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    patent summary: "aluminum alloy metal powder compact". The present invention relates to a metal powder compact. The metal powder compact includes a cellular nanomatrix comprising a nanomatrix material. The metal powder compact also includes a plurality of dispersed particles comprising a particle core material comprising an al-cu-mg, al-mn, al-si, al-mg, al-mg-si alloy. al-zn, al-zn-cu, zn-al-mg, al-zn-cr, al-zn-zr or al-sn-li, or a combination thereof, dispersed in the cellular nanomatrix.
    公开号:BR112014003726B1
    申请号:R112014003726-4
    申请日:2012-08-03
    公开日:2019-03-12
    发明作者:Zhiyue Xu
    申请人:Baker Hughes Incorporated；
    IPC主号:
    专利说明:

    Descriptive Report of the Patent of Invention for COMPACTED METAL POWDER OF ALUMINUM ALLOY.
    CROSS REFERENCE TO REACTED PATENT APPLICATIONS [001] This Patent Application claims the benefit of US Patent Application No. 13/220822, filed on August 30, 2011, which is incorporated here, in this patent application by reference in its entirety .
    BACKGROUND [002] Oil and natural gas wells often use borehole components or tools that, due to their function, are only required to have limited service life, which is considerably shorter than the well's service life. . After a component or tool service function is completed, it must be removed or disposed of in order to recover the original size of the fluid path to be used, including hydrocarbon production, CO2 sequestration, etc. The disposal of components or tools has been done conveniently by crushing or drilling the component or tool from the well, which is generally a time-consuming and expensive operation.
    [003] In order to eliminate the needy in relation to crushing or drilling operations, the removal of components or tools from the well hole through dissolution or corrosion with the use of various dissolving or corrosive materials has been proposed. Although these materials are useful, it is also very desirable that these materials are light weight and have a high strength, including a strength that can be compared to that of conventional engineering materials used to form well hole components or tools, such as the different grades of steel. Thus, the improvement of absorbable or unalterable materials to increase
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    2/25 their resistance, corrosion and manufacturing capacity are very desirable.
    SUMMARY [004] In one embodiment, as an example, a compacted metal powder is described. The compacted metal powder includes a cellular nanomatrix that comprises a nanomatrix material. The compacted metal powder also includes a plurality of dispersed particles that comprise a core particle material that comprises an Al-Cu-Mg, Al-Mn, Al-Si, Al-Mg, Al-Mg-Si, Al -Zn, Al-Zn-Cu, Al-ZnMg, Al-Zn-Cr, Al-Zn-Zr, or Al-Sn-Li, or a combination thereof, dispersed in the cellular nanomatrix.
    BRIEF DESCRIPTION OF THE DRAWINGS [005] With reference to the drawings in which the same elements have equal numbers in the various Figures:
    Fig. 1 is a schematic illustration of an example embodiment of a dust particle 10 and a dust particle 12;
    Fig. 2 is a schematic illustration of an example embodiment of compacted powder that has an equiaxial configuration of dispersed particles, as described here in this patent application;
    Fig. 3 is a schematic illustration of an example embodiment of compacted powder that has a substantially elongated configuration of dispersed particles as described herein, in this patent application;
    Fig. 4 is a schematic illustration of an example embodiment of compacted powder that has a substantially elongated configuration of the cellular nanomatrix and dispersed particles, wherein the cellular nanomatrix and the dispersed particles are substantially continuous, and
    Fig. 5 is a schematic illustration of an example embodiment of compacted powder that has a configuration
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    3/25 substantially elongated cell nanomatrix and dispersed particles, wherein the cell nanomatrix and dispersed particles are substantially discontinued.
    DETAILED DESCRIPTION [006] The materials of the aluminum alloy nanomatrix and light weight and high strength are described. The aluminum alloy used to form these nanomatrix materials is high-strength aluminum alloys. The resistance can be through the incorporation of nanostructure within the alloys. The strength of these alloys can also be improved by incorporating several resistance-forming sub-particles and second particles. The aluminum alloy nanomatrix materials described can also incorporate several characteristics of microstructures to control the mechanical properties of the alloy, such as the incorporation of microstructures of substantially elongated particles to increase the strength of the alloy, or a multimodal particle size in the microstructure. alloy to improve fracture toughness or a combination of these to control both strength, fracture toughness and other alloy properties.
