium where the gallium is present at a weight percent
greater than about two percent and less than about 20 percent
(e.g., optionally less than about 10 percent, and in some examples
less than about five percent). In such an example, atomization of
the melt can form particles with grains that reside in a continuum
of grain boundary material that includes gallium (e.g., a
substantially continuous boundary material that includes gallium).
In such an example, more than about 90 percent of the gallium can
be preferentially segregated to the grain boundary (e.g., located
within the grain boundary material). While higher percentages of
gallium may optionally be included in a melt, in general, a higher
the percentage of gallium can result in formation of globular
nodules within a particle. Such globular nodules can result in a
reduction of mechanical strength of a particle. Where a powder is
to be used to form a part or a tool (e.g., a downhole tool) that is
to withstand certain mechanical force(s), yet be degradable, the
powder may be formed of a melt that is tailored to meet mechanical
force and degradability criteria. As an example, a degradability
criterion may be met by including at least about two percent by
weight of a select material (e.g., or materials) in a melt. In such
an example, a powder formed by the melt can be at least about two
percent by weight of the select material (e.g., considering
material conservation). As an example, a powder may be of at least
about two percent by weight of a select material (e.g., or select
materials).
[0086] As an example, a melt may include greater than about 80
percent by weight of an aluminum alloy and greater than about two
percent by weight of a select material or materials. In such an
example, consider as the select material, or materials, one or more
of gallium, indium, tin, bismuth, and lead. As an example, a select
material or materials may include one or more basic metals where,
for example, basic metals include gallium, indium, tin, thallium,
lead and bismuth (e.g., basic metals of atomic number of 31 or
greater). As an example, grain boundary material may include
aluminum, which is a basic metal with an atomic number of 13, in
addition to one or more other basic metals. As an example, a basic
metal may be a post-transition metal (e.g., metallic elements in
the periodic table located between the transition metals (to their
left) and the metalloids (to their right) and including gallium,
indium and thallium; tin and lead; and bismuth). As an example, a
melt may optionally include mercury, which is a transition metal
(e.g., a group 12 transition metal). As an example, a powder formed
of such a melt can include mercury, which may be a boundary
material that bounds grains of particles of the powder. As an
example, a melt may optionally include zinc, which is a transition
metal (e.g., a group 12 transition metal).
[0087] As an example, a melt and a powder formed from the melt can
include one or more alkali metals. For example, consider one or
more of lithium, sodium, and potassium. As an example, a melt and a
powder formed from the melt can include one or more alkaline earth
metals. For example, consider one or more of beryllium, magnesium,
calcium, strontium and barium. As an example, a powder and/or a
melt may include one or more rare earth elements. As an example, a
powder and/or a melt may include scandium, thallium, etc.
[0088] As an example, one or more of an alkali metal, an alkaline
earth metal, or a basic metal may be used as the select material or
materials for a melt. As an example, a melt may include gallium and
indium. The gallium and indium may preferentially segregate to the
grain boundary, for example, during a severe plastic deformation
process, resulting in a desired powder particle. Materials of an
aluminum alloy, such as, for example, aluminum, magnesium, silicon,
copper, for example, may also appear in the grain boundary.
[0089] As an example, consider cooling a melt that includes
aluminum, magnesium and gallium such that grains form with a first
amount of gallium and such that at the boundaries of the grains
material forms with a second amount of gallium that exceeds the
first amount of gallium. In such an example, the material at the
boundaries may be characterized as gallium enriched. In such an
example, the amount of gallium in the grains may be negligible
(e.g., grains may be formed of an aluminum alloy substantially
devoid of gallium).
[0090] As an example, a material may include aluminum (e.g.,
melting point of about 1220 degrees F., about 660 degrees C. or
about 930 K), magnesium (e.g., melting point of about 1200 degrees
F., about 650 degrees C. or about 920 K) and gallium (e.g., melting
point of about 86 degrees F., about 30 degrees C. or about 300 K).
Such a material may be provided in a molten state and cooled to
form grains and boundaries where the boundaries are enriched in
gallium (e.g., a low melting point material of the bulk
material).
[0091] As an example, a material may include gallium, indium and
tin. In such an example, gallium, indium (e.g., melting point of
about 314 degrees F., about 157 degrees C. or about 430 K) and tin
(e.g., melting point of about 450 degrees F., about 232 degrees C.
or about 500 K) may alloy (e.g., forming a eutectic alloy with a
melting point of about -19 degrees C., about -2 degrees F. or about
250 K). Such a material may be provided in a molten state and
cooled to form grains and boundaries where the boundaries are
enriched in at least gallium (e.g., as an alloy of gallium, indium
and tin as a low melting point material of the bulk material).
[0092] As an example, a material may include aluminum, magnesium
and copper (e.g., melting point of about 1990 degrees F., about
1090 degrees C. or about 1360 K). In such an example, the material
may experience an increase in strength when subjected to solution
heat treatment and quenching. As an example, an aluminum, magnesium
and copper alloy may increase in strength and exhibit considerable
ductility upon ageing at ambient temperature (e.g., about 25
degrees C. or about 300 K).
[0093] As an example, an alloy may be characterized by a series
designation. For example, consider the following series that
include aluminum: 1000 series alloys that include a minimum of 99
weight percent aluminum content by weight, 2000 series alloys that
include copper, 3000 series alloys that include manganese, 4000
series alloys that include silicon, 5000 series alloys that include
magnesium, 6000 series alloys that include magnesium and silicon,
7000 series alloys that include zinc, and 8000 series alloys that
include one or more other elements not covered by other series
(e.g., consider aluminum-lithium alloys).
[0094] As an example, alloys that include aluminum may be
represented by designations such as: 1xx.x series that include a
minimum of 99 percent aluminum, 2xx.x series that include copper,
3xx.x series that include silicon, copper and/or magnesium, 4xx.x
series that include silicon, 5xx.x series that include magnesium,
7xx.x series that include zinc, 8xx.x series that include tin and
9xx.x that include other elements.
[0095] As to 1000 series alloys, with aluminum of 99 percent or
higher purity, such alloys may be characterized by considerable
resistance to corrosion, high thermal and electrical conductivity,
low mechanical properties and workability, while tending to be
non-heat treatable.
[0096] As to 2000 series alloys, these include copper as an
alloying element, which tends to impart strength, hardness and
machinability; noting that such alloys tend to be heat
treatable.
[0097] As to 3000 series alloys, these include manganese as an
alloying element and they tend to have a combination of corrosion
resistance and formability while tending to be non-heat
treatable.
[0098] As to 5000 series alloys, these include magnesium as an
alloying element, which may be, for example, optionally included
along with manganese to impart a moderate- to high-strength,
non-heat-treatable alloy. A 5000 series alloy may be weldable and
relatively resistance to corrosion (e.g., even in marine
applications).
[0099] As to 6000 series alloys, these include magnesium and
silicon in various proportions to form magnesium silicide, which
makes them heat treatable. Magnesium-silicon (or
magnesium-silicide) alloys tend to possess good formability and
corrosion resistance with high strength.
[0100] As to 7000 series alloys, these include zinc as an alloying
element and, for example, when coupled with a smaller percentage of
magnesium, such alloys may tend to be heat-treatable and of
relatively high strength.
[0101] As an example, a material may be degradable and, for
example, an alloy may be degradable (e.g., a degradable alloy). As
an example, a material may degrade when subject to one or more
conditions (e.g., over time). For example, consider one or more
environmental conditions and/or "artificial" conditions that may be
created via intervention, whether physical, chemical, electrical,
etc. As an example, conditions can include temperature, pressures
(e.g., including loads and forces), etc.
[0102] As an example, a degradable alloy may degrade at least in
part due to presence of internal galvanic cells (e.g., that provide
for galvanic coupling), for example, between structural
heterogeneities (e.g. phases, internal defects, inclusions, etc.).
As an example, a degradable material may resist passivation or, for
example, formation of one or more stable protective layers.
[0103] As an example, a degradable alloy can include one or more
alloying elements "trapped" in "solid solution". As an example, a
material may include a metal such as aluminum, which may be impeded
from passivating or building a resilient protective layer (e.g.,
aluminum oxide such as A.sup.1.sub.2.sup.0.sub.3).
[0104] As an example, a material can include one or more ceramics.
For example, a material can include an inorganic, nonmetallic solid
that includes metal, nonmetal or metalloid atoms, at least in part
held in ionic and covalent bonds. A ceramic may be regular and/or
irregular in structure, for example, atoms may be regularly
oriented and crystalline, semi-crystalline and/or amorphous (e.g.,
ceramic glass). As an example, a ceramic may be an oxide (e.g.,
alumina, beryllia, ceria, zirconia, etc.). As an example, a ceramic
may be a nonoxide (e.g., carbide, boride, nitride, silicide, etc.).
As an example, a ceramic may include an oxide and a nonoxide.
[0105] As an example, a material can include one or more oxides. As
an example, during processing of an alloy in the presence of
oxygen, one or more oxides may form. For example, consider an alloy
that includes aluminum where alumina (e.g., an aluminum oxide,
Al.sub.2O.sub.3) forms. As another example, consider an alloy that
includes silicon where silica (e.g., a silicon oxide, SiO.sub.2)
forms. As an example, an oxide may be a dispersed material in a
particle. As an example, an oxide may be of a size of about 10 nm
or less and optionally about 5 nm or less.
[0106] As an example, a material can include concentrations of one
or more solute elements, for example, trapped in interstitial and
in substitutional solid solutions. As an example, concentrations,
which may be spatially heterogeneous, of such one or more solute
elements, may be controlled through chemical composition,
processing, etc. As an example, consider rapid cooling where
solubility is higher than at ambient temperature or temperature of
use.
[0107] As an example, a material may include one or more elements
or phases that liquate (e.g., melt, etc.) once elevated beyond a
certain temperature, pressure, etc., which for alloys may be
predictable from phase diagrams, from thermodynamic calculations
(e.g., as in the CALPHAD method), etc.
[0108] As an example, a material may "intentionally" fail via
liquid-metal embrittlement, for example, as in an alloy that
includes gallium and/or indium. As an example, a degradable
material may include an alloy or alloys and possess phases that may
be susceptible to creep (e.g., superplastic) deformation (e.g.,
under intended force, etc.), possess phases that are brittle (e.g.,
which may rupture in response to impact, etc.).
[0109] As an example, a degradable material may include a calcium
alloy such as, for example, calcium-lithium (Ca--Li),
calcium-magnesium (Ca--Mg), calcium-aluminum (Ca--Al), calcium-zinc
(Ca--Zn), calcium-lithium-zinc (Ca--Li--Zn), etc. As an example, in
a calcium-based alloy, lithium may be included in concentrations,
for example, between about 0 to about 10 weight percent (e.g., to
enhance reactivity, etc.). As an example, concentrations ranging
from about 0 to about 10 weight percent of one or more of aluminum,
zinc, magnesium and silver may enhance mechanical strength.
[0110] As an example, a material may include one or more
magnesium-lithium (Mg--Li) alloys, for example, enriched with tin,
bismuth and/or one or more other low-solubility alloying
elements.
[0111] As an example, a material can include one or more alloys of
aluminum. As an example, a material may include one or more of an
aluminum-gallium (Al--Ga) alloy and an aluminum-indium (Al--In)
alloy. As an example, a material may include one or more of an
aluminum-gallium-indium (Al--Ga--In) and an
aluminum-gallium-bismuth-tin (Al--Ga--Bi--Sn) alloy.
[0112] As an example, a material can include aluminum, gallium and
indium. For example, consider a material with an alloy of about 80
weight percent aluminum, about 10 weight percent gallium and about
10 weight percent indium. Such a material may include Vickers
microhardness (500 g) of about 32 (#1), 34 (#2), 34 (#3), 30 (#4),
35 (#5), 36 (#6) and 33 (average) and estimated strength of about
100 (MPa), 15 (ksi) and 1.5 (normalized).
[0113] As an example, a component may be formed of material that
provides a desired degradation rate and desired mechanical
properties (e.g., strength, etc.). As an example, a degradation
rate may depend upon one or more conditions (e.g., temperature,
pressure, fluid environments), which may be exist in an environment
and/or may be achieved in an environment (e.g., via one or more
types of intervention). As an example, a material may be
conditionally degradable (e.g., degradable upon exposure to one or
more conditions).
[0114] As an example, a material may be a metal matrix composite
(MMC), which is a composite material with at least two constituent
parts, one being a metal, the other material may be a different
metal or another material, such as a ceramic or organic compound.
When at least three materials are present, it may be referred to as
a hybrid composite. As an example, a MMC may be complementary to a
cermet.
[0115] As an example, a method may utilize one or more powder
metallurgy (PM) techniques. As an example, one or more powder
metallurgy techniques may be utilized to form particulate material.
As an example, one or more powder metallurgy techniques may be
utilized to form a blend of particulate materials. As an example,
one or more powder metallurgy techniques may be utilized to form a
component or components, for example, from a blend of particulate
materials.
[0116] FIG. 5 shows various example materials 500 where two or more
of such materials 500 can be utilized to form one or more blends
where a blend includes at least one water reactive powder (e.g., at
least one water reactive particulate material).
[0117] In FIG. 5, the example materials include water reactive
powder 510, severe plastic deformation (SPD) water reactive powder
520, metal powder 530, severe plastic deformation (SPD) metal
powder 540, and non-metallic powder 550.
[0118] As an example, a blend may aim to achieve desired
characteristics. For example, consider characteristics such as one
or more of dissolution, strength and ductility. As an example, a
characteristic can be a mechanical characteristic (e.g., yield
strength, ultimate tensile strength, ductility, fracture toughness,
thermal stability, etc.). As an example, a characteristic can be a
dissolution characteristic (e.g., rate of dissolution, uniformity
of dissolution, left-over product after dissolution, etc.). As an
example, one or more powders can be added to a water reactive
powder to decrease a dissolution rate of a component formed from
the powders.
[0119] As an example, a method can include blending powders where
at least one of the powders is or includes water reactive powder.
