Degradable metal matrix composite

Abstract

The present invention relates to the composition and production of an engineered degradable metal matrix composite that is useful in constructing temporary systems requiring wear resistance, high hardness, and/or high resistance to deformation in water-bearing applications such as, but not limited to, oil and gas completion operations.

Description

TECHNICAL FIELD OF THE INVENTION

The present invention relates to the composition and production of an engineered degradable metal matrix composite that is useful in constructing temporary systems requiring wear resistance, high hardness, and/or high resistance to deformation in water-bearing applications such as, but not limited to, oil and gas completion operations. In particular, the engineered degradable metal matrix composite of the present invention includes a core material and a degradable binder matrix, and which composite includes the following properties: A) repeating ceramic particle core material of 20-90 vol. %, B) degradable metallic binder/matrix, C) galvanically-active phases formed in situ from a melt and/or added as solid particles, D) degradation rate of 5-800 mg/cm²/hr., or equivalent surface regression rates of 0.05-5 mm/hr. (and all values and ranges therebetween) in selected fluid environments such as, but not limited to, freshwater, brines and/or fracking liquids at a temperature of 35-200° C., and E) hardness exceeding 22 Rockwell C (ASTM E 18-07). The method of manufacturing the composite in accordance with the present invention includes the preparation of a plurality of ceramic particles, with or without galvanically-active materials such as, but not limited to, iron, nickel, copper, titanium, or cobalt, and infiltrating the ceramic particles with a degradable metal such as, but not limited to, magnesium, aluminum, magnesium alloy or aluminum alloy.

BACKGROUND OF THE INVENTION

The preparation of magnesium and aluminum degradable metal compositions, as well as degradable polymer compositions, has resulted in rapid commercialization of interventionless tools, including plugs, balls, valves, retainers, centralizers, and other applications. Generally, these products consist of materials that are engineered to dissolve or to corrode. Dissolving polymers and some powder metallurgy metals have been used in the oil and gas recovery industry.

While these prior art degradable systems have enjoyed success in reducing well completion costs, their ability to withstand deformation and to resist erosion in flowing fluid or to embed in steel casing are not suitable for a number of desired applications. For example, in the production of dissolving frac plugs, ceramic or steel inserts are currently used for gripping surfaces (to set the plug into the steel casing). Requirements for these grips include: a hardness higher than the steel casing; mechanical properties, including compression strength, deformation resistance (to retain a sharp edge); and fracture toughness that must be sufficient to withstand the setting operation where they are embedded slightly into the steel casing. Other applications such as 1) pump down seats currently fabricated from grey cast iron need to be milled out, and 2) frac balls or cones having very small overlaps with the seat ( 1/16″ or less) currently have limited pressure ratings with dissolvable materials due to limited swaging or deformation resistance of current materials.

For applications such as seats and valve components and other sealing surfaces that are subjected to sand or proppant flow, existing magnesium, aluminum, or polymer alloy degradables have insufficient hardness and erosion resistance. In frac ball applications, metallic and polymer degradable balls deform, swage, and shear in such conditions, thereby limiting their pressure rating in small overlap (e.g., below ⅛″ overlap) applications.

Sintered and cast products of metal matrix ceramic (MMC) plus metallic composites have been used in structural parts, wear parts, semiconductor substrates, printed circuit boards, high hardness and high precision machining materials (such as cutting tools, dies, bearings), and precision sinter molding materials, among other applications. These materials have found particular use in wear and high temperature highly loaded applications such as bearing sleeves, brake rotors, cutting tools, forming dies, and aerospace parts. Generally, these materials are selected from non-reactive components and are designed to not degrade, and the MMC and the cermets are formulated to resist all forms of corrosion/degradation, including wear and dissimilar metal corrosion.

To overcome the limitations of current degradable materials, a new material is required that has high strength, controlled degradation, and high hardness. Ideally, these high hardness degradable components and materials would also be able to be manufactured by a method that is low cost, scalable, and results in a controlled corrosion rate in a composite or alloy with similar or increased strength compared to traditional engineering alloys such as aluminum, magnesium, and iron and with hardnesses higher than cast iron. Ideally, traditional heat treatments, deformation processing and machining techniques could be used without impacting the dissolution rate and reliability of such components.

SUMMARY OF THE INVENTION

The present invention relates to the composition and production of an engineered degradable metal matrix composite that is useful in constructing temporary systems requiring wear resistance, high hardness, and/or high resistance to deformation in water-bearing applications such as, but not limited to, oil and gas completion operations. In one non-limiting embodiment of the invention, the engineered degradable metal matrix composite includes a core material and a degradable binder matrix, and which composite includes the following properties: A) a repeating ceramic particle core material of 20-90 vol. % (and all values and arranges therebetween), B) a degradable metallic binder/matrix of 10-75 vol. % (and all values and arranges therebetween), C) galvanically-active phases formed in-situ from a melt or added as solid particles, D) a degradation rate being controlled to rates of 5-800 mg/cm²/hr. (and all values and ranges therebetween), or equivalent surface regression rates of 0.05-5 mm/hr. (and all values and ranges therebetween) at a temperature of 35-200° C. (and all values and ranges therebetween) in 100-100,000 ppm (and all values and ranges therebetween) water or brines, and E) a hardness exceeding 22 (e.g., 22.01-60 Rockwell C and all values and ranges therebetween). Fluids seen in completion operations and which the composite of the present invention can be used in include 1) freshwater (generally 300-5000 ppm salt content), 2) drilling and completion brines including seawater which are generally chlorides and bromides of potassium, calcium, sodium, cesium, and zinc from about 5000 ppm to as high as 500,000 ppm or more, 3) some formates and acidic fluids, or 4) fluid produced or flowed back from the well formation which can include chlorides and carbonate salts. As can be appreciated, in some cases special fluids can be run in the well formation to cause or trigger the dissolution of the composite of the present invention, or a salt or chemical pills can be added to the fluid to cause or trigger the dissolution of the composite of the present invention. The present inventions also relates to the method of manufacturing the engineered degradable metal matrix composite of the present invention, which method includes the preparation of a plurality of ceramic particles, with or without galvanically-active materials such as, but not limited to, iron, nickel, copper, titanium, or cobalt, and infiltrating the ceramic particles with a degradable metal such as, but not limited to, magnesium or aluminum alloy.