    [007] The aluminum alloy nanomatrix materials described here, in this patent application can be used in all ways of application, including in various drilling well environments, for the manufacture of various lightweight and high strength articles including articles that include use in various pit environments, to make various lightweight, high-strength articles, including downhole articles, specifically tools or other components in wells. In addition to their light weight, high strength characteristics, these nanomatrix materials can be described as controlled electrolytic materials, which can be selectively and controlled disposable, degradable, soluble, corrosive or corrosive.
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    4/25 otherwise removable from the well. Many other applications to be used on both durable and disposable or degradable articles are possible. In one embodiment, these lightweight, highly resistant, selectively and controlled disposable materials include fully dense sintered powder compacts formed from powder coated materials, which include multiple light particle cores and multiple single layer core materials. and multilayer nano-scale coatings. In another embodiment, these materials which include selectively and controllably degradable materials may include powder compacts that are not completely dense or non-sintered, or a combination thereof, formed from these coated powder materials.
    [008] The materials and methods of nanomatrix for the manufacture of such materials are described, in general, for example, in US Patent Application 12 / 633,683, filed on December 8, 2009 and in US Patent Application 243 / 194,361 filed on July 29, 2011, which are incorporated here, in this patent application by reference in its entirety. These light weight, high strength, selectively and controlled disposable materials can range from fully dense, sintered compact powders to compact precursors or in a green (less than fully dense) state that can be sintered or non-sintered. They are formed from powder coated materials that include multiple light weight particle cores that have multiple single layers and multi-layer nanoscale coatings. These powder compacts can be made from coated metallic powders that include several light, high strength and electrically active particle cores (such as having relatively higher standard oxidation potentials) and core materials, such as metals electrically active, which are dispersed within a cellular nanomatrix formed from the
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    5/25 consolidation of the various metallic coating layers on the nanoscale of metallic coating materials, and are specifically useful in well drilling applications. Powder compacts can be made using any suitable powder compaction method, including cold isostatic pressing (CIP), hot isostatic pressing (HIP), dynamic forging and extrusion, and combinations thereof. These powder compacts provide a unique and advantageous combination of mechanical strength properties, such as compression and shear strength, low density and selectable and controllable corrosion properties, specifically fast and controlled dissolution in various well fluids. Fluids can include any number of highly polar fluids or ionic fluids, such as those containing various chlorides. Examples include fluids comprising potassium chloride (KCl), hydrochloric acid (HCl), calcium chloride (CaCL), calcium bromide (CaBr2) or zinc bromide (ZnBr2).
    [009] The descriptions of Patent Applications '682 and' 361 with respect to the nature of the coated powders and the methods for manufacturing and compacting the coated powders can be applied in general to the provision of materials to light weight and high strength aluminum alloy described here, in this patent application, and which, for the sake of brevity, will not be repeated here, in this patent application.
    [0010] As illustrated in Figures 1 and 2, a powder 10 comprising powder particles 12, including a core particle 14 and core material 18 and metallic coating layer 16 and coating material 20 can be selected, which are configured for compacting and sintering to provide a compacted metal 200 that is lightweight (ie, that has a relatively low density) high strength and that is selectively removable and
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    6/25 controlled from a well drilling in response to a change in the well drilling property, including being able to be selectively and controllably dissolvable in an appropriate drilling and well fluid, which includes various well drilling fluids such as those described here, in this patent application. The compacted metal powder 200 includes a cellular nanomatrix 216 comprising a nanomatrix material 220 and a plurality of dispersed particles 214 comprising a particle of core material 218 comprising an Al-Cu-Mg, Al-Mn, Al -Si, Al-Mg, Al-Mg-Si, AlZn, Al-Zn-Cu, Al-Zn-Mg, Al-Zn-Cr, Al-Zn-Zr, or Al-Sn-Li, or a combination of the dispersed in the cell nanomatrix 216.