Such a method can include performing one or more severe plastic
deformation processes. As an example, a powder can be or include a
metal powder and/or non-metal powder. As an example, the presence
of non-water reactive material may be included to achieve one or
more desired mechanical characteristics as well as, for example, to
achieve one or more desired dissolution characteristics. As an
example, a blend may act to tailor and/or enhance mechanical and/or
dissolution properties of a water reactive consolidated alloy.
[0120] As an example, a method can include blending of powders and
performing one or more severe plastic deformation processes. In
such an example, the method can include utilizing one or more metal
and/or non-metal powders, which may act to tailor and/or enhance
mechanical and/or dissolution properties of a water reactive
consolidated alloy.
[0121] As an example, a method can include blending different
materials where each of the materials provides particular
properties as to mechanical characteristics and/or dissolution
characteristics to allow for tailoring properties of a component to
one or more desired target values (e.g., strength values,
dissolution values, etc.).
[0122] As an example, a material may be formed via a process or
processes to achieve one or more particular properties. As an
example, via blending of different materials, one or more
particular mechanical properties such as strength, ductility,
fracture toughness, thermal stability or dissolution, can be
achieved (e.g., via a formulation of the different materials).
[0123] As an example, a method can include mixing that can occur at
one or more times during a manufacturing process. For example, a
method can include a sequence that is performed at least in part in
a serial manner to form a component with desired mechanical
characteristics and dissolution characteristics. As an example, a
method can include a sequence that is performed at least in part in
parallel and at least in part in series. For example, various
materials can be prepared in a parallel manner and then blended and
processed in a serial manner (e.g., to form a component, etc.).
[0124] As an example, a method can include blending via particle
mixing of different primary types of particles and/or optionally
sizes of particles to obtain a blend of a secondary type (e.g.,
that includes constituents of the primary types).
[0125] As an example, a blend can include one or more of the
following: water reactive powder (e.g., gas atomized powder); water
reactive powder processed via at least one SPD process; metal
powder; a metal powder that is an alloy powder (e.g., aluminum
alloy, magnesium alloy, iron alloy, titanium alloy, nickel alloy,
chromium alloy, steel, etc.); a metal powder processed via at one
SPD process; a metal powder that is an alloy powder processed via
at least one SPD process; and non-metallic powder (e.g., a ceramic,
etc.). As an example, a metal powder can be a "standard" metal
powder that is not degradable in water (e.g., does not undergo
galvanic coupling to readily degrade in water). As an example, a
non-metallic powder can include one or more of SiC, B.sub.4C, SiN,
yittria stabilized zirconia, alumina, carbon nano material (e.g.,
nano tube, nano balls, etc.), carbon fiber, diamond, clay, poly
lactic acid, etc.
[0126] FIG. 6 shows a table of examples of powder blends with
respect to timings as to various processes, including atomization
processes, SPD processes and post-SPD processes. As to the powder
blends, FIG. 6 shows a water reactive powder and SPD water reactive
powder blend; a water reactive powder, SPD water reactive powder
and "standard" metal powder blend (e.g., a metal powder that does
not undergo galvanic coupling to readily degrade in water).
[0127] A galvanic couple can be formed as an electrochemical cell
that develops where different metallic constituents are in contact
with electrolytes. For example, consider electrochemical action
produced by reaction of dissimilar metals in an electrolytic
environment or environments where a path conducive to flow of
electrons exists.
[0128] A galvanic couple can be utilized in cathodic protection
(e.g., passive cathodic protection). For example, consider a
galvanic anode (e.g., a more electrochemically active metal)
electrically coupled to a vulnerable metal surface exposed to an
electrolytic environment (e.g., an aqueous environment that can
include one or more salts, etc.). As an example, a galvanic anode
can corrode (e.g., via consumption of anode material) where
electrons flow from the galvanic anode to a cathode (e.g., where a
path or paths exist for such electron flow). In such an example,
the driving force for a cathodic protection current can depend on
the difference in electrode potential between the anode and the
cathode (e.g., where the anode electrode potential is lower than
that of the cathode). As an example, given a list of metals ordered
according to electrode potential, theoretically, an anode can be
selected as being lower on the list than a cathode (e.g., material
to be protected). For example, commercially pure aluminum can be a
cathode that is protected by a zinc anode where the zinc anode
degrades to protect the commercially pure aluminum.
[0129] As to commercially pure aluminum, its use as an anode to
protect a cathode can be limited by formation of a passivating
material. Theoretically, aluminum may be expected to perform
satisfactorily as a galvanic anode because the element aluminum
fulfills anodes specifications: (1) a high theoretical oxidation
potential (about 1.80 volts versus calomel reference); and (2) a
high theoretical electrical output per unit mass of metal consumed
(about 2.98 amp-hours per gram). However, a passive oxide surface
film can act as a barrier to the oxidation of aluminum metal
thereby reducing the effective oxidation potential to about 0.7
volt (e.g., as measured in closed circuit at either 250 or 1000
milliamperes/square foot in a synthetic seawater electrolyte with a
standard saturated KCl calomel cell as reference). At such low
operating voltages, for example, no substantial cathodic protection
is given to ferrous based structures. By comparison, the actual
working potential of magnesium is about 1.5 volt and of zinc is
about 1 volt.
[0130] As an example, aluminum with purity of about 99.99 percent
can be alloyed with a low amount of indium and gallium (e.g., as
low as 0.01 weight percent) such that the resulting alloy can
achieve potentials of greater than about 1.4 volts in seawater
(e.g., versus saturated KCl calomel cell). Such an aluminum based
gallium and indium containing ternary alloy can exhibit an
oxidation potential sufficient to be used to protect a metal such
as steel in a seawater environment.
[0131] As an example, an alloy may be formed where one or more
constituents are substantially segregated, for example, as grain
material and grain boundary material. In such an example, a
galvanic couple may be formed between the grain material and grain
boundary material. In such an example, the grain boundary material
may be "sacrificial" in an aqueous environment such that it
degrades to "free" the grain material. Such an alloy may be
considered to be a water reactive alloy. Where formed as a powder,
such an alloy may be a water reactive powder.
[0132] As an example, in an aluminum alloy that includes gallium,
gallium may be enriched at grain boundaries. Such enrichment may be
referred to as wetting of aluminum grain boundaries by gallium. As
an example, aluminum may be contacted with gallium where gallium
infiltrates the aluminum to wet aluminum grain boundaries.
[0133] As an example, a melt can include aluminum and gallium where
the melt is processed via gas atomization where cooling of the melt
can occur at a desired rate to facilitate composition of grain
material and/or grain boundary material. As an example, gas
atomization of a melt can produce powder where the powder includes
grain material and grain boundary material. In such an example,
individual particles of the powder can be water reactive and
degrade at least in part via differences between grain material and
grain boundary material. As an example, in an aqueous environment,
galvanic coupling may act to degrade at least grain boundary
material in a manner that acts to reduce forces that maintain
grains within a particle such that the particle degrades. It should
be appreciated that this is not limited to powder metallurgy. For
example, it may include cast materials.
[0134] Referring again to the table 600 of FIG. 6, as an example,
timing of blending of powders can occur at different points during
manufacture of a consolidated metallic component. In such an
example, timing of blending can be utilized to tailor and/or
enhance properties of a final consolidated blend (e.g., mechanical
and/or dissolution properties).
[0135] As indicated in the table 600 of FIG. 6, timing can be
during atomization, during one or more SPD processes; and/or after
one or more SPD processes.
[0136] As an example, during atomization, mixing may occur in a
liquid melt and/or in a chamber (e.g., consider processing two
melts via two nozzles where atomization of the melts occurs in a
common chamber). As an example, mixing may occur during an SPD
process. For example, mixing may occur during cryomilling where the
cryomilling mills multiple powders. As an example, mixing may occur
after a SPD process and before consolidation to form a blank for a
component (e.g., for machining, extrusion, etc.). As an example,
mixing can include utilizing a blender such as, for example, a
V-blender (e.g., with two or more inlets, etc.).
[0137] In the example of FIG. 6, powders may be blended and
processed such that a consolidated water reactive alloy is formed.
In such an example, tailoring may occur to enhance one or more
characteristics of the alloy.
[0138] As an example, a method can include blending a water
reactive powder with a SPD water reactive powder after performing
one or more SPD processes. As an example, a method can include
blending a water reactive powder, a SPD water reactive powder and a
standard metal powder after performing one or more SPD
processes.
[0139] FIG. 7 shows some examples of types of severe plastic
deformation (SPD) processes 710, including cryomilling 712, equal
channel angular pressing (ECAP) 714, high pressure torsion (HPT)
716, forging 718 (e.g., via a general forging machine, etc.), flow
forming 720, hammer peening 722, surface mechanical attrition
treatment (SMAT) 724, cold working 726, vacuum pressing 728 (e.g.,
hot and/or cold, isostatic and/or non-isostatic), and one or more
other types of severe plastic deformation processes 730.
[0140] As an example, one or more SPD processes may be applied to
material to produce equiaxed ultrafine grain (UFG) size (e.g., less
than about 500 nm) or nanocrystalline (NC) structures (e.g., less
than about 100 nm).
[0141] As an example, one or more SPD processes may be applied to
material to refine structures in the material. For example,
consider a material with grain sizes in a range from about 10
microns to about 100 microns and applying an SPD process that
reduces the grain sizes to less than about 10 microns. As an
example, one or more SPD processes may be applied, for example, to
increase yield strength of material.
[0142] As an example, an SPD process may result in grain-boundary
strengthening (e.g., Hall-Petch strengthening). For example, an SPD
process may reduce grain size, which, in turn, increases the number
of grain boundaries. As grain boundaries can act as pinning points,
they can impede dislocation movement, which, in turn, can increase
yield strength. Hall-Petch strengthening can exhibit a lower limit
as to size where, for example, phenomena such as grain boundary
diffusion may occur. In grain boundary diffusion, a lattice may
resolve applied stress by grain boundary sliding, resulting in a
decrease in yield strength.
[0143] As an example, a nanocrystalline material may exhibit a
lower limit as to size (e.g., consider a size of about 10 nm)
where, for smaller sizes, the yield strength may remain relatively
constant or decrease. Such a phenomenon may be referred to as the
reverse or inverse Hall-Petch relation, which may be driven by one
or more of dislocation-based, diffusion-based, grain-boundary
shearing-based, and/or multi-phase-based mechanisms.
[0144] As an example, a method can include refining grains to
develop a nano to ultrafine grained microstructure. In such an
example, refined grains may increase material strength (e.g., via
Hall-Petch strengthening) and/or may increase ductility (e.g., via
abetting grain boundary sliding, which may result in an alloy with
high strain rate superplasticity that can enhance formability,
workability, etc.).
[0145] As an example, a method can include dispersion
strengthening, for example, via introduction of dispersoids (e.g.,
second phase particles, etc.). In such an example, consider
introduction of one or more types of oxides and/or breakup of one
or more types of oxide layers that may be formed around metal
particles during a process such as, for example, gas atomization
(e.g., in the presence of oxygen). As an example, a method can
include introducing one or more types of dispersoids, for example,
to increase thermal stability of material. For example, consider a
method that introduces dispersoids into a bulk alloy synthesized
through a powder metallurgy route where the introduction of the
dispersoids (e.g., second phase particles, etc.) can increase drag
within the bulk alloy.
[0146] As an example, a material may be tailored as to one or more
of its mechanical properties and/or its dissolution characteristics
(e.g., degradation characteristics) via one or more processes,
which can include one or more SPD processes. In such an example,
the material may be refined as to its grain size and/or the defect
structure of its grain boundaries. As mentioned, the Hall-Petch
relation can exhibit a minimum size, which may be surpassed
depending on desired properties and/or characteristics of a
material. For example, such a material may still be strengthened
when compared to a non-SPD processed material yet include a
structure size that is less than the minimum Hall-Petch relation
size, which may, for example, benefit dissolution (e.g., in a
desired manner).
[0147] As to ductility, consider altering grain boundary angles via
one or more SPD processes where, for example, a SPD process that
promotes low angle grain boundaries may result in lower ductility
when compared to a SPD process that promotes high angle grain
boundaries. In such an example, consider ECAP equipment that may be
used to process material to achieve a desired range of grain
boundary angles; noting that dislocation density may also be
tailored by number of passes along one or more ECAP routes.
[0148] As an example, one or more SPD processes may be applied to
material to refine grain sizes where refinement of grain size
increases the number of grain boundaries. In turn, grain boundaries
act to impede dislocation movement as the number of dislocations
within a grain can have an effect on how easily dislocations can
traverse grain boundaries and travel from grain to grain. As an
example, a dislocation density may be defined by a dimension for
dislocation lines divided by a unit volume. As the dislocation
density of a material increases, resistance to dislocation motion
by other dislocations can become more pronounced. In such an
example, imposed stress to deform a material may increase with
increasing cold work.
[0149] As an example, the ability of a material to plastically
deform can depend on the ability of dislocations in the material to
move. In such an example, hardness and strength (e.g., yield
strength and tensile strength) can be related to the ease with
which plastic deformation can be made to occur; for example, by
reducing mobility of dislocations, mechanical strength of a
material may be enhanced (e.g., leading to greater mechanical force
to initiate plastic deformation of the material). In contrast, as
dislocation motion becomes less constrained, a material may be more
amenable to deformation (e.g., a softer and weaker material).
[0150] As explained above, a material may be tailored via one or
more of SPD processing and introduction of dispersoids. Such a
material may be at least in part dissolvable (e.g., degradable).
For example, a method can include one or more of SPD processing and
dispersoid introduction for tailoring mechanical properties of a
material for a particular use and/or tailoring degradation
characteristics for a particular use.
[0151] FIG. 8 shows example plots 810, 830 and 850 where the plot
810 illustrates an approximate relationship between dissolution
rate and percent of a first material versus one or more other
materials (e.g., a second material, a third material, etc.), where
the plot 830 illustrates an approximate relationship between
strength and percent of a first material versus one or more other
materials (e.g., a second material, a third material, etc.), and
where the plot 850 illustrates an approximate relationship between
ductility and percent of a first material versus one or more other
materials (e.g., a second material, a third material, etc.).