In one non-limiting aspect of the invention, the invention relates to the formation of high hardness, wear-, deformation-, and erosion-resistant metal matrix composite materials that exhibit controlled degradation rates in aqueous media at temperatures that are at least 35° C., and typically about 35-200° C. (and all values and ranges therebetween) conditions. The ability to control the dissolution of a down hole well component in a variety of solutions is very important to the utilization of interventionless drilling, production, and completion tools such as sleeves, frac balls, hydraulic actuated tooling, scrapers, valves, screens, perforators and penetrators, knives, grips/slips, and the like. Reactive materials useful in this invention that dissolve or corrode when exposed to acid, salt, or other wellbore conditions have been proposed for some time. Incorporated by reference are U.S. Pat. Nos. 9,903,010; 9,757,796, and US Publication No. 2015/0239795 which describe techniques for creating and manufacturing dissolvable magnesium alloys through the addition of galvanically-active phases.

To obtain resistance to one type of degradation such as wear, but also to have high susceptibility to another type of corrosion such as aqueous corrosion, a composite containing two distinct phases was found to be required. One phase, being a high hardness phase, is present in large amounts (greater than 30 vol. %, and typically greater than 50 vol. %) of the composite. This high hardness phase provides resistance to wear and erosion and increases the hardness and deformation resistance of the composite. Useful deformation resistance is achieved by a second ceramic phase present in an amount of at least 10 vol. % in the composite. The deformation resistance can be enhanced by use of a higher aspect ratio ceramic phase. Useful hardness increases in the composite can be achieved with greater than 35% volumetric loading of the second ceramic phase, and can be further increased with increasing the loading. By selecting the right materials and controlling their percentages, distribution, and surface areas, novel composites can be fabricated that resist one type of degradation (namely wear or erosion) but are highly susceptible to other types of degradation (aqueous corrosion).

To achieve the desired degradation, galvanically-active phase(s) are required. This is achieved by adding a second phase either as a separate powder blended with the ceramic powder, a coating on the ceramic particles, and/or in situ by solidification or precipitation for the melt or solid solution. For example, when magnesium is selected as a degradable matrix alloy, the galvanically active phase in the magnesium matrix alloy can be formed of 1) iron and/or carbon (graphite) particle additions or coatings on ceramic particles, and/or 2) through the formation of Mg₂M (where M is nickel, copper, or cobalt) -active intermetallics created during solidification from a highly alloyed melt. In terms of effectiveness for increasing corrosion rates, the following ranking can be used: Fe>Ni>Co>Cu, with carbon falling between nickel and copper depending on its structure. In another example, when aluminum or aluminum alloys are selected as the degradable matrix alloy, additions of gallium and/or indium are effective for managing corrosion, and such metals can be added as a coating on the ceramic particles, as intermetallic particles, and/or by adding as a solid solution from an aluminum alloy melt. Additional strengthening phases and solid solution material can be used to accelerate or inhibit corrosion rates. In general, aluminum and magnesium decrease corrosion rates, while zinc is neutral or can enhance corrosion rates. Corrosion rates of 0.02-5 mm/hr. (and all values and ranges therebetween) at a temperature of 35-200° C. for the composite can be achieved in freshwater or brine environments.

When the ceramic content is significant (greater than about 20 vol. %), the ceramic particles begin to block the corrosion process and inhibit the access of the aqueous solution to the degradable metal matrix. A 10-20 times decrease in degradation rates has been observed in a composite that includes 50 vol. % ceramic content. As such, the addition of ceramic content that is greater than about 20 vol. % has been found to result in a non-linear decrease in degradation rates. The decrease is generally more substantial with very fine particles of ceramic material (e.g., less than 100 micron). To compensate for a lower surface area exposed for dissolution due to a large inert loading of ceramic, a much higher dissolution rate in the matrix must be used to generate useful degradation rates. This can be accomplished by substituting more active catalysts (e.g., iron for nickel, nickel for copper), and by reducing the content of inhibiting phases (aluminum or other more cathodic metals). This may be done by moving to a ZK series alloy in magnesium from a WE or AZ series, for example. In general, the degradable matrix alloy and catalyst (galvanically-active phase) is selected to be 5-25 times as active (faster rate) than an equivalent non-composite system.

By selecting the right alloy chemistry and catalyst phase and its content (primarily exposed surface area), degradable MMCs are possible over temperatures ranging from 35-200° C., in low salinity (less than 1000 ppm dissolved solids, and typically 1-5 vol. % dissolved solids, normally KCl, NaCl), and heavy brines (CaCl₂, CaBr₂, ZnBr₂, carbonates, etc.). By reducing galvanically-active phases and adding inhibiting phases, materials having suitable corrosion/degradation rates in acidic media (such as 5 vol. % HCl or formic acid) can also be created.