    [0011] The dispersed particles 214 can comprise any of the materials described here, in this patent application with respect to the particle cores 12, even though the chemical composition of the dispersed particles 214 may be different due to the diffusion effects, as described here, in this patent application. In one embodiment, for example, dispersed particles 214 are formed from particle cores 14 which comprise an Al-Cu-Mg, Al-Mn, Al-Si, Al-Mg, Al-Mg-Si alloy, Al-Zn, Al-Zn-Cu, Al-ZnMg, Al-Zn-Cr, Al-Zn-Zr, or Al-Sn-Li or a combination thereof. In an exemplary embodiment, the dispersed particles 214 include a particle core material 218 comprising an aluminum alloy of the 2000 series, and, more specifically, may include, by weight of the alloy, of about 0, 05% to about 2.0% Mg, about 0.1% to about 0.8% Si, about 0.7% to about 6.0% Cu, about 0.1% about 1.2% Mn; about 0.1% to about 0.8% Zn, about 0.05% to about 0.25% Ti, and about 0.1% -1.2% Fe; and remainder of Al and incidental impurities. In another embodiment, for example, dispersed particles 214 include a particle core material 218 comprising a
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    7/25 5000 series aluminum alloy, and more specifically can include in weight percent of the alloy, from about 0.5% to about 6.0% Mg, about 0.05% to about 0, 30% Zn, about 0.10% to about 1.0% Mn; about 0.08% to about 0.75% Si and the rest of Al and incidental impurities. The scattered particles 214 and the particle core material 218 may also include a rare earth element, or a combination of rare earth elements. In the form used here, in this patent application, rare earth elements include Sc, Y, La, Ce, Pr, Nd or Er, or a combination of rare earth elements. When present, a rare earth element or a combination of rare earth elements may be present, by weight, in an amount of about 5 percent or less.
    [0012] The dispersed particles 214 and the particle core material 218 may also comprise nano structured materials 215. In one embodiment, for example, a nano structured material 215 is a material that has a grain size, or a size sub-grain or crystalline, of less than about 200 nm, and more specifically a grain size of about 10 nm to about 200 nm, and even more specifically an average grain size of less than about 100 nm. The nanostructure can include high angle limits 227, which are commonly used for grain size definition or low angle limits 229 that can occur as a substructure within a specific grain, which are sometimes used to define a crystallite size. , or a combination thereof. The nanostructure can be formed in the core particle 14 used to form the dispersed particles 214 by any suitable method, including strain-induced nanostructures such as can be provided by powder ball milling to provide particle cores 14, and more specifically by cryoprotection (for example, ball milling in
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    8/25 ball grinding media at a cryogenic temperature or a cryogenic fluid, such as liquid nitrogen) from a powder to provide the particle cores 14 used for the formation of the dispersed particles 214. The particle cores 14 can be formed as a nano structured material 215 by any suitable method, such as, for example, by grinding or creating a grinding of pre-bonded powder particles of the aluminum alloys described herein, in this patent application. The core particles 14 can also be formed by mechanically bonding pure metal powders in the desired amounts of the various constituents of the alloy. The mechanical formation of alloys involves ball milling, including the cryomaging of these constituents into powder to mechanically wrap and mix the components and form the nuclei of the particles 14. In addition to the creation of the nanostructure as described above, ball milling and cryomaging can contribute to the strengthening in solid solution of the particle cores 14 and the core material 18, which, in turn, contributes to the strengthening of the solid solution of the dispersed particles 214 and the particle core material 218. The strengthening of the solid solution can result from the ability of mechanically intermixtures a higher concentration of interstitial or substitute solute atoms, in the solid solution than is possible according to the phase balance of the specific constituent alloy, thereby providing an obstacle to, or serving to restrict the movement of displacements within the particle , which in turn provides a strengthening mechanism in the particle nucleus 14 and in the dispersed particle 214. The particle nucleus 14 can also be formed as a nanostructured material 215 by methods that include inert gas condensation, chemical vapor condensation, deposition by electron pulse, plasma synthesis, crystallization of amorphous solids, electro deposition and plastic deformation
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    Serious 9/25, for example. The nanostructure can also include a high displacement density, such as, for example, a density between about 10 17 m -2 and 10 18 m -2 displacement, which can be two to three orders of magnitude higher than the similar alloy materials deformed by traditional methods, such as cold rolling.