[0152] FIG. 8 also shows blocks 812, 832 and 852, which indicate
that one or more blending processes may be applied to tailor
dissolution rate as in the plot 810, strength as in the plot 830
and/or ductility as in the plot 850. The examples of relationships
shown in the plots 810, 830 and 850 may be used, for example, in
combination with one or more processes (e.g., atomization, SPD
processes, etc.).
[0153] As an example, a method may include one or more heat
treatments (e.g., thermal treatments). In such an example, time may
be a factor over which a component may be subjected to one or more
heat treatments. As an example, families of plots may be provided
where, for example, temperature-time profile information allows for
providing a component with particular characteristics that occur at
a particular time or times.
[0154] In the plot 810, where the first material is a powder of
degradable material formed at least in part via gas atomization
(e.g., GA), the dissolution rate of a bulk material formed of the
constituent materials may be less than an "ideal". For example, the
bulk material may exhibit a relatively low dissolution rate (e.g.,
less than about 20 percent of a dissolution rate of the first
material itself), until the first material approaches a certain
percentage or range of percentages of the total. As an example, the
change in dissolution rate may be more sensitive to the percentage
of the first material in a particular range (e.g., a relatively
high slope in dissolution rate versus percentage of the first
material).
[0155] As an example, strength as in the plot 830 may be a
characteristic of a bulk material (e.g., as formed into a
component) that quantifies an ability to withstand an applied load
without failure. As an example, strength may be characterized by
one or more of yield strength (e.g., stress to cause an amount of
plastic strain), compressive strength, tensile strength or ultimate
tensile strength, fatigue strength, and impact strength.
[0156] As an example, ductility as in the plot 850 may be a
characteristic of a bulk material (e.g., as formed into a
component) that quantifies an ability to deform under tensile
stress (e.g., consider fracture strain as a measure).
[0157] As illustrated in the plots 810, 830 and 850, a bulk
material may be formed of various constituent materials to achieve
one or more desired properties such as dissolution rate, strength
and ductility.
[0158] As an example, a component may be formed of a bulk material
that is a blend of a plurality of materials, which may be
particulate materials. In such an example, mixing to form a blend
may make, for example, a high strength degradable alloy with
tailored dissolution and adequate ductility for load bearing
applications. Such an approach may be achieved, for example,
through a powder metallurgy (PM) route of blending of various
powders.
[0159] Powder metallurgy (PM) processing can be suitable for light
metals. For example, rapid solidification and mechanical attrition
processes can produce PM alloys having improved mechanical
properties. Such PM alloys may be characterized by, for example,
one or more of: (1) high strength; (2) reduced density; (3)
increased modulus; and (4) high-temperature properties.
[0160] As an example, near-nanostructured or ultrafine-grained
(UFG) materials may be defined as materials having grain sizes
whose linear dimensions are in the range of, for example, about 100
nm to about 500 nm. Such materials may optionally be or include
alloys and, for example, be formed at least in part via one or more
severe plastic deformation (SPD) processes. For example, an
atomized powder may be subjected to one or more SPD processes.
[0161] In contrast to coarse-grained counterparts,
near-nanostructured or UFG materials may benefit from reduced size
or dimensionality of near nanometer-sized crystallites as well as,
for example, from numerous interfaces between adjacent
crystallites.
[0162] As an example, a bulk material or a portion thereof may be a
metal matrix composite (MMC). In such an example, a component may
be formed of such a material where the component or a portion
thereof may be high strength and water reactive or degradable. Such
a component may be suitable for load bearing applications. As an
example, a bulk material and/or a component may be formed using a
process that implements one or more powder metallurgy (PM)
techniques.
[0163] As an example, a structural scale may be selected to achieve
mechanical properties of an alloy. As an example, a structural
scale may be selected to achieve a desired strength, as may be
obtained by an ability to impede motion of dislocations with
obstacles (e.g., as inversely proportional to the mean-free-path
between the obstacles).
[0164] As an example, a material can include dispersed particles
where the size or sizes of such particles (e.g., and shape or
shapes) may be selected (e.g., or achieved during processing) such
that the dispersed particles are less apt to serve as
fracture-initiating flaws (e.g., when compared to larger
particles).
[0165] As an example, a process can include rapid cooling to
achieve a desired rate of cooling of material. As an example, a
powder metallurgy (PM) process can refine features and improve
properties of material. For example, grain size can be reduced
because of the short time available for nuclei to grow during
solidification. As an example, rapid cooling can increase one or
more alloying limits in aluminum, for example, by enhancing
supersaturation, which can enable greater precipitation-hardening
with a reduction in undesirable segregation effects that may occur
when IM alloys are over-alloyed. Moreover, elements that are low in
solubility (e.g., practically insoluble) in a solid state may be
soluble in a liquid state and may be relatively uniformly dispersed
in powder particles during a process that employs rapid
solidification. Non-equilibrium metastable phases or atom
`clusters` that do not exist in more slowly cooled ingots may be
created by employing a rapid solidification rate; such phases can
increase strength.
[0166] As an example, a process can include introduction of
strengthening features via powder surfaces, for example, as scale
of particles becomes finer, surface-to-volume ratio of the
particles increases.
[0167] As an example, one or more oxides can be introduced on a
desired scale from powder surfaces by mechanical attrition, for
example, to result in oxide dispersion strengthening (ODS).
[0168] As an example, a process may include introducing one or more
carbides (B.sub.4C, SiC, etc.). As an example, a process may
include introducing one or more insoluble dispersoids (e.g., one or
more materials that are practically insoluble in one or more
defined environments).
[0169] As an example, a process can include cold-working powder
particles by ball-milling. For example, a process can include
cold-working powder particles in a cryogenic medium (e.g., or
cryogenic media). Such a process can result in increased
dislocation strengthening and, upon consolidation, a finer grain
(and sub-grain) size which can be further stabilized by one or more
ceramic dispersoids (e.g., as may be introduced during such a SPD
process).
[0170] As an example, processed powder (e.g., particulate material)
can be consolidated to form a metal matrix composite (MMC). For
example, consider a process that consolidates particulate material
to form a billet, which may be subjected to one or more additional
forming operations.
[0171] As an example, a process may include directly consolidated
particulate material into a product form. For example, one or more
of extruding, forging, rolled sheeting, etc., may be employed.
[0172] As to formation of a MMC, in comparison to an un-reinforced
solid made from consolidating powder, the MMC may exhibit an
ability to blunt crack tips, for example, if a crack initiation
event in the MMC occurs or, for example, if a crack is nucleated at
a tri-axial stress state. A MMC may exhibit resistance to the
initiation of a crack. A MMC may provide support to an overall
structure by preventing ceramic particulate material or
reinforcement material to be bisected by dislocation transport or
de-cohesion from the matrix during plastic deformation due to
mechanical bonding to the powder interior during a SPD process.
Such an approach may impart desirable load bearing strength as well
as, for example, desirable ductility that can resist cracking and,
for example, resist subsequent failure through a shear mode.
[0173] As explained, a component may be subjected to one or more
heat treatments. Table 1, below, includes information pertaining to
heat treatment.
TABLE-US-00001 TABLE 1 Heat Treatment Trial Example Without With
Diameter: 0.1255 in 0.1250 in Area: 0.0124 sq in 0.0123 sq in
Specimen Gage Length: 1.0000 in 1.0000 in Tensile Strength: 50970
psi 62200 psi Peak Load: 632 lbf 765 lbf Tangent Modulus: 9074480
psi 9855730 psi Load at Offset: 446 lbf 693 lbf Stress at Offset:
35950 psi 56320 psi Elongation at Offset: 0.0055 in 0.0079 in
Proportional Limit: 0.0021 in 0.0050 in Percent Elongation: 0.5550%
0.7870% Total Elongation: 2.5000% 2.8000% Pretest Punch Length:
1.00 in 1.00 in Posttest Punch Length: 1.025 in 1.028 in
[0174] Specifically, Table 1 includes mechanical property values of
a hot isostatic pressed (HIPed) water reactive solid alloy formed
in part by blending un-milled IGA powder with cryomilled IGA powder
and a solid alloy formed in part by blending un-milled IGA powder
with cryomilled IGA powder that has been heat treated to promote
precipitate hardening (PH). Without heat treatment, yield strength
of the solid is about 25 ksi and the ultimate tensile strength is
about 51 ksi; the ductility of the solid is about 7 percent and
stiffness is around 9000 ksi. With heat treatment, yield strength
of the solid is about 50 ksi and the ultimate tensile strength is
about 62 ksi; the ductility of the solid is about 7.5 percent and
stiffness is around 10,000 ksi.
[0175] As an example, a method can include naturally ageing one or
more components in a wellbore at one or more wellbore temperatures
for one or more periods of time to thereby alter properties of the
one or more components, which may be at least in part
degradable.
[0176] As an example, a component may have an operational lifetime
in a wellbore that is less than about 8 hours and then age in a
manner at least in part thermally that causes the component to fail
more readily. In such an example, where the component is degradable
in the wellbore environment, ageing may assist with degradation,
for example, via one or more failure mechanisms (e.g., elongation
to failure, etc.).
[0177] As an example, a material may undergo Ostwald ripening where
a portion of smaller entities dissolve and redeposit on larger
entities. For example, consider small crystalline grains dissolving
and constituents thereof redepositing onto larger crystalline
grains such that the larger crystalline grains increase in size.
Near a larger crystalline grain, a zone may exist, which may be due
to a gradient or gradients in composition. As an example,
intermetallic precipitates may form about a larger crystalline
grain, which may be considered a macroscopic process (e.g., on a
scale of about 50 microns).
[0178] As an example, a material may be treated to undergo Ostwald
ripening and halo-ing to achieve desired properties, which can
include dissolution rate, strength and/or ductility. For example, a
haloed entity in the material may dissolve at a rate that differs
from smaller entities in the material. As an example, a treatment
may aim to achieve a population density of haloed entities to
smaller entities, for example, to tailor one or more of dissolution
rate, strength and ductility.
[0179] As an example, a water reactive or degradable powder can be
blended with thermally stable nanocrystalline grains processed by
cryomilling and further stabilized by inclusion of one or more
types of dispersoids (e.g., SiC, B.sub.4C, Al.sub.2O.sub.3, etc.).
Such an approach may help to enhance potential shear failure of
high strength UFG and/or nano alloy with less ductility.
[0180] As an example, a method can include heat treating a solid
that includes a MMC. In such an example, crack blunting ability of
the solid may be enhanced by the heat treating. Such an enhancement
may be via formation of precipitates that can pin agglomerated
coarse particles. For example, consider a solid that includes a MMC
that has an ability to blunt cracks and heat treating that solid to
form precipitates that can further blunt cracks. In such an
example, the heat treating may be performed before deployment of
the solid (e.g., as a component), during deployment of the solid
and/or after deployment of the solid. In such an example, the solid
may degrade over time when subjected to conditions in a downhole
environment in to which the solid is being deployed and/or is
deployed.
[0181] As an example, a method can include consolidating a blend of
un-milled coarse powder(s) with a cryomilled-blend of water
reactive or degradable powder (e.g., in a range of about 5 percent
to about 95 percent) and one or more ceramic dispersoids (e.g.,
SiC, B.sub.4C, Al.sub.2O.sub.3, etc.). In such an example, the
average size of the water reactive powders or otherwise degradable
powder is larger than the average size of the one or more ceramic
dispersoids. As an example, a consolidated solid can include a
multimodal grain size distribution where dispersoids can provide
additional ductility.
[0182] As an example, a method can include blending water reactive
or degradable powder (e.g., in a range of about 5 percent to about
95 percent) with a material that includes thermally stable
nanocrystalline grains processed by cryomilling. In such an
example, the method may include consolidating of the blend (e.g.,
via one or more of HIPing, vacuum hot pressing (VHP), extrusion,
etc.) to form a solid. In such an example, the solid may optionally
be further processed by solution annealing and ageing to develop
intermetallic precipitates and stabilize nano and/or coarse grain
structures (e.g., increasing thermal stability). As an example, a
precipitate hardened (PH) alloy may provide a mechanism of crack
blunting, for example, if a crack is initiated in a matrix, while
increasing stiffness. Such an approach can help to enhance
potential shear failure of a high strength UFG and/or nano alloy
with less ductility.
[0183] As an example, a method can include consolidating a blend of
water reactive or degradable powder from an inert gas atomization
(IGA) tank, a first cyclone and a second cyclone, for example, to
help maximize yield from melt that is atomized and to help produce
a multi-powder size distribution. In such an example, the blend
(e.g., in a range of about 5 percent to about 95 percent) may be
further blended, for example, with thermally stable nanocrystalline
grains processed by cryomilling and further blended with one or
more dispersoids (e.g., SiC, B.sub.4C, Al.sub.2O.sub.3, etc.). The
bulk alloy from such a blend, for example, when heat treated to
promote intermetallic particulates, may provide additional
strengthening due to thermally stable finer powder from the first
and second cyclones in contrast to the IGA tank yield.
[0184] FIG. 9 shows an example of a system 900 that can process a
melt 920 using gas 930 to form particles. In such an example, the
particles may be composed of melt constituents and/or composed of
melt constituents and optionally one or more gas constituents
(e.g., consider oxygen in the gas 920 forming an oxide such as
alumina upon exposure to aluminum in the melt 920). Particles
formed via the system 900 may be powder particles. The system 900
may be considered to be a powder metallurgical system that can be
implemented using powder metallurgy technology.
[0185] As shown in FIG. 9, the system 900 includes a vacuum
induction furnace 910, an optional heat exchanger 912 (HX), a
chamber 916, a cyclone chamber 918, and a nozzle 950. As
illustrated, a rapid expansion of the gas 930 as provided to the
nozzle 950 can break up the melt 920, which may form a thin sheet
and subsequently ligaments, ellipsoids and/or spheres (e.g.,
particles). In an example of an inert gas atomization process,
particles formed may be substantially spheroidal. As an example, an
atomization process may be a gas atomization process (e.g.,
including inert and/or non-inert gas), a water atomization process,
a mechanical pulverization process, etc.