In summary, the present invention relates to a degradable high hardness composite material that includes 1) plurality of ceramic particles having a hardness greater than 50 HRC and up to 10,000 VHN that forms 20-90 vol. % of the composite, 2) degradable alloy matrix selected from magnesium, aluminum, zinc, or their alloys that forms 10-75 vol. % of the composite, 3) plurality of degradation catalyst particles, zones, and/or regions that are galvanically-active (wherein such particles, zones, and/or regions contain one or more galvanically-active elements such as, but not limited to, iron, nickel, copper, cobalt, silver, gold, gallium, bismuth, lead, carbon or indium metals) and whose content is engineered to control degradation rates of 5-800 mg/cm²/hr. (and all values and ranges therebetween), or equivalent surface regression rates of 0.05-5 mm/hr. (and all values and ranges therebetween) at a temperature of 35-200° C. (and all values and ranges therebetween) in 100-100,000 ppm (and all values and ranges therebetween) water or brines, and 4) ceramic particle content is 25-90 vol. % (and all values and ranges therebetween); to create a composite having a hardness of greater than 22 Rockwell C (ASTM E-18), and typically greater than 30 Rockwell C, and typically up to 70 Rockwell C (and all values and ranges therebetween).

The ceramic or intermetallic particles in the degradable high hardness composite material can be selected from metal carbides, borides, oxides, silicides, or nitrides such as, but not limited to, SiC, B₄C, TiB₂, TiC, Al₂O₃, MgO, SiC, Si₃N₄, ZrO₂, ZrSiO₄, SiB₆, SiAlON, WC, or other high hardness ceramic or intermetallic phases. The particles can be hollow or solid.

The ceramic or intermetallic particles in the degradable high hardness composite material can have a particle size of 0.1-1000 microns (and all values and ranges therebetween), and typically 5-100 microns, and may optionally have a broad or multimodal distribution of sizes to increase ceramic content.

Some or all of the ceramic or intermetallic particles in the degradable high hardness composite material can be shards, fragments, preformed or machined shapes, flakes, or other large particles with dimensions of 0.1-4 mm (and all values and ranges therebetween).

The surface coating on the ceramic or intermetallic particles can include nickel, iron, cobalt, titanium, nickel and/or copper to control dissolution and wetting as well as provide some or all of the galvanic activation. The surface coating on the ceramic or intermetallic particles can include magnesium, zinc, aluminum, tin, titanium, nickel, copper and/or other wetting agent to facilitate melt infiltration and/or particle distribution. The surface coating thickness is generally at least 60 nm and typically up to about 100 microns (and all values and ranges therebetween). The surface coating generally constitutes at least 0.1 wt. % of the coated ceramic or intermetallic particle, and typically constitutes up to 15 wt. % of the coated ceramic or intermetallic particle (and all values and ranges therebetween). The ceramic or intermetallic particles can be coated by a variety of coating techniques (e.g., chemical vapor deposition, wurster coating, physical vapor deposition, hydrometallurgy processes and other chemical or physical methods.

The particle surface of the ceramic or intermetallic particles can be modified with metal particles or other techniques to control the spacing of the ceramic particles, such as through the addition of titanium, zirconium, niobium, vanadium, and/or chromium active metal particles. Generally, these metal particles constitute about 0.1-15 wt. % (and all values and ranges therebetween) of the coated ceramic or intermetallic particles. It has been found that by coating the ceramic or intermetallic particles with such metals prior to adding the matrix metal, the metal coating facilitates in the building of a metal layer on the ceramic or intermetallic particles to create a boundary between the ceramic or intermetallic particles in the final composite, thereby effectively separating the ceramic or intermetallic particles in the final composite by at least 1.2 and typically at least 2× the coating thickness of the metal coating on the ceramic or intermetallic particles that exist on the ceramic or intermetallic particles prior to the addition of the matrix metal.

The degradable alloy matrix includes magnesium, aluminum, zinc, and their combinations and alloys which forms 10-75 vol. % of the composite, and the composite may optionally contain one or more active metals such as calcium, barium, indium, gallium, lithium, sodium, or potassium. Such active metals, when used, constitute about 0.05-10 wt. % (and all values and ranges therebetween) of the metal matrix material.

The degradation rate of the degradable high hardness composite material can be 0.01-5 mm/hr. (and all values and ranges therebetween) in fresh water or brines at a temperature of 35-200° C. (and all values and ranges therebetween).

The degradation rate of the degradable high hardness composite material can be engineered to be 0.05-5 mm/hr. (and all values and ranges therebetween) in a selected brine composition with a total dissolved solids of 300-300,000 ppm (and all values and ranges therebetween) of chloride, bromide, formate, or carbonate brines at selected temperatures of 35-200° C. (and all values and ranges therebetween).

The degradable high hardness composite material can have a compression strength of greater than 40 ksi, and typically greater than 80 ksi, and more typically greater than 100 ksi.

The degradable high hardness composite material can be fabricated by powder metallurgy, melt infiltration, squeeze casting, or other metallurgical process to create a greater than 92% pore-free structure, and typically greater than 98% pore-free structure.

The degradable high hardness composite material can be deformed and/or heat treated to develop improved mechanical properties, reduce porosity, or to form net shape or near net shape dimensions.

The degradable high hardness composite material can be useful in oil and gas or other subterranean operations, including a seat, seal, ball, sleeve, grip, slip, valve, valve component, spring, retainer, scraper, poppet, penetrator, perforator, shear, blade, insert, or other component requiring wear, erosion, or deformation resistance, edge retention, or high hardness.

The degradable high hardness composite material can be used as a portion of a component or structure, such as a surface coating or cladding, an insert, sleeve, ring, or other limited volume portion of a component or system

The degradable high hardness composite material can be applied to a component surface through a cold spray, thermal spray, or plasma spray process

The degradable high hardness composite material can be fabricated using pressure-assisted or pressureless infiltration of a bed of ceramic particles, wherein the galvanic catalyst, dopant, or phase is formed in situ (from solidification and precipitation of the melt), ex situ (from addition of particles or coatings in the powder bed or preform) sources, and/or formed in situ prior to or during infiltration or composite preparation.

The degradable high hardness composite material can be fabricated through powder metallurgy processes, including mixing of powders, compacting, and sintering, or alternate isostatic pressing, spark plasma sintering, powder forging, injection molding, or similar processes to produce the desired composite.