    [0013] The scattered particle 214 and the particle core material 218 may also comprise a subparticle 222, and may preferably comprise a plurality of subparticles. Sub-particle 222 provides a mechanism for strengthening dispersion within dispersed particle 214 and provides an obstacle to, or serves to restrict the movement of displacements within, the particle. Sub-particle 222 can be of any suitable size, and in an exemplary embodiment it can have an average particle size of about 10 nm to about 1 micron, and more specifically it can have an average particle size of about from 150 nm to about 200 nm. Sub-particle 222 can comprise any suitable form of sub-particle, including an embedded sub-particle 224, a precipitate 226 or a dispersoid 228. The embedded particle 224 can include any suitable embedded sub-particles, including several rigid sub-particles. The embedded subparticle or the plurality of embedded subparticles can include various metals, carbon, metal oxide, metal nitride, metal carbide, intermetallic compound or ceramic metal particles (cermet), or a combination thereof. In an exemplary embodiment the rigid particles may include Ni, Fe, Cu, Co, W, Al, Zn, Mn or Si, or an oxide, nitride, carbide, intermetallic compound or ceramic metal comprising at least one precedents, or a combination thereof. The embedded sub-particle 224 can be embedded using any
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    10/25 suitable method, including, for example, by grinding with balls, or by crunching the hard particles together with the particle core material 18. A precipitated sub-particle 226 may include a sub-particle that can be precipitated within the dispersed particle 214, including precipitated sub-particles 226, consistent with the phase balance of the aluminum alloy constituents of interest and their relative amounts (such as an alloy that can be precipitated by precipitation), and including those that can be precipitated due to non-equilibrium conditions, as can occur when an alloy constituent that has been forced into a solid solution of the alloy in an amount above the limit of its equilibrium phase, as is known to occur during the mechanical formation of alloy is heated sufficiently to activate diffusion mechanisms that allow precipitation. Dispersoidal subparticles 228 can include nanoscale particles or assemblages of elements that result from the manufacture of particle cores 14, such as those associated with ball grinding, including the constituents of grinding media (such as balls) the grinding fluid (such as liquid nitrogen) or the surfaces of the particle 14 nuclei themselves (such as metal oxides or nitrides). Dispersoidal subparticles 228 may include, for example, Fe, Ni, Cr, Mn, N, P, C and
    H. Sub-particles 222 can be located anywhere in conjunction with particle cores of 14 and dispersed particles214. In an example embodiment, the sub-particles 222 can be arranged inside or on the surface of the dispersed particles 214, or a combination thereof, as shown in Fig. 1. In another example, a plurality of sub-particles 222 are arranged on the surface of the particle core 14 and the scattered particles 214 and can also
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    11/25 comprising the material of nanomatrix 216, as illustrated in Fig. 1. [0014] The compacted powder 200 includes a cellular nanomatrix 216 of a nanomatrix material 220 that has a plurality of dispersed particles 214 dispersed throughout the cellular nanomatrix 216 The scattered particles 214 can be equiaxial in a substantially continuous cell nanomatrix 216, or can be substantially elongated, as described herein, in this patent application, and illustrated in FIG. 3. In the event that dispersed particles 214 are substantially elongated, dispersed particles 214 and cell nanomatrix 216 can be continuous or discontinuous as shown in Figures 4 and 5 respectively. The substantially continuous cellular nanomatrix 216 and the material of nanomatrix 220 formed by sintered metal cladding layers 16 is formed by compacting and sintering the plurality of metal cladding layers 16, the plurality of powder particles 12 such as by CIP, HIP or dynamic forging. The chemical composition of the material of nanomatrix 220 may be different than that of coating material 20 due to the diffusion effects associated with sintering. The compacted metal powder 200 also includes a plurality of dispersed particles 214 comprising the particle core material 218. The dispersed particle cores 214 and the core material 218 correspond to and are formed from a plurality of particle cores 14 and core material 18 of the plurality of powder particles 12 as the metallic coating layers 16 are sintered together to form nanomatrix 216. The chemical composition of core material 218 may also be different than that of the core material 18 due to the diffusion effects associated with sintering.