[0186] Particles may be collected in the chamber 916 and in the
cyclone chamber 918, which can allow gas to exit and optionally
recycle (e.g., with make-up gas, etc. to maintain a gas composition
where multiple gases may be used). In such an example, the cyclone
chamber 918 may collect particles that are finer than the particles
collected in the chamber 916. Particles of either or both chambers
916 and 918 may be combined, separated, etc.
[0187] As an example, the system 900 may include multiple cyclones,
which may be in parallel and/or in series. For example, the system
900 may include a cyclone in fluid communication with the cyclone
718. As an example, particles collected (e.g., powder particles)
may be of different size distributions, etc., depending on where
the particles are collected (e.g., chamber 916, cyclone 918, other
cyclone, etc.).
[0188] As to operational parameters of an atomization process,
consider, for example, alloy composition, melt feed rate, melt
temperature, melt viscosity, heat exchanger temperature (e.g., heat
transfer rate, etc.), gas pressure and temperature, type of gas,
nozzle geometry, etc. Gas atomization may produce particles that
are substantially spherical in their shapes and that include grains
and grain boundaries. As an example, gas atomization may produce
particles that include crystalline structure and/or amorphous
structure.
[0189] As an example, a melt temperature (see, e.g., T.sub.M) may
be a superheated temperature. As an example, a melt temperature may
be greater than about 650 degrees C. (e.g., greater than about 700
degree C. and optionally greater than about 800 degrees C.). As an
example, a chamber such as the chamber 916 may be at a temperature
of about 70 degrees C. (e.g., a temperature of the order of
hundreds of degrees C. less than a melt temperature). As an
example, gas may expand relatively adiabatically, which may
facilitate cooling of melt and reducing thermal shock.
[0190] As an example, heat transfer may occur within a system such
as the system 900 such that particles are crystalline, amorphous or
crystalline and amorphous.
[0191] As an example, a method may include cooling melt at a rate
that causes at least a portion of a particle formed from the melt
to be amorphous. For example, a method may include cooling via a
cryogenic cooled target (e.g., consider the heat exchanger 912 of
the system 900). As an example, a cryogenic cooled target may be
positioned in front of an atomizing nozzle, for example, to achieve
a cooling rate (e.g., R.sub.C) where vitrification occurs for
atomized (melt) droplets (e.g., to be at least in part a metallic
glass structure, which may be a bulk metallic glass structure). As
an example, a material may be characterized at least in part by a
glass transition temperature (T.sub.g) where below that temperature
an amorphous material may be glassy (e.g., whereas above T.sub.g it
may be molten).
[0192] As an example, a method may include introduction of a gas at
a low temperature. For example, consider introduction of helium in
an atomization stream (e.g., introduction of helium as a gas, in a
gas provided to a nozzle or nozzles).
[0193] As an example, a method may include increasing the
superheating temperature of a melt, which may increase a driving
force (e.g., a temperature differential) as to heat transfer (e.g.,
cooling). As an example, a method may include forming particles of
a particular size or smaller such that heat transfer may occur more
rapidly for the particles. For example, consider selecting a nozzle
dimension (e.g., diameter, slit width, etc.) to achieve a
particular particle size. As an example, a method may include
analyzing dendrite arm spacing during cooling and adjusting one or
more parameters of a gas atomization process such that amorphous
particles may be formed.
[0194] As an example, a melt may be analyzed as to one or more
properties such as, for example, a glass-transition or
vitrification temperature (e.g., T.sub.g). As an example, a system
may be operated such that transformation takes place at the
glass-transition temperature, T.sub.g, below an equilibrium
temperature for the solidification (e.g., a liquidus temperature,
T.sub.L), which may act to "freeze" an atomized melt in a
non-equilibrium state (e.g., at least in part as an amorphous
material). As an example, a liquidus temperature may be the maximum
temperature at which crystals can co-exist with a melt in
thermodynamic equilibrium. As an example, a method may consider a
solidus temperature (Ts) that quantifies a point at which a
material crystallizes. As an example, for a material, a gap may
exist between its liquidus and solidus temperatures such that
material can include solid and liquid phases simultaneously (e.g.,
akin to a slurry).
[0195] As an example, a method may include cooling a melt to
produce an amorphous melt-span ribbon. In such an example, the
ribbon may be further processed, for example, by mechanical
crushing of the ribbon to form a powder.
[0196] As an example, a water reactive powder (e.g., a degradable
powder) may be processed to form a component or components. In such
an example, the powder may be produced by gas atomization (e.g.,
using one or more gases, optionally one or more inert gases), by
ball milling, by crushing or other mechanical means, by sol-gel,
etc.
[0197] As an example, a powder may include particles of one or more
particle size distributions. For example, consider D90 less than
about 44 microns (e.g., a mesh size of about 325), D90 less than
about 60 microns, D90 less than about 90 microns, etc.
[0198] As an example, a material may be subjected to one or more
SPD processes. As an example, a method can include employing one or
more SPD processes.
[0199] As an example, where a method includes processing via ECAP,
the method can include shearing of grains in consolidated or
unconsolidated powder through a channeled die at low to high
angles. As an example, ECAP can include passing material through a
die (e.g., or dies) at various angles, which may abet refining of
grains (e.g., of a water reactive powder), for example, to achieve
a desired minimum grain size (e.g., after a certain number of ECAP
passes). As an example, a method can include ECA pressing, for
example, at one or more temperatures. In such an example, the
pressing may cause in situ consolidation of powder into a solid.
Such a solid may be further consolidated into an approximately 100
percent dense billet (e.g., via forging, extrusion, etc.).
[0200] As an example, a method can include performing ECAP to abet
refining of grains, for example, to achieve a minimum grain size
(e.g., after a certain number of ECAP passes).
[0201] As an example, a method can include performing cryomilling
to abet refining of grains, for example, to achieve a minimum grain
size (e.g., after a certain duration of milling).
[0202] As an example, a method can include performing HPT to abet
refining of grains, for example, to achieve a minimum grain size
(e.g., after a certain number of HPT turns or revolutions).
[0203] As an example, a method can include performing cold working
to abet refining of grains, for example, to achieve a minimum grain
size (e.g., after a certain percentage of cold working).
[0204] As an example, a powder or a blend of powders may be
processed to achieve one or more desired properties such as, for
example, one or more desired properties of strength, ductility,
fracture toughness, thermal stability, microstructure, etc.
[0205] As an example, a desired strength may be achieved at least
in part via control of grain size. As an example, a desired
ductility may be achieved at least in part via control of grain
size. As an example, a desired fracture toughness may be achieved
at least in part via control of grain size. As an example, a
desired thermal stability may be achieved at least in part via
control of grain size. As an example, a desired microstructure may
be achieved at least in part via control of grain size.
[0206] As an example, a method may include controlling grain size.
For example, consider alternating grain size from the point of
inflection of an inverse Hall-Petch trend (e.g., varying for
different alloys, consider about 50 nm) to an upper limit of
ultrafine grains (e.g., about 1000 nm or 1 micron). As an example,
a method can include controlling grain size by controlling one or
more parameters of one or more SPD processes (e.g., cryomilling
time, ECAP passes, HPT turns or revolutions, percentage of cold
work, etc.).
[0207] As an example, a method can include controlling properties
of material via grinding the material with one or more grinding
media. In such an example, a method may include controlling size of
a grinding medium and/or controlling ratio of a grinding medium to
material.
[0208] As an example, a method can include processing water
reactive powder via one or more SPD processes, for example, to
tailor dissolution rate in a fluid, to tailor dissolution rates in
various fluids, etc. As an example, a fluid may be a hydraulic
fracturing fluid. As an example, a fluid may include a salt
concentration or concentrations of salts. For example, consider a
fluid that includes one or more of NaCl, KCl and MgCl.sub.2. As an
example, a fluid may be an aqueous fluid. Such an aqueous fluid may
include one or more salts. As an example, a method may include
varying percentages of one or more inhibited acid that may be used
in one or more spearheading operations during hydraulic fracturing.
As an example, a method can include tailoring dissolution rate
(e.g., degradation rate) by controlling grain size. As an example,
one or more SPD processes may be used for refining grains, for
example, to achieve a minimum grain size (e.g., optionally altering
grain size from the point of inflection of an inverse Hall-Petch
trend).
[0209] As an example, dissolution rate (e.g., degradation rate) may
be influenced by disruption of a continuous grain boundary network.
One or more characteristics of such a network may be influenced by
one or more SPD processes (e.g., consider a number of ECAP passes,
etc.). As an example, dissolution rate (e.g., degradation rate) may
be influenced by precipitation of an additional phase of
dispersoids, for example, as may be processed during high
temperature ECAP and/or one or more other SPD processes.
[0210] As an example, a method can include precipitating second
phase dispersoids. In such an example, the properties of such
dispersoids may be influenced by choice of one or more cryogenic
media. For example, consider use of one or more of liquid nitrogen
and liquid argon. As an example, precipitation of second phase
dispersoids may be influenced by choice of one or more grinding
media. For example, consider use of one or more of low alloy/carbon
steel balls, stainless steel balls, Ni alloy balls, ceramic balls,
etc.
[0211] As an example, a method can include making a high strength
degradable alloy with ductility from a brittle cast equivalent for
load bearing applications via powder metallurgy (PM) technology. In
such an example, the high strength degradable alloy may be utilized
in a variety of contexts including, for example, downhole contexts
(see, e.g., various components of FIGS. 1, 2 and 3).
[0212] As an example, a degradable alloy may be designed to
dissolve upon exposure to one or more downhole conditions. As an
example, a degradable alloy may be used to make at least a portion
of one or more downhole tools or apparatuses that can withstand
pressures, such as those used in a fracturing operation (see, e.g.,
FIGS. 1, 2 and 3). For example, a degradable alloy may be used to
create one or more components used in a fracturing operation. For
example, a degradable alloy may be used in some embodiments as an
obstruction member (e.g., a dart, a ball, etc.) and/or one or more
parts of a seat configured to catch the obstruction member. As a
material may be designed to dissolve under downhole conditions
(e.g., after completion of at least a portion of a fracturing
operation), one or more components made of the degradable alloy can
disappear (e.g., optionally without further intervention).
[0213] As an example, fine-grained (FG) materials may be defined as
materials having grain sizes whose linear dimensions are of the
order of about 10.sup.-6 meters or a micrometer (e.g., .mu.m, or
micron, .mu.). In some embodiments, one or more physical properties
of such FG materials may result in enhanced strength when compared
to a coarse-grained counterpart, for example, due to Hall-Petch
strengthening of a FG material. As an example, a FG material may
exhibit fair elongation to failure when compared to a
coarse-grained counterpart.
[0214] As an example, a FG material may exhibit characteristics
associated with reduced size or dimensionality of fine crystallites
as well as from numerous interfaces between adjacent crystallites.
As an example, a FG material may be formed where material of
crystallites (e.g., grains) have a first composition and where
material between crystallites (e.g., at grain boundaries) have a
second composition that differs from the first composition. For
example, where a bulk FG material includes aluminum and gallium, a
second composition (e.g., of material between grains) may be
gallium enriched when compared to a first composition (e.g., of
material forming grains).
[0215] Various routes exist for engineering alloys with fine
grains. For example, SPD may result in formation of an ultra-fine
or a nanostructure in a bulk material. As another example, consider
the system 900 of FIG. 9 where gas atomization (e.g., using inert
and/or other gas or gasses) may result in production of controlled
fines. For example, consider a gas atomization process that can
generate particles that may be characterized at least in part by
size (e.g., consider a size distribution of about 10 microns to
about 20 microns). In such an example, grains in particles may be
of the order of about a micron. As an example, particles may be
formed via gas atomization that include grains of the order of less
than about one micron (e.g., optionally less than about half a
micron).
[0216] Consolidation of a powder to form a solid may be
accomplished, for example, via one or more processes. For example,
consider using hot isostatic pressing (HlPing) and/or vacuum hot
pressing (VHF') followed by back extrusion, a warm working
technique, etc. In such examples, a product may be a component,
which may be, for example, a homogeneous engineering solid with
desired mechanical properties and fracture toughness. As an
example, a product may be a component that includes heterogeneity,
for example, consider a surface subject to SMAT such that near
surface material differs at least structurally from other material
disposed a greater distance from the surface.
[0217] As an example, a consolidated solid (e.g., as produced at
least in part from a powder, which may be a blend of powders) may
include thermally stable fine grains that resist grain growth due
to thermal activation, which may oppose degradation in their
mechanical properties at elevated temperatures. As an example,
combinations of high strength, enhanced ductility and/or high
strain rate superplasticity may manifest in an alloy due to various
competing mechanisms, for example, grain boundary sliding, etc. As
an example, one or more SPD processes may be applied to one or more
consolidated solids to augment mechanical properties (e.g., to
achieve one or more target criteria).
[0218] As an example, a degradable alloy (e.g., water reactive,
etc.) may be processed to from a segregated brittle cast solid, a
high strength engineering alloy, etc. As an example, a degradable
alloy may be prepared via inert gas atomization (IGA) followed by
consolidation via one or more SPD processes, optionally followed by
extrusion. In such an example, a resulting bulk alloy may include
one or more sub-structural features. For example, consider a
resulting bulk alloy that includes oxide particles resulting from
breakup of oxide layers that are formed around metal particles
during gas atomization to provide enhanced thermal stability and
strength by mitigating dislocation motion.
[0219] As an example, a process may include one or more of the
following: refining grains to develop a nano to ultrafine grained
microstructure; Hall-Petch strengthening to increase strength;
forming desirable grain boundaries to increase ductility (e.g.,
abetting grain boundary sliding to make a treated alloy high strain
rate superplastic to enhance formability and working); dispersion
strengthening (e.g., via introduction of one or more additional
phase particles/oxides, which may result from the breakup of oxide
layers that are formed around metal particles during gas
atomization); and increasing thermal stability of a bulk alloy
(e.g., synthesized through powder metallurgy technology via
introduction of particles of an additional phase, which may impact
drag).
[0220] As an example, a processed material (e.g., a resulting
alloy, etc.) may exhibit one or more of the following: increased
strength and ductility, relatively uniform properties (e.g., bulk
homogeneity in comparison to a brittle, precipitate hardened cast
counterpart material), increased thermal stability, and an ability
to abet strain hardening through dislocation strengthening.