The degradable high hardness composite material can have a ceramic phase that contains flakes, platelets, whiskers, or short fibers with an aspect ratio of at least 4:1, and typically 10:1 or more.

These and other advantages of the present invention will become more apparent to those skilled in the art from a review of the figures and the description of the embodiments and claims.

BRIEF DESCRIPTION OF FIGURES

FIGS. 1-3 illustrate various non-limiting degradable metal matrix composite structures in accordance with the present invention. These figures illustrate the ceramic particles dispersed into a dissolvable metal matrix, generally at a concentration of 30-60 vol. %. FIG. 1 illustrates a composite formed of ceramic particles 12 in a dissolvable metallic matrix 10. FIG. 2 illustrates a composite formed of ceramic particles 16 in a water degradable matrix 14 with the entire composite surrounded by a protective coating 18 (e.g., degradable polymer material, degradable metal) wherein the coating is triggered to degrade or is removed by some method. FIG. 3 illustrates a composite formed of degradable matrix 20 with ceramic particles 22 and platelet or fiber mechanically reinforcement from flakes, platelets, or fibers 24.

FIG. 4 is a chart illustrating the galvanic series showing electronegative materials. Magnesium is a very electronegative material and undergoes active corrosion when coupled with a variety of metals. Particularly effective are iron, nickel, copper, and cobalt, as well as Fe₃Al since they do not form insulating oxides under typical conditions and, as such, maintain electrical connectivity with the fluid. Dissolution rates are controlled by the amount and size of these additives, driven by the electrically connected surface area of the positive and negative metals in the galvanic series.

FIGS. 5 and 6 illustrate a representative microstructure for a magnesium-graphite composite that is galvanically active and could be used as a low friction or deformation-resistant structure, but is not generally effective for wear resistance. FIG. 5 is a magnesium-coated graphite, consolidated magnesium-germanium part, and microstructure of Mg₂B₄C MMC. FIG. 6 is a magnesium-iron-germanium reactive MMC composite microstructure.

FIG. 7 illustrates the comparative impingement loss at 30° impact angle of a typical seat versus material. FIG. 7 also illustrates the improvement in erosion resistance of a degradable Mg—B₄C composition of the present invention (Tervalloy™ MMC with 149 micron D50 ceramic particles) as compared to the baseline cast iron materials used today, and also to a non-MMC degradable magnesium alloy.

FIG. 8 is a table that illustrates impingement erosion loss of dissolvable alloys, hardened grey cast iron, and dissolvable magnesium metal matrix composite at different impingement angels.

DETAILED DESCRIPTION OF NON-LIMITING EMBODIMENTS OF THE INVENTION

The present invention relates to the composition and production of an engineered degradable metal matrix composite that is useful in constructing temporary systems requiring wear resistance, high hardness, and/or high resistance to deformation in water-bearing applications such as, but not limited to, oil and gas completion operations. In one non-limiting embodiment of the invention, the engineered degradable metal matrix composite includes a core material and a degradable binder matrix, and which composite includes the following properties: A) repeating ceramic particle core material of 20-90 vol. % of the composite; B) degradable metallic binder/matrix of 10-75 vol. % of the composite; C) galvanically-active phases formed in situ from a melt and/or added as solid particles that form 0.03-10 vol. % (and all values and ranges therebetween) of the composite; D) degradation rate being controlled to 0.1-5 mm/hr. in selected fluid environments including freshwater and brines at 35-200° C.; and E) hardness of the composite that exceeds 25 Rockwell C. The present inventions also relates to the method of manufacturing the engineered degradable metal matrix composite, which method includes the preparation of a plurality of ceramic particles, with or without galvanically-active materials such as, but not limited to, iron, nickel, copper, or cobalt, and infiltrating the ceramic particles with a degradable metal such as, but not limited to, magnesium or aluminum alloy. The invention also relates to the formation of high hardness, wear-, deformation-, and erosion-resistant metal matrix composite materials that exhibit controlled degradation rates in aqueous media at a temperature of at least 35° C., and typically about 35-200° C. (and all values and ranges therebetween) conditions. The ability to control the dissolution of a down hole well component in a variety of solutions is very important to the utilization of interventionless drilling, production, and completion tools such as sleeves, frac balls, hydraulic actuated tooling, scrapers, valves, screens, perforators and penetrators, knives, grips/slips, and the like.

The invention combines corrodible materials that include highly electronegative metals of magnesium, zinc, and/or aluminum, combined with a high hardness, generally inert phase such as SiC, B₄C, WC, TiB₂, Si₃N₄, TiC, Al₂O₃, ZrO₂, high carbon ferrochrome, Cr₂O₃, chrome carbide, or other high hardness ceramic, and a more electropositive, conductive phase generally selected from copper, nickel, iron, silver, lead, gallium, indium, tin, titanium, and/or carbon and their alloys or compounds. Tool steel, hard amorphous or semi-amorphous steel, and/or stellite alloy-type shards, shavings or particles can offer both galvanic and wear resistance. Other electronegative and electropositive combinations can be envisioned, but are generally less attractive due to cost or toxicity. The more electropositive phase should be able to sustain current, e.g., it should be conductive to drive the galvanic current. The ceramic phase is generally dispersed particles which are fine enough to be able to be easily removed by fluid flow and to not plug devices or form restrictions in a wellbore. It is generally accepted that particles having a size that is less than ⅛″ are sufficient for this purpose, although most composites of the present invention utilize much finer particles, generally in the 100 mesh, and very often 200 or 325 mesh sizes, down to 2500 mesh (5 micron and below for increase hardness).