    [0015] In the form used here, in this patent application, the use of the expression cell nanomatrix 216 does not indicate the main constituent of the
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    12/25 compacted powder, however it refers to the constituent or minority constituents, whether in weight or volume. This differs from most matrix composite materials in which the matrix comprises the majority component by weight or volume. The use of the term substantially continuous cellular nanomatrix is intended to describe the extensive, regular, continuous and interconnected nature of the distribution of the material of nanomatrix 220 within compacted powder 200. In the form used here, in this patent application, substantially continuous describes the extent of nanomatrix material through all compacted powder 200 such that it extends between envelopes and substantially all dispersed particles 214. Substantially continuous is used to indicate that the complete continuity and regular order of the nanomatrix around each dispersed particle 214 does not is needed. For example, defects in the coating layer 16 on the core 14 of powder particles on some particles 12 can cause a bonding of the particle cores 14, during the sintering of the compacted powder 200, thus causing discontinuities located for result in cell nanomatrix 216, although in other parts of the compacted powder the nanomatrix is substantially continuous and exhibits the structure described here, in this patent application. In contrast, in the case of substantially elongated dispersed particles 214, such as those that are formed through extrusion, substantially discontinuous is used to indicate that the continuity and incomplete rupture (e.g., cracks, or separation) of the nanomatrix around each particle dispersion 214, as may occur in a predetermined extrusion direction 622, or in a direction transverse to that direction. In the form used here, in this patent application, cell phone is used to indicate that the nanomatrix defines a repetition network, of generally interconnected compartments, or cells of
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    13/25 nanomatrix 220 and which encompass and also interconnect dispersed particles 214. In the form used here in this patent application, nanomatrix is used to describe the size or dimension of the matrix, specifically the thickness of the matrix between adjacent dispersed particles 214. The metallic coating layers that are sintered together to form the nanomatrix, have themselves nanoscale thick coating layers. Since the nanomatrix in most locations, with the exception of the intersection of more than two dispersed particles 214, generally comprises the interdiffusion and bonding of two layers of coating 16, from adjacent powder particles 12 with nanoscale thicknesses the formed matrix also has a nanoscale thickness (for example, about twice the thickness of the coating layer, as described here, in this patent application) and is therefore described as a nanomatrix. In addition, the use of the term dispersed particles 214 does not indicate the minor constituent of the compacted powder 200, however it refers to the major component or constituent, whether in weight or volume. The use of the term dispersed particle is intended to convey the discontinuous and separate distribution of the particle core material 218 in the compacted powder 200.
    [0016] The compacted powder 200 can have any desired shape or size, including that of a cylindrical bilet, bar, sheet or other shape that can be machined, formed or otherwise used to form useful articles of manufacture, including various drilling well tools and components. The pressing used to form compact powder precursors 100 and the sintering and pressing processes used to form compact powder 200 and to deform powder particles 12, including particle cores 14 and coating layers 16, to provide the desired total density and macroscopic shape and size of the powder
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    Compacted 14/25 200, as well as its microstructure. The morphology (such as, for example, equiaxial or substantially elongated) of the dispersed particles 214 and cell network 216 of particle layers results from the sintering and deformation of the powder particles 12 as they are compacted and interdifused and deformed to fill the interparticle spaces 15 (fig. 1). Sintering temperatures and pressures can be selected with the purpose of ensuring that the density of the compacted powder 200 reaches substantially total theoretical density.