[0221] As an example, a method may include one or more of the
following processes and/or produce a material that includes one or
more properties listed below (e.g., of a desired high strength
degradable alloy): inert gas atomization (IGA) of a brittle cast
melt with controlled flow through one or more nozzles (e.g.,
optionally of varying sizes) to yield powder particles of varying
mesh size; particulate (approximately 80 percent to approximately
100 percent (e.g., approximately 90 percent) screened distribution)
with sizes varying between about 10 microns and about 70 microns
(e.g., between about 20 microns and about 60 microns).
[0222] FIG. 10 shows a scanning electron micrograph 1000 of
particles produced via gas atomization of a brittle cast melt. Such
particles may be formed by cooling the melt as it exits a nozzle
(see, e.g., the nozzle 950 of the system 900 of FIG. 9). Such
cooling may be adiabatic cooling. For example, adiabatic cooling
can occur when pressure on an adiabatically isolated system is
decreased, allowing it to expand, thus causing it to do work on its
surroundings. When the pressure applied on a parcel of gas is
reduced, the gas in the parcel is allowed to expand; as the volume
increases, the temperature falls as internal energy decreases.
[0223] As an example, a gas atomization process may "capture" melt
in a particle as a supersaturated solid solution. As an example, a
particle may include properties that can reduce segregation of
alloying constituents in solid solution. As an example, a gas
atomization process may yield fine to ultrafine grain
microstructure in particles that form a powder.
[0224] FIG. 11 shows an example of a transmission electron
micrograph (TEM) 1100 of a particle of a powder. The TEM 1100 shows
ultrafine grains with darker grain boundaries; noting focus ion
beam (FIB) sample preparation. Specifically, the TEM 1100 shows
that the particle includes grains with dimensions of the order of
about one micron or less. The TEM 1100 shows various grains that
include dimensions of about 0.5 microns.
[0225] As an example, a process can generate particles with grains
where, for example, the processing provides for segregation of one
or more low melting point constituents at grain boundaries. In such
an example, the one or more low melting point constituents can coat
grains and through such coating form a galvanic couple.
[0226] As an example, particles of a powder may include grain
boundary interfaces where intermetallic precipitates can form
during one or more ageing process, which may, for example, result
in additional strengthening of the material (e.g., alloy, alloy and
ceramic, etc.).
[0227] As an example, a process may provide for weakening of grain
boundary interfaces in a component formed of a powder produced via
gas atomization, which may help to promote embrittlement of the
boundaries and further enhance a degradation mechanism (e.g., or
degradation mechanisms). For example, consider a particle of a
material that includes aluminum and gallium where gallium
enrichment at grain boundary interfaces may promote embrittlement
of the boundaries and where at least gallium interacts with fluid
in a manner that causes degradation of the particle. As an example,
a component formed of such particles (e.g., via processing of such
particles) may degrade upon exposure to fluid and via
embrittlement.
[0228] As an example, a material may include one or more oxide
dispersoids, which may provide enhanced thermal stability and
strengthening, for example, due to pinning of grain boundaries and
dislocations.
[0229] As an example, differential cooling of a warm powder may
abet diffusion of one or more low melting point constituents from a
trapped supersaturated solid solution to a grain interior along a
grain boundary, for example, causing liquid-metal embrittlement,
which may enhance a degradation mechanism (e.g., consider a
mechanism where gallium interacts with fluid in a manner that
causes degradation).
[0230] FIG. 12 shows an example of a TEM 1200 that includes a
triple junction between three grains (e.g., a GBTP) in a particle
of a powder. The TEM 1200 shows contrast and compositional
differences between the grain boundary and the grain; noting Focus
Ion Beam (FIB) sample preparation. The TEM 1200 includes two
windows that correspond to samples: Sample 1 for grain material
composition and Sample 2 for grain boundary material
composition.
[0231] As an example, a method can include energy-dispersive X-ray
(EDX) analysis of composition of a sample (e.g., Sample 1 of the
TEM 1200 and Sample 2 of the TEM 1200). EDX is an analytical
technique that can be applied for elemental analysis or chemical
characterization of a sample. EDX involves interaction of a source
of X-ray excitation (e.g., electrons) and a sample where, for
example, a number and energy of X-rays emitted from the sample can
be measured by an energy-dispersive spectrometer (e.g., EDS). As
energy of X-rays can be characteristic of the difference in energy
between two shells, and of the atomic structure of an element from
which they were emitted, this allows the elemental composition of
the sample to be measured.
[0232] As an example, in a particle, material at a grain boundary
may be enriched in gallium when compared to material in a grain. As
an example, in a particle, material at a grain boundary may be
enriched in indium when compared to material in a grain. As an
example, in a particle, material at a grain boundary may be
enriched in gallium and indium when compared to material in a
grain.
[0233] As an example, a particle may include material at a grain
boundary that, upon analysis, generates gallium counts at one or
more energies of less than about 2 keV and generates counts gallium
counts at one or more energies greater than about 8 keV. In such an
example, a ratio of counts may be about two to one. As an example,
such a particle may include material at a grain boundary that, upon
analysis, generates indium counts at energies from about 2 keV to
about 5 keV. In such an example, such counts may be less than
counts of a maximum gallium count at an energy greater than about 8
keV and less than counts of a maximum gallium count at an energy
less than about 2 keV.
[0234] As an example, a powder may respond to dissolution and may
be reactive (e.g., upon exposure to fluid, etc.). As an example, a
powder may be consolidated, for example, to produce a relatively
homogeneous solid that has a desired rate of degradation (e.g.,
when subjected to one or more conditions). As an example, a process
such as SMAT may be applied to alter near surface properties and,
for example, dissolution characteristics of a solid. As an example,
a consolidated solid may exhibit a high strength and fair
ductility. As an example, degradation of powder, and hence a
consolidated solid made at least in part therefrom, can be
controlled by blending of one or more other powders (e.g., of one
or more mesh sizes, etc.).
[0235] As an example, one or more ceramic and/or other particulates
may be added to a powder (e.g., or powders) to form a metal matrix
composites (MMC). In such an example, such addition(s) may achieve
higher stiffness or Young's modulus and, for example, abet blunting
of crack tips initiated during a fracture event. As an example, one
or more consolidated solids from blended powders may yield high
strength and good ductility.
[0236] As an example, one or more consolidated solids, as made from
one or more degradable alloy powders and/or blended powders, may
respond to ageing to augment strength and one or more associated
mechanical properties.
[0237] As an example, processing may alter strength, ductility or
strength and ductility. The strength of a material may be defined
as the material's ability to withstand an applied load without
failure. Strength may characterize a material, for example, via
calculations of stresses, strains, stresses and strains, etc. For
example, consider predicting response of a structure under loading
and its susceptibility to various failure modes, which can take
into account material properties such as its yield strength,
ultimate strength, Young's modulus, and Poisson's ratio. Mechanical
macroscopic properties (e.g., geometric properties) such as length,
width, thickness, boundary constraints, abrupt changes in geometry,
etc. may be considered when determining strength of a material.
[0238] Ductility pertains to deformation under tensile stress
(e.g., measurable by stretching material). Malleability pertains to
deformation under compressive stress (e.g., measureable by
hammering or rolling material). Ductility and malleability are
mechanical properties that pertain to plasticity (e.g., extent to
which a material can be plastically deformed without fracture).
[0239] An alloy can include crystalline, amorphous or mixed
structure (e.g. partially crystalline, partially amorphous).
Features characterizing the structure can include grains, grain
boundaries, phases, inclusions, etc. As an example, one or more
features may be of the order of macroscopic, micron or submicron
scale, for instance nanoscale. Shape, size, shape and size, etc.
may be characteristics that can influence mechanical properties
and, for example, reactivity.
[0240] As an example, a reactive material may include an element
that tends to form positive ions when its compounds are dissolved
in a liquid solution and whose oxides form hydroxides rather than
acids with water. As an example, a material may disintegrate. For
example, consider an alloy that loses structural integrity and
becomes dysfunctional for instance due to grain-boundary
embrittlement or dissolution of one of its elements. As an example,
a byproduct of degradation from grain boundaries may not
necessarily include an ionic compound such as a hydroxide and may
include a metallic powder residue (e.g., consider severely
embrittled aluminum alloys of gallium and indium).
[0241] As an example, a material may be electrically conductive and
may include a metallic luster. As an example, a material may
possess a relatively high mechanical strength in tension, shear and
compression (e.g., exhibit a relatively high hardness).
[0242] As an example, a material may be degradable and, for
example, an alloy may be degradable (e.g., a degradable alloy). As
an example, a material may degrade when subject to one or more
conditions (e.g., over time). For example, consider one or more
environmental conditions and/or "artificial" conditions that may be
created via intervention, whether physical, chemical, electrical,
etc. As an example, conditions can include temperature, pressures
(e.g., including loads and forces), etc.
[0243] As an example, a component may be consolidated from a blend
of particulate materials that include at least one age-hardenable
particulate material. In such an example, the blend can include one
or more degradable particulate materials and one or more
non-degradable particulate materials. As an example, a component
may be age-hardened prior to deployment, during deployment and/or
after deployment.
[0244] As an example, a blend of particulate materials can include
an aluminum alloy that may be an age-hardenable aluminum alloy. In
such an example, the blend can include particulate material that is
degradable, for example, when exposed to an aqueous environment. As
an example, a component may be formed of a blend of materials where
the component is age-hardenable and degradable in an aqueous
environment (e.g., a downhole environment that includes water).
[0245] As an example, one or more thermal treatment processes may
be applied to material to, for example, increase thermal stability,
increase strength, increase stiffness, retain or improve ductility
or elongation to failure, and/or promote crack arresting
properties. Such a material may be an engineered high strength
water reactive or degradable alloy that optionally includes a metal
matrix composite (MMC). Such a material may be suitable for load
bearing applications. As an example, a material may be processed at
least in part through powder metallurgy (PM).
[0246] As an example, a material can include cryomilled
nanocrystalline grains, which may be thermally stable. For example,
a cryomilled nano and/or UFG solid may be thermally stable up to
about 0.8 of an alloy's melting point.
[0247] As an example, a method can include thermal treatment of a
water reactive or degradable alloy that includes a MMC, which may
be consolidated into a component, for example, from a blend of
cryomilled and un-milled particulate material. In such an example,
the method can include solution annealing, which may act to put
coarse un-milled grains into solution and promote precipitate
hardening during an ageing cycle in an annealed fraction. In such
an example, cryomilled nano grains may be retained from going into
solution due to their enhanced thermal stability, however, growth
may occur to a multimodal nano and/or UFG size abetting ductility
to the blended solid.
[0248] As an example, a method can include refining grains to
develop a nano to ultrafine grained microstructure. Such a method
may achieve increased strength, for example, via Hall-Petch
strengthening and/or may achieve increased ductility by abetting
grain boundary sliding, thus possibly making a treated alloy high
strain rate superplastic, resulting in better formability and
working.
[0249] As an example, heat or thermal treatment can include
solution annealing, for example, to put coarse grains into solution
while retaining thermally stable cryomilled nano grains from going
into solution. Such a process may include following a temperature
thermal cycle or cycles.
[0250] As an example, heat or thermal treatment can include ageing,
for example, to induce precipitate hardening of solution annealed
coarse grain counterparts while promoting slight grain growth of
thermally stable cryomilled nano grains, for example, to abet
ductility of a solid consolidated from particulate materials. Such
a process may include following a temperature thermal cycle or
cycles.
[0251] As an example, thermal processing can increase strength,
retain and/or improve ductility or elongation to failure, promote
distinct plastic deformation after thermal treatment, abet strain
hardening through dislocation strengthening, increase stiffness of
a consolidated bulk solid, promotes resistance to initiation of a
crack by blunting of crack tips, improve thermal stability of a
consolidated bulk solid, etc.
[0252] As an example, a blend of materials can optionally include
ceramic particulates and/or other particulates that can effectuate
dispersion strengthening to form a MMC. For example, a method can
include introduction of second phase particles (e.g., optionally
oxides), which may result from the breakup of oxide layers that are
formed around metal particles during a process such as a gas
atomization process. As an example, a method can include
introducing ceramic particulates during one or more SPD processes.
As an example, a method can alter structure of material in a manner
that allows for mechanical bonding of ceramic dispersoids within
powder particulates, which may provide for strengthening of a solid
consolidated at least in part from the powder.
[0253] As an example, a method can include increasing thermal
stability of bulk alloy synthesized through application of powder
metallurgy, for example, by introduction of second phase particles
(e.g., that increase drag).
[0254] As an example, a method can process material to increase
strength; retain and/or improve ductility or elongation to failure;
promote distinct plastic deformation after thermal treatment; abet
strain hardening through dislocation strengthening; increase
stiffness of consolidated bulk solid processed via one or more
thermal treatments; and/or resist initiation of a crack by blunting
of crack tips, for example, if a crack initiation event in a matrix
occurs or, for example, if a crack is nucleated at a tri-axial
stress state.
[0255] As an example, a method can include processing material to
provide structural support, for example, by preventing ceramic
particulate or reinforcement material to be bisected by dislocation
transport or de-cohesion from a matrix during plastic deformation.
Such a method may impart a mechanism that acts at least in part due
to mechanical bonding to powder particulate interiors during a SPD
process.
[0256] As an example, a thermal treatment (e.g., one or more of
solution annealing, ageing, etc.) may be applied during and/or
after formation of a consolidated solid from a blend of un-milled
gas atomized powder with cryomilled gas atomized (GA) powder. As an
example, an un-milled GA powder can be a water reactive powder. As
an example, an un-milled GA powder can be formed of a melt of a
heat treatable aluminum alloy series (e.g., consider 6XXX and/or
7XXX series). As an example, a cryomilled GA powder can be water
reactive powder (e.g., degradable in an aqueous environment). As an
example, a cryomilled GA powder can be formed of a melt of a heat
treatable aluminum alloy series (e.g., consider 6000, 7000 series).
As an example, a blend can be stabilized by ceramic particulates
(e.g., SiC, B.sub.4C, Al.sub.2O.sub.3, etc.) to produce a metal
matrix composite (MMC). In such an example, addition of ceramic
particulates may be before cryomilling or, for example, during
blending of un-milled and cryomilled GA powders.