The ceramic or intermetallic, high hardness particles are dispersed in an electronegative metal or metal alloy matrix at concentrations at least 25 vol. %, and typically greater than 50 vol. % of the composite. Very high compressive strength and hardness can be achieved when sufficient ceramic volume has been obtained to limit the effects of the electropositive metal matrix on mechanical properties. This property can be obtained at lower ceramic content when using high aspect ratio particles, such as whiskers, flakes, platelets, or fibers, and substantial deformation resistance can be obtained with higher aspect ratio particles.

Because the generally inert ceramic phase (inert primarily due to low conductivity) inhibits corrosion rates, higher corrosion rate electronegative-electropositive alloy couples are generally used. For example, in a magnesium system, eliminating the addition of aluminum from the alloy (to make the matrix more electronegative), or shifting from copper additions to nickel or even iron (with carbon) additions can be used to increase corrosion rates. For example, using a freshwater or low temperature combination metal matrix (such as Terves FW) instead of a higher temperature brine dissolvable (such as TervAlloy™ TAx-100E and TAx-50E) can be used to sufficiently boost the corrosion rate of a 50 vol. % B₄C—Mg containing composite to reach 35 mg/cm²/hr. at 70-90° C. The addition of carbonyl iron particles to the magnesium alloy matrix can be used to form a useful lower temperature brine, or freshwater dissolvable metal matrix composite. Terves FW, TervAlloy™ TAx-100E and TAx-50E are magnesium or magnesium alloys with 0.05-5 wt. % nickel, and/or 0.5-10 wt. % copper additions. In one non-limiting embodiment, magnesium alloy includes over 50 wt. % magnesium and one or more metals selected from the group consisting of aluminum, boron, bismuth, zinc, zirconium, and manganese, and optionally 0.05-35 wt. % nickel, copper and/or cobalt. In another non-limiting embodiment, the magnesium alloy includes over 50 wt. % magnesium and one or more metals selected from the group consisting of aluminum in an amount of about 0.5-10 wt. %, zinc in amount of about 0.1-6 wt. %, zirconium in an amount of about 0.01-3 wt. %, manganese in an amount of about 0.15-2 wt. %; boron in amount of about 0.0002-0.04 wt. %, and bismuth in amount of about 0.4-0.7 wt. %, and optionally 0.05-35 wt. % nickel, copper and/or cobalt. In another non-limiting embodiment, the magnesium alloy includes over 50 wt. % magnesium and one or more metals selected from the group consisting of aluminum in an amount of about 0.5-10 wt. %, zinc in amount of about 0.1-3 wt. %, zirconium in an amount of about 0.01-1 wt. %, manganese in an amount of about 0.15-2 wt. %; boron in amount of about 0.0002-0.04 wt. %, and bismuth in amount of about 0.4-0.7 wt. %, and optionally 0.05-35 wt. % nickel, copper and/or cobalt. In another non-limiting embodiment, the magnesium alloy comprises at least 85 wt. % magnesium; one or more metals selected from the group consisting of 0.5-10 wt. % aluminum, 0.05-6 wt. % zinc, 0.01-3 wt. % zirconium, and 0.15-2 wt. % manganese; and optionally about 0.05-45 wt. % of a secondary metal selected from the group consisting of copper, nickel, cobalt, titanium and iron. In another non-limiting embodiment, the magnesium alloy composite comprises 60-95 wt. % magnesium; 0.01-1 wt. % zirconium; and optionally about 0.05-45 wt. % copper, nickel, cobalt, titanium and/or iron. In another non-limiting embodiment, the magnesium alloy comprises 60-95 wt. % magnesium; 0.5-10 wt. % aluminum; 0.05-6 wt. % zinc; 0.15-2 wt. % manganese; and optionally about 0.05-45 wt. % of copper, nickel, cobalt, titanium and/or iron. In another non-limiting embodiment, the magnesium alloy comprising 60-95 wt. % magnesium; 0.05-6 wt. % zinc; 0.01-1 wt. % zirconium; and optionally about 0.05-45 wt. % of copper, nickel, cobalt, titanium and/or iron. In another non-limiting embodiment, the magnesium alloy comprises over 50 wt. % magnesium; one or more metals selected from the group consisting of 0.5-10 wt. % aluminum, 0.1-2 wt. % zinc, 0.01-1 wt. % zirconium, and 0.15-2 wt. % manganese; and optionally about 0.05-45 wt. % of copper, nickel and/or cobalt. In another non-limiting embodiment, the magnesium alloy comprises over 50 wt. % magnesium; one or more metals selected from the group consisting of 0.1-3 wt. % zinc, 0.01-1 wt. % zirconium, 0.05-1 wt. % manganese, 0.0002-0.04 wt. % boron and 0.4-0.7 wt. % bismuth; and optionally about 0.05-45 wt. % of copper, nickel, and/or cobalt. In another non-limiting embodiment, the magnesium alloy comprises 60-95 wt. % magnesium and 0.01-1 wt. % zirconium. In another non-limiting embodiment, the magnesium alloy comprises over 50 wt. % magnesium and one or more metals selected from the group consisting of aluminum in an amount of about 0.5-10 wt. %, zinc in amount of about 0.1-3 wt. %, zirconium in an amount of about 0.01-1 wt. %, manganese in an amount of about 0.15-2 wt. %, boron in amount of about 0.0002-0.04 wt. %, and bismuth in amount of about 0.4-0.7 wt. %.

The electropositive driving phase can be added by adding soluble or insoluble electropositive particles to the ceramic powder prior to melt infiltration or mixing into a melt by adding the electropositive material as a coating or cladding to the inert ceramic phase, or by adding as an alloying element that forms a fully liquid phase with the electropositive metal or alloy. In the liquid phase, generally an electropositive metal that forms a eutectic with the electronegative metal and an intermetallic of the electropositive metal can be used. Non-limiting examples of such coatings or claddings are Mg—Ni, Mg—Cu, Mg—Co, and Mg—Ag. FIG. 4 is a chart illustrating the galvanic series showing electronegative materials (magnesium through cadmium, electronegative being more electronegative than steel), and electropositive metals (steel through carbon).