    [0017] In an exemplary embodiment, the dispersed particles 214 are formed from the particle cores 14 dispersed in the cellular nanomatrix 216 of the sintered metal coating layers 16, and the nanomatrix 216 includes a solid metallurgical bond or a binding layer that extends between the dispersed particles 214 through the entire cell nanomatrix 216 that is formed at a sintering temperature (Ts), where Ts is less than the melting temperature of the coating (TC) and the temperature of particle melting (TP). As indicated, the solid-state metallurgical bond is formed in solid state through the interdiffusion between the coating layers 16 of the adjacent powder particles 12 which are compressed in touch contact during the compacting and sintering processes used for forming of the compacted powder 200, as described here, in this patent application. As such, the sintered coating layers 16 of the cell nanomatrix 216 include a solid state bonding layer that has a thickness defined by the extent of the interdiffusion of the coating materials 20 of the coating layers 16, which will in turn be defined by the nature of the coating layers 16, even if they are single-layered or multilayered, if they
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    15/25 have been selected to promote or limit inter-diffusion, and other factors, as described here, in this patent application, as well as the sintering and compacting conditions, including the sintering time, temperature and pressure used for the formation of compacted powder 200.
    [0018] As nanomatrix 216 is formed, including the metallurgical bond and the bonding layer, the chemical composition or phase distribution, or both, of the metallic coating layers 16 may change. Nanomatrix 216 also has a melting temperature TM. In the form used here, in this patent application, TM includes the lowest temperature at which incipient fusion or liquefaction or other forms of partial fusion will occur within nanomatrix 216, regardless of the fact that the material of nanomatrix 220 comprises a metal pure, an alloy with multiple phases, each having different melting temperatures or a composite, including a composite comprising a plurality of layers of various coating materials with different melting temperatures, or a combination thereof, or otherwise . As dispersed particles 214 and particles of core materials 218 are formed together with nanomatrix 216, diffusion of the constituents of the metallic coating layers 16 within the particle cores 14 is also possible, which can result in changes in chemical composition or phase distribution, or both, of particle cores 14. As a result, dispersed particles 214 and particle core materials 218 may have a melting temperature (TDP) that is different than that of TP. In the form used here, in this patent application TDP includes the lowest temperature at which incipient melting or liquefaction or other forms of partial melting will occur within the dispersed particles 214, regardless of the fact that the particle material of the core
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    16/25
    218 comprises a pure metal, an alloy with multiple phases, each having different melting temperatures or a composite, or otherwise. In one embodiment, compacted powder 200 is formed at a sintering temperature (Ts) where Ts is less than Tc, Tp, Tm and Tdp, and sintering is performed entirely in the solid state resulting in a bonding layer in solid state. In another embodiment, for example, compacted powder 200 is formed at a sintering temperature (Ts) where Ts is greater than or equal to one or more of Tc, Tp, Tm or Tdp, and sintering includes limited or partial melting within the compacted powder 200 as described herein, in this patent application, and may further include sintering in a liquid state or in a liquid phase resulting in a bonding layer that is at least partially fused and resolidated. In this modality, the combination of a predetermined Ts and a predetermined sintering time (ts) will be selected for the preservation of the desired microstructure that includes cell nanomatrix 216 and dispersed particles 214. For example, localized liquefaction or fusion may be allowed that occur, for example, in all or part of the nanomatrix 216, as long as the morphology of the cell nanomatrix 216 / dispersed particle 214 is preserved, such as through the selection of particle cores 14, and ts that do not provide the complete fusion of the particle cores. Similarly, localized liquefaction may be allowed to occur, for example, in all or part of the dispersed particles 214 as long as the morphology of the cell nanomatrix 216 / dispersed particle 214 is preserved, such as through the selection of coating layers metallic 15, Ts and ts that do not provide complete melting of the layer or coating layers 16. The melting of the metallic coating layers 16 can occur, for example, during sintering along the interface of the metallic layer 16 /
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    17/25 particle core 14, or along the interface between adjacent layers of multilayer coating layers 16. It will be noted that combinations of Ts and ts that do not exceed predetermined values can result in other microstructures, such as an equilibrium melting / liquefaction microstructure, if, for example, both the nanomatrix 216 (i.e., the combination of the metallic coating layers 16) and the dispersed particles 214 (i.e., the particle cores 14) are fused, thereby allowing reason for a rapid interdiffusion of these materials.