[0257] As an example, a method can include blending GA powders that
can have different, close or similar peak age properties and
thermal cycles.
[0258] As an example, a method can include solution annealing of a
bulk solid consolidated from blended cryomilled and un-milled
powders. In such an example, solution annealing may aim to put
un-milled component(s) (e.g., coarse grained) into solution (e.g.,
for a set time duration) while retaining structure of highly
thermally stable cryomilled (e.g., nano grain) counterparts; noting
that some grain growth may occur in nano-cryomilled grains, for
example, transforming them to nano and/or ultra-fine duplex grains,
which may abet additional ductility post thermal treatment.
[0259] As an example, a method can include applying a thermal
treatment that develops intermetallic precipitates where
dispersoids "halo" coarse particulates, for example, pinning them
to provide for thermal stability, strength, improved stiffness,
improved elongation to failure, strain hardening and/or distinct
plastic deformation. As an example, a precipitate hardened (PH)
alloy may provide a mechanism of crack blunting, for example, if a
crack is initiated in a matrix while increasing stiffness. Such an
approach may help to enhance potential shear failure of high
strength UFG and/or nano alloy with less ductility.
[0260] As an example, a method can include ageing of a solution
annealed solid, which may induce intermetallic precipitation and
thereby increase thermal stability, strength, stiffness, retain or
improves ductility, and/or promote crack arresting properties.
[0261] As an example, a component may include a high strength water
reactive alloy processed using one or more powder metallurgy (PM)
processes. In such an example, the component may experience
improvement of one or more mechanical properties when deployed in a
wellbore, for example, due to heat energy (e.g., in situ thermal
treatment). In such an example, the component may be
degradable.
[0262] As an example, a component may degrade upon exposure to
water in an aqueous environment and may strengthen upon exposure to
heat energy. A degradation mechanism and a strengthen mechanism may
act simultaneously, sequentially, etc. As an example, strengthening
may occur over a first period of time and degradation may occur
over a second period of time. In such an example, an overlap may
exist between the first period of time and the second period of
time. As an example, a component may be utilized in an operation
where strengthening and degradation mechanisms impart the component
with characteristics that benefit a pre-operation phase, an
operation phase and/or a post-operation phase.
[0263] As an example, a method can include blending powders and
consolidating the blended powders to produce a solid. Such a solid
may then undergo natural ageing when exposed to wellbore
conditions, which may, for example, improve its mechanical
properties over time. For example, a component may achieve a peak
age condition with tailored dissolution and adequate ductility for
load bearing applications.
[0264] As an example, powder metallurgy can include one or more of
production of powder; compaction of powder by forming or molding;
sintering of compacted powders; and machining of sintered
articles.
[0265] As an example, a metal powder may be manufactured via one or
more techniques, for example, depending on type of metal and alloy
and desired properties. For example, a powder may be manufactured
by reduction of oxides and other chemical techniques; atomization
of metallic melts; pulverization of solids; electrolysis of water
solutions or molten salts; etc.
[0266] As an example, dense particles of different chemical
composition may be obtained by atomizing molten metal or alloys.
For example, a metal stream can be atomized by process that may
include one or more of atomizing in water, air, or an inert gas
(e.g., argon or nitrogen).
[0267] As an example, a powder may be screened and, for example,
subject to heat under a reducing atmosphere (e.g., consider
surfaces of particles that are oxidized).
[0268] As an example, an atomization process may be employed to
obtain one or more alloy powders, which may include an even
distribution of alloying metals in the volume of each particle.
[0269] As an example, a PM alloy may circumvent segregation
associated with ingot metallurgy (IM) product (casting etc.), where
cooling from a molten state tends to be relatively slow, which may
be detrimental to workability, etc.
[0270] In a PM process, an increased cooling rate may be employed
compared to an IM process where, for example, the increased cooling
rate may result in an extension of solid solubility limits that can
lead to larger volume fractions of finer second-phase particles
and/or formation of metastable phases.
[0271] As an example, a PM process may produce relatively
homogeneous powder particles with substantial uniformity and with
fine microstructure. Such characteristics may result enhanced
mechanical properties.
[0272] As an example, an extension of phase fields and creation of
additional phases can relate to supercooling, as achieved via one
or more powder metallurgy techniques. As an example,
microstructural refinement can occur in part due to reduced
diffusion distances.
[0273] As an example, rapid cooling via a PM process can result in
an increased tolerance to trapped elements (e.g., compared to
material obtained via an IM process). For example, in a PM process,
material may experience reduced segregation, especially as to sites
such as grain boundaries. If a consolidated bulk alloy is made by
hot isotropic pressing (HlPing) of particulate material(s), a lack
of texture can result in a homogenous solid (e.g., in contrast to a
highly textured IM product). As an example, a PM approach can also
allow for addition of one or more powders that may have different
compositions, for example, at a loose powder stage. In such an
example, microstructures and mechanical properties may be tailored
(e.g., before, during or after one or more processes). As an
example, a nanostructured alloy produced via a PM processing route
can exhibit ultra-high strength, increased modulus, etc.
[0274] As an example, a method can include blending powders from
different alloys where, for example, an alloy may be age-hardenable
or non-age-hardenable and/or degradable or non-degradable. As an
example, an aluminum alloy may be selected from the 5000 series or
from the 7000 series. As an example, a blend of powders can include
particles with nanocrystalline grains. As an example, a blend of
powder can include milled particles, for example, mechanically
milled particles (e.g., consider cryomilling). As an example, a
blend of powders can include one or more dispersoids. As an
example, a blend of powders may include or may be formed to include
a metal matrix composite (MMC). As an example, a blend of powders
may be consolidated to form a component that can be subject to
direct ageing where the component responds to direct ageing by an
alteration in one or more mechanical properties. In such an
example, direct ageing may be or include naturally ageing at one or
more wellbore temperatures.
[0275] As an example, a method can include refining grains and
developing a nano to ultrafine grained microstructure through rapid
solidification into powder. In such an example, the powder may be
consolidated to form a component that may exhibit, for example,
increased strength (e.g., via Hall-Petch strengthening); and/or
increased ductility (e.g., by abetting grain boundary sliding, thus
possibly making a treated alloy high strain rate superplastic,
resulting in better formability and working); increased thermal
stability (e.g., forming the component via a powder metallurgy
route, optionally introducing second phase particles (e.g., for
drag)).
[0276] As an example, a method can include tailoring dissolution of
a component. For example, such a method may include consolidating
blended powders of one or more non-degradable alloys with one or
more degradable powders.
[0277] As an example, a method can include producing a high
strength water reactive alloy via one or more PM processes. In such
an example, the alloy may be formed into a component. As an
example, such a component may be deployed into an environment
where, for example, improvement of mechanical properties occurs for
at least a period of time in the environment. For example, the
component may strengthen, harden, etc., when deployed in a wellbore
due in part to natural ageing in wellbore conditions and the
component may degrade when exposed to certain wellbore
conditions.
[0278] As an example, a method can include blending of water
reactive or degradable powder with one or more other powders where
the water reactive or degradable powder is in a range of about 5
percent to about 95 percent of the weight of a blend. In such an
example, a powder may be an age-hardenable non-degradable powders
(e.g., consider aluminum 6000 and 7000 series); may be a strain
hardenable non-degradable powders (e.g., consider aluminum 5000
series, etc.); may be a powder that includes highly thermally
stable nanocrystalline grains processed by cryomilling; may be a
powder that includes highly thermally stable nanocrystalline grains
processed by cryomilling that are further stabilized by dispersoids
(e.g., SiC, B.sub.4C, Al.sub.2O.sub.3, etc.), for example, to
produce a metal matrix composite (MMC); etc.
[0279] As an example, a method can include direct ageing of a solid
formed by consolidating a blend of powders or a processed blend of
powders to improve mechanical properties of the solid at one or
more wellbore temperatures.
[0280] As an example, a method can include partial solution
annealing of a solid formed at least in part via consolidation of a
blend of powders. In such an example, a duration may be selected
for solution annealing that aims to put coarse grained alloying
particulates into solution while retaining a substantial amount of
highly thermally stable particulates with nanocrystalline grains;
noting that some grain growth may be expected for nanocrystalline
grains. Such a method may optionally include deploying the
consolidated solid (e.g., as a component) and subsequent ageing of
the consolidated solid (e.g., as a component) at wellbore
conditions and/or naturally when deployed in a wellbore. In such an
example, the solid may undergo precipitate hardening as a
response.
[0281] As an example, a method may produce a component at least in
part via consolidation of a blend of powders where the component
exhibits one or more of increased strength and ductility; a
tailored dissolution rate; inter-granular corrosion and cracking as
degradation mechanism; galvanic coupling between dissimilar powders
to promote degradation; increase thermal stability; and continuous
improvement of mechanical properties when deployed in a wellbore
(e.g., due to thermal effects).
[0282] As an example, a method can include blending of water
reactive or degradable powder with one or more age-hardenable
non-degradable powders (e.g., consider 6000 and 7000 series
aluminum alloys) to produce a high strength water reactive alloy
through one or more PM processes. In such an example, a component
formed by the produced alloy may exhibit continuous improvement of
mechanical properties when deployed in a wellbore, for example, by
allowing the produced alloy to naturally age in wellbore
conditions.
[0283] As an example, a water reactive alloy and an age hardenable
alloy (e.g., consider a 7000 series aluminum alloy such as 7075)
may be age-hardenable and may reach peak age conditions when heat
treated at a set temperature for a given time duration.
[0284] As an example, a blend may include a blend ratio of between
about 0.05 to about 0.95 of degradable material to and
age-hardenable material. In such an example, a component formed
from the blend may be direct age-hardenable at one or more wellbore
temperatures, which may augment mechanical properties. In such an
example, augmented mechanical properties may exist for a particular
duration of time and be beneficial to performance of the component
in a wellbore; thereafter, a degradation mechanism may degrade the
component.
[0285] As an example, a method can include blending of water
reactive or degradable powder with one or more strain hardenable
non-degradable powders where the water reactive or degradable
powder is in a range of about 5 percent to about 95 percent of the
weight of a blend. In such an example, a strain hardenable
non-degradable powder may include an aluminum alloy (e.g., consider
a 5000 series alloy, etc.). In such an example, a resulting blend
may be processed to form a component. For example, consider a
component made of a high strength water reactive alloy through one
or more PM processes where the component may be deployed in an
environment that promotes ageing. As an example, consider such a
component undergoing continuous improvement of mechanical
properties for a period of time when deployed in a wellbore (e.g.,
naturally ageing under wellbore conditions).
[0286] As an example, a component may include a water reactive
alloy that is age-hardenable and a strain hardenable alloy. In such
an example, when heat treated at a set temperature (e.g., a
wellbore temperature) for a given time duration, the strain
hardenable alloy may provide for work hardening under strain beyond
its yield to allow the component to perform under desired
conditions.
[0287] As an example, a blend may include a blend ratio of between
about 0.05 to about 0.95 of degradable and age-hardenable material
and one or more other materials, a direct age hardenable response
at wellbore temperatures can be achieved to augment the mechanical
properties, further supported by strain hardening of the one or
more other materials.
[0288] As an example, a method can include blending of water
reactive or degradable powder with material that includes highly
thermally stable nanocrystalline grains processed by cryomilling.
In such an example, a blend may include a blend ratio of between
about 0.05 to about 0.95 (e.g., water reactive or degradable powder
to other material). In such an example, a component formed using
the blend may exhibit improvement of mechanical properties when
deployed in a wellbore, for example, where naturally ageing occurs
under wellbore conditions.
[0289] As an example, in a component, one or more coarse grained
polycrystalline heat treatable material can age-harden when heat
treated at a set temperature that may be a targeted (e.g.,
predicted or expected) wellbore temperature (e.g., for a given time
duration). In such an example, thermally stable UFG and/or nano
grains can provide for Hall-Petch strengthening. As an example, a
multimodal microstructure can promote grain boundary sliding and
dislocation arrest, which may, for example, result in strengthening
(e.g., at UFG and/or nano grain interfaces). Such strengthening may
result in better ductility of component.
[0290] As an example, a method can include blending water reactive
or degradable powder with material that includes highly thermally
stable nanocrystalline grains processed by cryomilling and
optionally further blending dispersoids (e.g., SiC, B.sub.4C,
Al.sub.2O.sub.3, etc.), which may produce a metal matrix composite
(MMC).
[0291] As an example, a MMC may include a mechanism of crack
blunting, for example, if a crack is initiated in the matrix, such
a mechanism may act to blunt the crack (e.g., tip of the crack).
Such a mechanism may help to enhance potential shear failure of a
high strength UFG and/or nano alloy with less ductility.
[0292] As an example, a method can include producing a high
strength water reactive alloy through one or more PM processes
where improvement of its mechanical properties may occur when
deployed in a wellbore, for example, by allowing a component formed
of the alloy to be partially solution annealed for a short duration
to put coarse grains into solution while retaining highly thermally
stable nanocrystalline grains; noting that some grain growth of the
nanocrystalline grains may be expected. As an example, a method can
include ageing of a partially solution annealed component, for
example, to yield higher strength than as a consolidated alloy or
direct aged alloy.
[0293] FIG. 13 shows an example plot 1300 of component dimension
versus time of degradation for various temperatures and an example
of an assembly 1310 that includes components that may be made by
consolidating particulate materials. As indicated, degradation of a
component may be determined by a physical characteristic of the
component and an environmental condition such as, for example,
temperature. For example, fluid at a temperature of about 120
degrees C. may cause a component to degrade more rapidly than fluid
at a temperature of about 66 degrees C. As an example, a component
may be constructed to include one or more layers where at least one
layer includes a degradable material, which may include a dimension
(e.g., thickness, etc.) that is based at least in part on
information such as the information of the plot 1300 of FIG.
13.
[0294] As an example, the assembly 1310 may include one component
that degrades at a rate that differs from another component. For
example, a plug 1312 (e.g., a ball, etc.) may degrade more rapidly
than a plug seat 1314 (e.g., a ring that can include a plug seat
and that may act to locate the plug seat). As shown in FIG. 13, the
assembly 1310 can include a plurality of pieces where such pieces
may be formed according to desired dissolution rate, strength
and/or ductility.