The electropositive driving phase can also be added to electropositive metal powders, along with the ceramic phase, and the dissolvable MMC fabricated from powder metallurgy or spray consolidation techniques such as press and sinter, hot isostatic pressing, spark plasma sintering, powder sinter-forging, direct powder extrusion, thermal spray, cold spray, plasma spray, or other powder consolidation techniques.

For melt infiltration of a ceramic preform or powder bed, techniques that can be used include pressureless infiltration (when the ceramic and electronegative metal wet each other, or when the ceramic has been coated with a wetting phase such as a eutectic forming or other easily wet metal), or pressure-assisted infiltration technique such as squeeze casting, high pressure die casting (into the ceramic preform), vacuum casting, or pressure-assisted casting techniques, among others. Particularly at lower ceramic volumes (25-50 vol. %), the particles can be stir-cast, thixocast, or slurry cast by mixing the ceramic (and electropositive material, if in powder form) and formed in the liquid plus ceramic or semi-solid state. Net shape or near net shape fabrication techniques are preferred due to machining cost of precision grinding of the high hardness materials. Active wetting metals such as titanium, zirconium, vanadium, niobium, silicon, boron, and palladium can be added to the melt system to enhance wetting. Surface wetting coatings, often eutectic liquid formers such as niobium, zirconium, magnesium, aluminum, silicon, and/or bismuth can provide strong wetting ability to enhance pressureless infiltration.

After consolidation, the compact can be further formed by forging, extrusion, or rolling. The compact can also be taken back to an elevated temperature, normally in the semi-solid region between the electropositive alloy liquidus and solidus, and formed using closed die forming, squeeze casting, thixocasting, or other semi-solid forming technique.

The cast or formed part can be machined to close tolerances using grinding or electrode discharge machining (EDM). Diamond, CBN, and other high hardness tools can also be used.

The degradable metal matrix composite can be applied as a coating, such as by cold spray, to a separate part, to impart wear-, erosion-, or deformation-resistance, or to slow initial dissolution rates to give added life. A higher degradation rate core is generally desired. In one embodiment, the MMC can be created by surface alloying the higher degradation rate, or lower hardness core, with the ceramic phase by such techniques as friction stir surfacing, supersonic particle spray, or reactive heat treatments (such as boronizing). Other routes to a dual structured component include overcasting or overmolding, or physical assembly with or without an adhesive or bonding step such as forging, hot pressing, friction welding, or use of adhesives.

After machining, parts may be further coated or modified to control initiation of dissolution or to further increase hardness or ceramic content. Techniques such as cold spray, thermal spray, friction surfacing, powder coating, anodizing, painting, dip coating, e-coating, etc. may be used to add a surface coating or otherwise modify the surface.

The degradable MMCs of the present invention are particularly useful in the construction of downhole tools for oil and gas, geothermal, and in situ resource extraction applications. The higher hardness enables tools such as reamers, valve seats, ball seats, and grips to be engineered to be fully degradable, eliminating debris as well as the need to retrieve or drill-out the tools. The degradable MMC is a useful, degradable substitute for hardened cast iron in applications such as plug seats and gripping devices for bridge and frac plugs. The degradable MMC is also useful for the design and production of cement plugs, reamers, scrapers, and other devices.

The deformation resistance of the degradable MMCs allows the construction of higher pressure rating valve and plug systems than non-MMC degradable products. For example, a degradable MMC frac ball can withstand 15,000 psi across a 1/16″ seat overlap compared to less than 7,000 psi for a conventional degradable magnesium alloy or polymer ball.

FIGS. 1-3 illustrate various degradable metal matrix composite structures in accordance with the present invention. FIGS. 1-3 illustrate a composite formed of ceramic particles 12 in a dissolvable metallic matrix 10.

The composite material is formed by 1) providing ceramic particles, 2) providing a galvanically-active material such as iron, nickel, copper, titanium, and/or cobalt, 3) combining the ceramic particles and galvanically-active material with molten matrix material such as molten magnesium, molten aluminum, molten magnesium alloy or molten aluminum alloy, and 4) cooling the mixture to form the composite material. The cooled and solid dissolvable metallic matrix generally includes over 50 wt. % magnesium or aluminum. The ceramic material is generally coated with the galvanically-active material prior to adding the motel matrix material; however, this is not required.

The galvanically-active material coating on the ceramic material, when precoated, can be applied by any number of techniques (e.g., vapor deposition, dipping in molten metal, spray coating, dry coated and then heated, sintering, melt coating technique, etc.). Generally, each of the coated ceramic particles are formed of 30-98 wt. % ceramic material (and all values and ranges therebetween), and typically greater than 50 wt. % ceramic material. The thickness of the galvanically-active material coating is generally less than 1 mm, and typically less than 0.5 mm.

After the composite is formed, the ceramic material constitutes about 10-85 wt. % (and all values and arranges therebetween) of the composite, the galvanically-active material constitutes about 0.5-30 wt. % (and all values and arranges therebetween) of the composite, and the molten matrix material constitutes about 10-85 wt. % (and all values and arranges therebetween) of the composite.

The dissolution rate of the composite is at least 5-800 mg/cm²/hr., or equivalent surface regression rates of 0.05-5 mm/hr. at a temperature of 35-200° C. in 100-100,000 ppm water or brines, and typically at least 45 mg/cm²/hr. in 3 wt. % KCl water mixture at 90° C., more typically up to 325 mg/cm²/hr. in 3 wt. % KCl water mixture at 90° C.

FIG. 2 illustrates the composite surrounded by a protective coating 18 (e.g., degradable polymer material, degradable metal). The protective coating can be formulated to dissolve or degrade when exposed to one or more activation or trigger conditions such as, but not limited to, temperature, electromagnetic waves, sound waves, certain chemicals, vibrations, salt content, electrolyte content, magnetism, pressure, electricity, and/or pH. Once the protective coating has sufficiently dissolved or degraded, the composite is then exposed to the surrounding fluid, thus causing the composite to dissolve, corrode, etc. when exposed to certain surrounding conditions. The protective coating can be formed of one or more metal and/or polymer layers. Non-limiting polymer protective coatings that can be used include ethylene-α-olefin copolymer; linear styrene-isoprene-styrene copolymer; ethylene-butadiene copolymer; styrene-butadiene-styrene copolymer; copolymer having styrene endblocks and ethylene-butadiene or ethylene-butene midblocks; copolymer of ethylene and alpha olefin; ethylene-octene copolymer; ethylene-hexene copolymer; ethylene-butene copolymer; ethylene-pentene copolymer; ethylene-butene copolymer; polyvinyl alcohol (PVA); silicone, and/or polyvinyl butyral (PVB). The thickness of the protective coating is generally less than 3 mm, and more typically about 0.0001-1 mm.

FIG. 3 illustrates a composite formed of degradable matrix 20 with ceramic particles 22 and platelet or fiber mechanically-reinforced flakes, platelets, or fibers 24. The platelets or fibers typically have an aspect ratio of at least 4:1, and typically 10:1 or more. The length of the platelets or fibers is generally less than 3 mm, and typically less than 2 mm. The platelets or fibers, when used, are generally formed of boron carbide silicon carbide, and/or graphite; however, other materials can be used.

EXAMPLES

In one embodiment, the reactivity of an electrolytically activated reactive composite of magnesium or zinc and iron with ceramic reinforcements is controlled to produce a dissolution rate of 1-10 mm/day (and all values and ranges therebetween), or 0.5-800 mg/cm²/hr. (and all values and ranges therebetween) (depending on density) by controlling the relative phase amounts and interfacial surface area of the two galvanically-active phases. In one example, a mechanical mixture of iron or graphite and magnesium is prepared by mechanical milling of magnesium or magnesium alloy powder and 40 vol. % of 30-200 micron iron graphite (and all values and ranges therebetween) graphite or 10 wt. % nickel-coated graphite particles, followed by consolidation using spark plasma sintering or powder forging at a temperature below the magnesium or zinc melting point. The resultant structure has an accelerated rate of reaction due to the high exposed surface area of the iron or graphite cathode phase, but low relative area of the anodic (zinc or magnesium) reactive binder.

The degradable MMC can be used for powder metallurgical processing. FIGS. 5 and 6 illustrate a representative microstructure for a magnesium-graphite composite.

In general, larger ceramic particles, typically above 40 mesh, including flake, impart great impingement erosion resistance at higher angels, while smaller particles, typically below 200 mesh, provide higher sliding wear resistance. Larger particles can also facilitate gripping (in frac plug grips/slips, to facilitate locking a device to a mating surface), such as when mm-sized crushed carbides are added to a dissolvable matrix. Such embedded metal matrix composites can also be used in reamer-type applications as abrasives, such as by adding larger chunks or even preformed shapes, such as crushed, machined, or formed carbides or tool steel discreet elements.

Example 1

Boron carbide powder with an average particle size of 325 mesh is surface modified by the addition of zinc by blending 200 grams of B₄C powder with 15 grams of zinc powder and heated in a sealed, evacuated container to 700° C. to distribute the zinc to the particle surfaces. The zinc-coated B₄C powder is placed into a graphite crucible and heated to 500° C. with an inert gas cover. In a separate steel crucible, 500 grams of Terves FW low temperature dissolvable degradable magnesium alloy is melted to a temperature of 720° C. The degradable magnesium alloy is poured into the 8-inch deep graphite crucible containing the zinc-coated B₄C particles sufficient to cover the particles by at least two inches and allowed to solidify.

The material had a hardness 52 Rockwell C, and a measured dissolution rate of 35 mg/cm²/hr. in 3 vol. % KCl at 90° C.

Example 2

300 g of 600 mesh boron carbide powder was placed to a depth of 4″×2″ diameter by ten-inch deep graphite crucible containing a two inch layer of ¼″ steel balls (600 g of steel) covered by a 325 mesh steel screen and heated to 500° C. under inert gas. The graphite crucible was heated inside of a steel tube, which was heated with the crucible. Five pounds of Terves FW degradable magnesium alloy were melted in a steel crucible to a temperature of 730° C. and poured into the graphite crucible sufficient to cover the B₄C and steel balls to reach within two inches of the top of the graphite crucible. The crucible was removed from the furnace and transferred to a 12-ton carver press, where a die was rammed into the crucible forcing the magnesium into and through the powder bed. The crucible was removed from the press and allowed to cool.

The MMC section was separated from the non-MMC material and showed a dissolution rate of 45 gm/cm²/hr. at 90° C. in 3 vol. % KCl solution. The measured hardness was 32 Rockwell C.

Example 3

125 grams of 325 mesh B₄C powder was blended with 4 grams of 100 mesh titanium powder and sintered at 500° C. to form a rigid preform. A 500 gram ingot of TAx-50E dissolvable metal alloy was placed on top of the preform in a graphite crucible. The crucible was placed in the inert gas furnace and heated to 850° C. for 90 minutes to allow for infiltration of the preform. The infiltrated preform had a hardness of 24 Rockwell C.