[0295] FIG. 14 shows an example of a method 1400 that includes
atomizing material 1410 in an inert gas atomization system with,
for example, a cyclone separator for separating atomized particles
and gas 1420. In the method 1400, powder, as atomized and
separated, may be subjected to cryomilling 1430, for example, in
liquid nitrogen. In such an example, a powder mass ratio of about
30:1 may be used and an agent such as stearic acid (e.g., at about
0.2 weight percent) may be introduced. As shown in FIG. 14, the
method 1400 can include hot isostatic pressing (HIPing) 1440 of the
cryomilled powder. The example method 1400 can include hot
extruding 1450 of the hot isostatic pressed (HIPed) cryomilled
powder, for example, to produce hipped bulk material that may then
be subjected to, for example, heat treating 1460.
[0296] As an example, a material that includes aluminum and one or
more elements that impart degradability may be spray-atomized. The
resulting spray-atomized powder may have a particle size less than
about 150 microns, which may be mechanically milled in liquid
nitrogen (e.g., cryomilling), for example, to reduce the
micron-sized grains in the atomized powder to nanocrystalline size.
The nanograined cryomilled particulates may be subsequently hot
isostatic pressed (HIPed or hipped) and extruded at a temperature
of about 473 K to produce a bulk ultra-fine grain (UFG)
material.
[0297] As an example, a process may introduce dispersoids that act
to inhibited grain growth and/or to pin grains. For example, a
method that includes gas atomizing and/or cryomilling may introduce
one or more types of dispersoids. The presence of such dispersoids
can contribute to UFG stability in consolidated nanocrystalline
materials.
[0298] As an example, a method may include processing a material
below its incipient melting temperature. For example, consider an
alloy with an incipient melting temperature of about 340 degrees C.
Such a material may be processed at a lesser temperature where such
processing introduces severe plastic deformation (SPD).
[0299] As mentioned, a material may be formed of a plurality of
alloys. For example, consider the data of Table 2 below, which
indicates application of severe plastic deformation for materials
that include one or more of 5083 Al and 7075 Al. In such an
example, the resulting properties indicate that a method can
include tailoring, for example, to meet one or more desired
properties of at least a portion of component. For example,
consider the 25/75, 50/50 and 75/25 examples of 5083/7075, which
provide for different ultimate tensile strengths (UTS), as
presented in units ksi. Table 2 also shows data for percent
elongation (%e), which may be considered a measure of ductility.
Accordingly, as shown in Table 2, severe plastic deformation may be
applied to a mixture of alloys to tailor strength and/or
ductility.
TABLE-US-00002 TABLE 2 Tailored Material Properties 5083 Al 7075 Al
UTS % SPD AR % SPD AR ksi % e 100 x 47.4 20 100 x 96 10 100 x 56.5
23 100 x 77 7 25 x 75 x 58 9.3 50 x 50 x 61.2 7.2 75 x 25 x 68
9.3
[0300] As to a SPD process such as ECAP, FIG. 15 shows an example
of a method 1500 that includes a provision block 1510 for providing
material, a provision block 1520 for providing a die that includes
a channel, a passage block 1530 for passing the material through
the channel of the die multiple times, and a formation block 1540
for forming a part.
[0301] FIG. 16 shows an example of a method 1600 that includes
ECAP. As shown, a die 1602 with a channel 1603 is provided along
with material 1604. In an introduction block 1610, the material
1604 is introduced to the channel 1603 of the die 1602. In a first
pass block 1620, the material 1604 is passed through the channel
1603 of the die 1602 to expose the material 1604 to deformation to
produce deformed material 1605. In another introduction block 1630,
the material 1605 is rotated about a longitudinal axis (e.g., about
90 degrees) and introduced to the channel 1603. In a second pass
block 1640, the material 1605 is passed through the channel 1603 of
the die 1602 to expose the material 1605 to deformation to produce
deformed material 1606. In another introduction block 1650, the
material 1606 is rotated about a longitudinal axis (e.g., about
another 90 degrees for a total of 180 degrees from the introduction
block 1610) and introduced to the channel 1603. In a third pass
block 1660, the material 1606 is passed through the channel 1603 of
the die 1602 to expose the material 1606 to deformation to produce
deformed material 1607.
[0302] As an example, the material 1604 may be stock material, for
example, a bar, a rod, etc. In the example method 1600, the
resulting material 1605, 1606 or 1607 may be processed material,
for example, as a processed bar or a processed rod. As an example,
the processed material may be machined. As an example, the
processed material may be machined to form a part. As an example, a
part may be a ball, a plug, a plug tool, a portion of a tool,
etc.
[0303] FIG. 17 shows an example of an assembly 1700 that includes a
die 1702 that includes a channel 1703, a forward punch 1705 and a
backward punch 1707. As shown powder 1710 can be introduced to the
channel 1703 where the powder 1710 may be passed through the
channel 1703 to deform the powder to form deformed powder 1712.
[0304] As an example, the channel 1703 may include an entry portion
and an exit portion where the forward punch 1705 is received at
least in part by the entry portion of the channel 1703 and where
the backward punch 1707 is received at least in part by the exit
portion of the channel 1703. As an example, a method can include
controlling at least one of a force applied to a forward punch and
force applied to a backward punch.
[0305] FIG. 18 shows an example of a die 1802 that includes a
channel 1803. As shown, the die 1802 includes various dimensions
including an x dimension and a y dimension, as well as an angle
.phi.. As shown, a workpiece 1810 may be passed through the channel
1803. In the example of FIG. 18, the channel diameter per the
dimension x is equal to the horizontal displacement between the two
center lines of the channels, per the dimension y.
[0306] FIG. 19 shows an example of SMAT equipment 1910, which
includes a chamber 1912 for a sample 1914 and a vibration generator
1916 that can vibrate particles 1918 that can impact the sample
1914. FIG. 19 also shows a simplified schematic illustration of a
SMAT process 1920 where one of the particles 1918 impacts the
sample 1914 to cause localized plastic deformation.
[0307] As an example, SMAT equipment may include an ultrasonic horn
with an ultrasonic (e.g., consider a frequency of about 20 kHz or
more, etc.) transducer. Such equipment may be provided with balls
and a mount or mounts for one or more workpieces. During operation,
the ultrasonic energy can drive the balls to cause collisions
between the balls and the surface(s) of the one or more workpieces.
SMAT may be considered to be a regionally selective process. Other
regionally selective processes can include, for example, shot or
hammer peening; noting that kinetic energy of balls in SMAT may
exceed that of shot peening.
[0308] As an example, a method can include employing SMAT to form a
structural gradient within a material, which may be a stock
material (e.g., a billet, etc.) and/or a component. In such an
example, a near surface layer of the material may be of a finer
structural size than a core of the material. As an example, a near
surface layer may be nanostructured at least in part via an SMAT
process.
[0309] As an example, a method may employ an SMAT process that
includes bombarding one or more surfaces of material with particles
where a driver or drivers operate at frequencies of between about
50 Hz and about 25 kHz to propel the particles. In such an example,
a suitable particle size may be selected, for example, to control
kinetic energy per impact. As an example, consider particle sizes
in a range from the order of nanometers to about tens of
millimeters. As an example, density and size (e.g., mass) and
optionally shape of particles may be selected to alter impact on a
material surface, which can affect depth of a compressive layer
(e.g., a nanostructured layer). As an example, particles made of,
for example, ceramic, steel and chromium, etc., may be
employed.
[0310] As an example, during an SMAT process, a material may be in
a gas environment and/or in a substantial vacuum. As to a gas
environment, a gas may include an element that may form a
passivation layer with one or more elements of the material. For
example, consider oxygen forming an aluminum oxide. As an example,
oxides may exist on the surface of a material or within a material
where an SMAT process may interact with such oxides.
[0311] As an example, an SMAT process may include one or more of a
heater, an insulator and a cooler. As an example, an SMAT process
may include a temperature controller that can control one or more
temperatures (e.g., chamber, workpiece, etc.). As an example, an
SMAT process may be implemented in a cryogenic environment (e.g.,
consider a cryogenically cooled chamber).
[0312] As an example, SMAT equipment may include one or more
mechanisms for suspending material, moving material (e.g.,
translating and/or rotating), introducing material, removing
material, etc. As an example, where material has a shape with an
"inside" surface (e.g., consider a tube, etc.), SMAT equipment may
be configured to bombard the inside surface with particles and, for
example, optionally be configured to bombard another surface of the
material with particles (e.g., optionally particles of different
characteristics, different velocities, different angles of flight,
etc.). As an example, SMAT equipment may be configured to bombard
an interior surface of a workpiece and/or an exterior surface of a
workpiece.
[0313] As an example, a SMAT process may be employed to alter near
surface properties of a material. In such an example, a depth of an
SMAT altered layer may be of the order of up to several
millimeters. As an example, a SMAT process may be employed to
harden a layer of a component, which may, for example, increase
durability of the component. In such an example, consider a
degradable component that may include a seat that seats another
component where SMAT processing acts to increase the durability of
the seat of the degradable component without substantially
affecting degradability characteristics of the component.
[0314] As an example, SMAT equipment may process a seat in a
directional manner such that a seating surface is bombarded while
one or more other surfaces remain unaffected. In such an example,
the seating surface may be more durable than the one or more other
surfaces and the degradation characteristics of the seat may remain
substantially unaffected by the SMAT processing (e.g., the one or
more unaffected surfaces retain their degradation
characteristics).
[0315] As an example, a plug may be processed using SMAT equipment.
For example, a dart plug may be directional with a head and vanes.
In such an example, a portion of the head may be subject SMAT to
increase its hardness within a near surface layer. For example, a
front facing portion (e.g., a lead portion) may be subjected to
bombardment via an SMAT process.
[0316] As an example, a plug may be processed using SMAT equipment,
for example, to subject an entire exterior surface of the plug to
bombardment. In such an example, a near surface layer of the plug
(e.g., a ball, etc.) may be hardened and, for example, the
degradation characteristics of the near surface layer may be
altered (e.g., compared to an adjacent interior layer). Such
alteration of degradation characteristics may act, for example, to
slow down dissolution rate of the near surface layer. However, once
the near surface layer has dissolved, the dissolution rate may, for
example, increase (e.g., per characteristics of the adjacent
interior layer when it becomes exposed).
[0317] As an example, a degradable component can include a near
surface layer with a hardness that is greater than an adjacent
interior layer. In such an example, the near surface layer may be
of a thickness of approximately 5 mm or less, optionally in a range
from about 0.5 mm to about 3 mm. As an example, a near surface
layer may span an entire degradable component or may span a portion
(e.g., a region) of a degradable component.
[0318] As an example, material may be processed via ECAP followed,
directly or indirectly, by SMAT. In such an example, grain
refinement may occur via ECAP and further grain refinement may
occur in a near surface layer of the material via SMAT.
[0319] As an example, a method can include adding scandium,
thallium or other element(s) to material that includes aluminum. In
such an example, the mixture may be subjected to one or more SPD
processes. As an example, scandium may be added to a powder
material that includes aluminum to form a mixture that can then be
subjected to ECAP. In such an example, the number of ECAP passes
may optionally be reduced with scandium versus without scandium. As
an example, scandium may enhance grain refinement of material and,
for example, allow for formation of finer grains when compared to
such material without scandium.
[0320] As an example, where a bulk material includes dispersoids, a
process such as SMAT may be applied to alter a near surface layer
of the bulk material. In such an example, structures in the near
surface layer may be refined, including breaking of dispersoids
into finer structures.
[0321] As an example, material may be processed via one or more SPD
processes to alter creep of a component formed at least in part
from such material. For example, SPD processing may result in a
harder component that exhibits less creep when subject to loading
during utilization of the component. In such an example, consider a
component such as, for example, a plug, a seat for a plug, etc.
[0322] FIG. 20 shows an example of a life cycle 2010. In the life
cycle 2010, various times are illustrated as to stages or phases.
For example, material may be processed via one or more SPD process,
a blend may be made and be processed via one or more SPD process
and/or a blend of materials may be consolidated, optionally via one
or more SPD process and/or subjected to one or more SPD process
after consolidation (e.g., consider SMAT, etc.). A component, as
consolidated, may be deployed, utilized and then degraded. As an
example, the life cycle 2010 may optionally include ageing, for
example, to heat treat material, consolidated material, etc. In the
life cycle 2010, ageing may occur before, after and/or during
deployment of a component and, for example, optionally into
utilization. Thereafter, the component may degrade.
[0323] As an example, consider a scenario where a downhole
environment has a temperature of about 20 degrees C. (e.g., about
70 degrees F.). Such a temperature may achieve sufficient ageing,
however, on a time scale that is not practical and/or economical.
In such an example, artificial ageing may be employed, for example,
at a temperature greater than about 20 degrees C. (e.g., about 70
degrees F.). As an example, consider artificial ageing at a
temperature greater than about 40 degrees C. (e.g., about 100
degrees F.).
[0324] As an example, ageing, whether artificial and/or downhole,
may occur at temperatures greater than about 20 degrees C. (e.g.,
about 70 degrees F.) to about 230 degrees C. (e.g., about 450
degrees F.). As an example, ageing may occur according to a
time-temperature profile, which may include one or more time
periods (e.g., surface and/or downhole) and one or more different
temperatures (e.g., surface/artificial and/or downhole). As an
example, where a field operation occurs in a cold environment
(e.g., less than about 10 degrees C. or about 50 degrees F.),
artificial ageing may employ a heater and optionally a heat chamber
(e.g., an oven). As an example, where a field operation occurs in a
warm or hot environment (e.g., greater than about 10 degrees C. or
about 50 degrees F.), ageing may occur for one or more components
prior to deployment to a downhole environment where such ageing may
include, for example, exposure to sunlight, placement in a chamber
exposed to sunlight, etc. As an example, ageing may include ageing
via solar energy (e.g., directly and/or indirectly).
[0325] As an example, a material may "intentionally" fail via
liquid-metal embrittlement, for example, as in an alloy that
includes gallium and/or indium. As an example, a degradable
material may include an alloy or alloys and possess phases that may
be susceptible to creep (e.g., superplastic) deformation (e.g.,
under intended force, etc.), possess phases that are brittle (e.g.,
which may rupture in response to impact, etc.).
[0326] As an example, a component may be formed of material that
provides a desired degradation rate and desired mechanical
properties (e.g., strength, etc.). As an example, a degradation
rate may depend upon one or more conditions (e.g., temperature,
pressure, fluid environments), which may be exist in an environment
and/or may be achieved in an environment (e.g., via one or more
types of intervention).
[0327] As an example, a degradable material may be suitable for use
in an operation that may include stages. For example, consider a
cementing operation, a fracturing operation, etc. As explained, a
process may be associated with a completion where portions of the
completion are constructed, managed, altered, etc. in one or more
stages. For example, cementing may occur in stages that extend
successively deeper into a drilled borehole and, for example,
fracturing may occur in stages.
[0328] As an example, a method can include subjecting a material or
materials to severe plastic deformation (SPD). As an example, a
method can include consolidating powder via a process that includes
severe plastic deforming (e.g., an SPD process or processes). As an
example, a method can employ one or more metalworking techniques
that involve introducing very large strains that may provide for
complex stress state or high shear, resulting in a high defect
density and equiaxed ultrafine grain (UFG) sizes (e.g., with a
dimension less than about 500 nm or, for example, less than about
300 nm) and/or nanocrystalline (NC) structures (e.g., with a
dimension less than about 100 nm).
[0329] As an example, a method can include equal channel angular
pressing (ECAP). As an example, a method can include cyromilling.
As an example, a method can include employing SMAT. As an example,
a method can include one or more of ECAP, cyromilling, SMAT, HIP,
VHP, HPT, etc. (see, e.g., FIG. 7).
[0330] As an example, a material may be processed to form a
degradable component or a portion of a component that is
degradable. For example, a method may include processing material
that includes a degradable alloy to strengthen the material. In
such an example, the resulting material may be used, for example,
as a component or as a portion of a component in a stage or stages
of a fracturing operation. As an example, such a material may be
used as a component or as a portion of a component in a
tensile-loaded application, for example, consider a bridge plug,
etc. As an example, a bridge plug may be a tool, for example, a
bridge plug tool. Such a tool may include one or more seats, which
may, for example, provide for seating of one or more plugs.
[0331] As an example, a material produced via a method that
includes ECAP may be of a size that includes a cross-sectional
dimension of the order of inches. For example, consider a material
with a cross-sectional dimension of the order of about 10 inches or
less (e.g., about 25 cm or less). As an example, a material
produced via a method that includes ECAP may form stock that can be
machined into a spherical form, a plug form, a plug tool form, a
seat form, a valve form, or other borehole tool form, etc. In such
an example, the resulting component may include grains of
relatively homogenous size and shape. Where the material is
degradable in an environment, the degradation mechanics may be
predictable via one or more models, for example, more so than a
material produced without ECAP that includes a less homogeneous
grain size and shape and, for example, larger grain sizes.
[0332] As an example, a method can include casting. As an example,
a method can include forming a material from chips. As an example,
a method can include forming a material from powder. As an example,
a method can include forming a material from powder and chips. As
an example, a method can include forming a near-net strengthened
ball. As an example, a method can include forming a near-net
strengthened dart. As an example, a method can include increasing
strength of a material via processing that increases homogeneity of
the material. As an example, a method can include processing that
enhances degradability, for example, uniformity of degradation
(e.g., CPL/PSG/WS).
[0333] As an example, a method can include reducing porosity in an
alloy through severe plastic deformation (SPD). As an example, such
an alloy may be a degradable alloy.
[0334] As an example, a material may be embedded with a material
that is one or more of active, passive, chemical, functionalized,
etc. As an example, an embedded material may alter thermal
conductivity, electrical conductivity, etc. of a bulk phase of the
material. As an example, an embedded material may operate at a
grain boundary or grain boundaries.
[0335] As an example, a process material may be formed as part of a
cable. For example, consider a power cable for an electric
submersible pump. In such an example, the processed material may be
armor, a strength member, a barrier, an insulator, etc.
[0336] As an example, a component formed from processed material
may be a bridge plug. A bridge plug may be a downhole tool (e.g., a
type of plug tool) that can be located and set to isolate a lower
part of a wellbore. As an example, a bridge plug may be permanent,
degradable, retrievable, etc. As an example, a bridge plug may be
tailored to enable a lower wellbore to be permanently sealed from
production or temporarily isolated, for example, from a treatment
conducted on an upper zone.
[0337] A part, a component, etc. constructed of a processed
material or processed materials may include be a fluid sampling
bottle, a pressure housing, a pump shaft, a cable (e.g., wireline,
a power cable, etc.), a bridge plug tool, a projectile (e.g., a
drop ball, a dart, etc.), a drill stem stabilizer, etc.
[0338] As an example, a method can include making a centralizer
using processed material. For example, a centralizer may exhibit
enhanced wear resistance that can reduce surface damage and
corrosion fatigue on a borehole assembly (e.g., BHA), for example,
thereby increasing BHA lifetime. As an example, via improved
abrasion wear resistance of a centralizer, reliability may be
improved, for example, when drilling over extended deviated
lengths.
[0339] As an example, where machining of stock material occurs,
machine swarf (e.g., chips, etc.) may be processed. Swarf, also
known as chips or by other process-specific names (such as
turnings, filings, or shavings) may be pieces of material resulting
from machining or similar subtractive (material-removing)
manufacturing processes. As an example, a method can include
recycling swarf. As an example, a method can include processing
swarf from processed stock that is machined to form one or more
components. In such an example, the processed stock may be a
degradable material that is used to form one or more degradable
components (e.g., parts, etc.). The swarf may be processed to form
processed stock and then machined to form one or more parts. As an
example, swarf may be subjected to cryomilling and/or one or more
other processes.
[0340] As an example, a processed material may be machined or
otherwise formed as a centralizer or as a part of a centralizer. As
an example, one or more blades, one or more springs (e.g., bow
springs), etc. may be formed using a processed material (e.g.,
processed via a severe plastic deformation process). As an example,
a centralizer may be optionally formed from ECAP processed
material. For example, consider a method that includes generating
stock processed material with a cross-sectional dimension
sufficient to machine at least a portion of a centralizer
therefrom. In such an example, a bore may be machined into the
stock processed material and, for example, surface protrusions may
be machined (e.g., consider a hydraulic centralizer).
[0341] As an example, a plug tool may include an outer dimension
(e.g., outer diameter) less than about six inches (e.g., less than
about 15 cm). In such an example, a part of the plug tool may be
formed from ECAP processed material. For example, consider a method
that includes generating stock processed material with a
cross-sectional dimension sufficient to machine at least a portion
of a plug tool therefrom. In such an example, a bore may be
machined into the stock processed material and, for example,
appropriate apertures, openings, fittings, etc. may be
machined.
[0342] As an example, a borehole tool may be a tool that is part of
a borehole assembly (e.g., "BHA") or borehole system. As an
example, a BHA may be a lower portion of the drillstring, including
(e.g., from a bottom up in a vertical well) a bit, a bit sub,
optionally a mud motor, stabilizers, a drill collar, a heavy-weight
drillpipe, a jarring devices (e.g., jars) and crossovers for
various threadforms. As BHA may provide force for a bit to break
rock (e.g., weight on bit), survive a hostile mechanical
environment and provide a driller with directional control of a
borehole. As an example, an assembly may include one or more of a
mud motor, directional drilling and measuring equipment,
measurements-while-drilling tools, logging-while-drilling tools or
other borehole tools.
[0343] As an example, a method can include producing stock material
via one or more SPD processes and machining the stock material into
at least one part. In such an example, the stock material can
include an aluminum alloy. For example, consider an aluminum alloy
that includes gallium.
[0344] As an example, a method may include machining stock material
produced via one or more SPD processes to form at least one
degradable part. As an example, a part may be a fracturing
operation plug, which may optionally be a degradable fracturing
operation plug. As an example, a fracturing operation plug may be a
layered plug, optionally including at least one degradable layer.
As an example, a fracturing operation plug may include a core and
one or more layers where at least one of the layers is degradable
and optionally where the core is degradable. As an example,
degradable layers, a degradable core, etc. may differ in properties
in a manner that effects degradability (e.g., with respect to one
or more conditions). As an example, a method may include machining
stock material produced via one or more SPD processes to form at
least part of a borehole tool. For example, consider forming a plug
tool or a portion of a plug tool such as a seat or seats of a plug
tool that may be dimensioned to seat a plug or plugs.
[0345] As an example, an apparatus can include a shape and material
that includes an aluminum alloy that has an average grain size less
than about 1 micron or, for example, less than about 500
nanometers. In such an example, the apparatus may be a degradable
apparatus. As an example, such an apparatus may be a degradable
plug. In such an example, the degradable plug may include aluminum
and gallium and, for example, indium.
[0346] As an example, a method can include producing stock material
via one or more SPD processes where the stock material includes an
alloy that includes an average grain size less than approximately 1
micron (e.g., or less than about 500 nanometers) and machining the
stock material into at least one part of borehole tool. As an
example, a borehole tool may be a tool such as, for example, a tool
operable in a downhole operation. For example, consider a plug as a
tool, a plug tool, a centralizer, a sampling bottle, a wireline, a
slickline, etc.
[0347] As an example, an alloy may include one or more of the
following group 13 elements: aluminum, gallium and indium. As an
example, an alloy may include at least one of the following group 2
elements: magnesium and calcium.
[0348] As an example, a method can include providing particulate
material that includes an aluminum alloy where the aluminum alloy
is at least approximately eighty percent by weight of the first
particulate material and that includes one or more metals selected
from a group of alkali metals, alkaline earth metals, group 12
transition metals, and basic metals having an atomic number equal
to or greater than 31, where the one or more metals selected from
the group total at least approximately two percent by weight of the
particulate material. Such a particulate material may optionally be
blended with one or more other particulate materials. For example,
consider blending with a second particulate material that includes
at least one aluminum alloy selected from a group of series 2000,
5000, 6000, 7000, and 9000.
[0349] As an example, a particulate material can include at least
one basic metal having an atomic number equal to or greater than 31
where, for example, the at least one basic metal having an atomic
number equal to or greater than 31 is at least approximately two
percent by weight of the particulate material.
[0350] As an example, particulate material can include gallium
(e.g., as a basic metal). In such an example, the gallium can be at
least approximately two percent by weight of the particulate
material. In such an example, the presence of gallium may make the
particulate material a degradable material (e.g., degradable in an
aqueous environment). For example, gallium may coat grains (e.g.,
as grain boundary material). As an example, a particulate material
can include indium. As an example, a particulate material can
include gallium and/or indium, which may be present, for example,
at at least approximately two percent by weight of the particulate
material.
[0351] As an example, a particulate material can include at least
one group 12 transition metal selected from a group of zinc and
mercury. As an example, a particulate material can include at least
one of gallium, indium, tin, bismuth, zinc, mercury, lithium,
sodium and potassium.
[0352] As an example, one or more methods described herein may
include associated computer-readable storage media (CRM) blocks.
Such blocks can include instructions suitable for execution by one
or more processors (or cores) to instruct a computing device or
system to perform one or more actions. As an example, equipment may
include a processor (e.g., a microcontroller, etc.) and memory as a
storage device for storing processor-executable instructions. In
such an example, execution of the instructions may, in part, cause
the equipment to perform one or more actions (e.g., consider a
controller to control processing such as ECAP, cryomilling,
machining, forming, cementing, fracturing, etc.). As an example, a
computer-readable storage medium may be non-transitory and not a
carrier wave.
[0353] According to an embodiment, one or more computer-readable
media may include computer-executable instructions to instruct a
computing system to output information for controlling a process.
For example, such instructions may provide for output to sensing
process, an injection process, drilling process, an extraction
process, an extrusion process, a pumping process, a heating
process, etc.
[0354] FIG. 21 shows components of a computing system 2100 and a
networked system 2110. The system 2100 includes one or more
processors 2102, memory and/or storage components 2104, one or more
input and/or output devices 2106 and a bus 2108. According to an
embodiment, instructions may be stored in one or more
computer-readable media (e.g., memory/storage components 2104).
Such instructions may be read by one or more processors (e.g., the
processor(s) 2102) via a communication bus (e.g., the bus 2108),
which may be wired or wireless. As an example, instructions may be
stored as one or more modules. As an example, one or more
processors may execute instructions to implement (wholly or in
part) one or more attributes (e.g., as part of a method). A user
may view output from and interact with a process via an I/O device
(e.g., the device 2106). According to an embodiment, a
computer-readable medium may be a storage component such as a
physical memory storage device, for example, a chip, a chip on a
package, a memory card, etc.
[0355] According to an embodiment, components may be distributed,
such as in the network system 2110. The network system 2110
includes components 2122-1, 2122-2, 2122-3, . . . , 2122-N. For
example, the components 2122-1 may include the processor(s) 2402
while the component(s) 2122-3 may include memory accessible by the
processor(s) 2102. Further, the component(s) 2102-2 may include an
I/O device for display and optionally interaction with a method.
The network may be or include the Internet, an intranet, a cellular
network, a satellite network, etc.
CONCLUSION
[0356] Although only a few examples have been described in detail
above, those skilled in the art will readily appreciate that many
modifications are possible in the examples. Accordingly, all such
modifications are intended to be included within the scope of this
disclosure as defined in the following claims. In the claims,
means-plus-function clauses are intended to cover the structures
described herein as performing the recited function and not only
structural equivalents, but also equivalent structures. Thus,
although a nail and a screw may not be structural equivalents in
that a nail employs a cylindrical surface to secure wooden parts
together, whereas a screw employs a helical surface, in the
environment of fastening wooden parts, a nail and a screw may be
equivalent structures. It is the express intention of the applicant
not to invoke 35 U.S.C. .sctn.112, paragraph 6 for any limitations
of any of the claims herein, except for those in which the claim
expressly uses the words "means for" together with an associated
function.
* * * * *