Example 4

Degradable MMC from Example 3 was machined into a frac ball. A 3″ ball (3.000+/−0.002), when tested against a cast iron seat with a 45° seat angle and inner diameter of 2.896″, was shown to hold greater than 15,000 psig pressure at room temperature. The degradable magnesium frac ball was machined from a high dissolution rate dissolving alloy having a dissolution rate of greater than 100 mg/cm²/hr. at 90° C. The frac ball was undermachined by 0.010″, to 2.980+/−0.002, and the degradable MMC was applied using cold spray application from a powder generated by ball milling 400 grams of standard degradable alloy machine chips with 600 grams 325 mesh of B₄C powder using a centerline Windsor SST cold spray system and nitrogen gas as the carrier gas. The ball was then machined to 3″+/−0.002″. The ball held >10,000 psig against a 45° cast iron seat at 2.875″ inner diameter. The frac ball was designed to give two hours of operating time, before dissolving rapidly in less than 48 hours at 90° C. in 3% KCl brine solution.

Example 5

Degradable MMC from Example 3 was machined into a frac ball except that TAx-100E was used instead of TAx-50E. The TAx-100E included trace amounts of iron to form a composite having a hardness of 74HRB and a dissolution rate of 34 mg/cm²/hr. in 3% vol. % KCl at 90° C. during a six-hour test. 125 grams of 325 mesh B₄C powder was blended with 4 grams of 100 mesh titanium powder and sintered at 500° C. to form a rigid preform. A 500 gram ingot of TAx-100E with 0.1% iron was placed on top of the preform in a steel crucible. The crucible was placed in the inert gas furnace and heated to 850° C. for 90 minutes to allow for infiltration of the preform. The infiltrated preform had a hardness of 74HRB and a dissolution rate of 34 mg/cm²/hr. in 3% KCl at 90° C. during six hours of brine exposure.

It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained, and since certain changes may be made in the constructions set forth without departing from the spirit and scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. The invention has been described with reference to preferred and alternate embodiments. Modifications and alterations will become apparent to those skilled in the art upon reading and understanding the detailed discussion of the invention provided herein. This invention is intended to include all such modifications and alterations insofar as they come within the scope of the present invention. It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described and all statements of the scope of the invention, which, as a matter of language, might be said to fall there between. The invention has been described with reference to the preferred embodiments. These and other modifications of the preferred embodiments as well as other embodiments of the invention will be obvious from the disclosure herein, whereby the foregoing descriptive matter is to be interpreted merely as illustrative of the invention and not as a limitation. It is intended to include all such modifications and alterations insofar as they come within the scope of the appended claims.

Claims

1. A method for forming a degradable composite, said method comprises: a. providing ceramic particles, a plurality of said ceramic particles having a hardness of greater than 50 HRC;b. providing one or more galvanically-active elements selected from the group consisting of iron, carbon, nickel, copper, cobalt, gallium, indium, and titanium;c. combining ceramic particles and said one or more galvanically-active elements with a degradable metal material, said degradable metal material selected from magnesium, magnesium alloy including greater than 50 wt. % magnesium, and an aluminum alloy;d. dispersing said plurality of ceramic particles and said one or more galvanically-active elements in said degradable metal material while said degradable metal material is in a molten state to form a mixture; and,e. cooling said mixture to form said degradable composite, said degradable composite having a degradation rate of at least 5 mg/cm2/hr. in freshwater or brine at a temperature of at least 90° C.

2. The method as defined in claim 1, wherein said degradable composite has a hardness of greater than 22 Rockwell C.

3. The method as defined in claim 1, wherein said degradable composite includes at least 10 vol. % degradable metal material, at least 0.03 vol. % galvanically-active elements, and at least 10 vol. % ceramic particles.

4. The method as defined in claim 1, wherein said degradable composite includes one or more metals selected from the group constating of calcium, barium, lithium, sodium, potassium, silver, gold, bismuth, lead, and palladium.

5. The method as defined in claim 1, wherein said ceramic particles include one or more materials selected from the group consisting of B4C, TiB2, TiC, Al2O3, MgO, SiC, Si3N4, ZrO2, ZrSiO4, SiB6, SiAlON, WC, carbon ferrochrome, Cr2O3, and chrome carbide.

6. The method as defined in claim 1, wherein a plurality of said ceramic particles are surface coated with said one or more galvanically-active elements to form a coating on said ceramic particles prior to being combined with said degradable metal material.

7. The method as defined in claim 1, wherein said coating on said ceramic particles has a thickness of 60 nm to 100 microns.

8. The method as defined in claim 1, wherein said degradable metal material is a magnesium alloy, said magnesium alloy including one or more metal additives selected from the group consisting of nickel, copper, aluminum, boron, bismuth, zinc, zirconium, cobalt, manganese, titanium, and iron.

9. The method as defined in claim 1, wherein said method further includes the step of coating said degradable composite with a protective coating, said protective coating having a thickness less than 3 mm, said protective coating including a polymer layer.

10. The method as defined in claim 1, wherein said method further includes the step of adding flakes, fibers, or platelets to said mixture of said molten degradable metal matrix, said ceramic or intermetallic particles, and said galvanically-active elements, said flakes, fibers, or platelets having an aspect ratio of at least 4:1, said flakes, fibers, or platelets having a length of up to 4 mm, said flakes, fibers, or platelets including one or more materials selected from the group consisting of boron carbide, silicon carbide, and graphite.

11. The method as defined in claim 9, wherein said method further includes the step of forming said degradable composite to partially or fully form a structure selected from the group consisting of a seat, a seal, a ball, a frac ball, a cone, a wedge, an insert for a slip, a sleeve, a valve, a frac seat, a grip, a slip, a valve component, a spring, a retainer, a scraper, a poppet, a penetrator, a perforator, a shear, a blade, and an insert.

12. The method as defined in claim 9, wherein said ceramic particles have a particle size of 0.1 microns to 1000 microns.

13. The method as defined in claim 9, wherein said degradable composite has a structure that is greater than 92% pore-free.