    [0019] The particle cores 14 and dispersed particles 214 of the compacted powder 200 can have any suitable particle size. In an exemplary embodiment, particle cores 14 can have a unimodal distribution and average particle diameter or size from about 5 pm to about 300 pm, more specifically from about 80 pm to about 120 pm, and even more specifically about 100 pm. In another embodiment by way of example, which may include multimodal particle size distribution, particle cores 14 may have an average diameter or particle size of about 50 nm to about 500 pm, more specifically about 500 nm until about 300 pm and even more specifically from about 5 pm to 300 pm. In one embodiment, for example, particle cores 14 or dispersed particles can have an average particle size of about 50 nm to about 500 pm.
    [0020] The dispersed particles 214 can have any suitable shape depending on the shape selected for the particle cores 14 and the powder particles 12, as well as the method used to sinter the powder compact 10. In an example embodiment, the particles of powder 12 can be spheroids or substantially spheroidal of the dispersed particles 214 can include a configuration
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    18/25 equiaxial particle as described here, in this patent application. In another embodiment, for example, the dispersed particles may have a non-spheroidal shape. In yet another embodiment, the dispersed particles can be substantially elongated in an extrusion direction 622, as can occur when extrusion is used to form compact 200. As illustrated in Figures 3 to 5, for example, a cell nanomatrix 616 substantially elongated which comprises a network of interconnected elongated cells of nanomatrix material 620 which has a plurality of substantially elongated scattered particle cores 614 of core material 618 arranged within the cell. Depending on the amount of deformation conferred to the formation of elongated particles, the elongated coating layers and the nanomatrix 616 can be substantially continuous in the predetermined direction 622 as shown in FIG. 4, or substantially discontinuous, as shown in FIG. 5.
    [0021] The nature of the dispersion of the dispersed particles 214 can be affected by the selection of powder 10 or powders 10 used to manufacture the particle compact 200. In one embodiment, for example, a powder 10 that has a unimodal distribution of particle sizes of powder 12 can be selected for the formation of compacted powder 200 and will produce a substantially homogeneous unimodal dispersion of particle sizes of dispersed particles 214 within cell nanomatrix 216. In another example embodiment, a plurality of powders 10 having a plurality of powder particles with particle cores 14 having the same core materials18 and different core sizes and the same coating material 20 can be selected and mixed uniformly as described here, in this patent application for provide a powder 10 that has a homogeneous distribution
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    19/25 multimodal of the particle sizes of powder 12, and which can be used for the formation of compacted powder 200 that has a homogeneous multimodal dispersion of particle sizes of the dispersed particles 214 within the cell nanomatrix 216. Similarly, in yet another embodiment, by way of example, a plurality of powders 10 having a plurality of particle cores 14 which can have the same materials 18 and different core sizes and the same coating material 20 can be selected and distributed in a non uniform to provide a particle size distribution of multimodal and inhomogeneous powder, and can be used for the formation of compacted powder 200 that has a non-homogeneous multimodal dispersion of particle sizes of the dispersed particles 214 within the cell nanomatrix 216. A selection of the particle size distribution of the core can be used for the determination of, for example , the particle size and inter-particle spacing of the dispersed particles 214 within the cellular nanomatrix 216 of the compacted powder 200 made from the powder 10.
    [0022] As illustrated in general in Figures 1 and 2, compacted metal powder 1200 can also be formed using a coated metal powder 10 and an additional or second powder 30 as described here in this patent application. The use of an additional powder 30 provides a compact powder 200 which also includes a plurality of second dispersed particles 234, as described herein, in this patent application which are dispersed within the nanomatrix 216 and are also dispersed with respect to the dispersed particles 214. The second dispersed particles 234 can be formed from coated or uncoated second powder particles 32 as described herein, in this patent application. In one embodiment, for example, the second coated powder particles 32 can be coated with a coating layer 36 which is the same as the coating layer.
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    20/25 coating 16 of the powder particles 12, such that the coating layers 36 also contribute to the nanomatrix 216. In another embodiment, for example, the second powder particles 232 may be uncoated in such a way that the second dispersed particles 234 are embedded within the nanomatrix 216. As described here, in this patent application, powder 10 and additional powder 30 can be mixed to form a homogeneous dispersion of dispersed particles 214 and second dispersed particles 234 or for the formation of a non-homogeneous dispersion of these particles. The second dispersed particles 234 can be formed from any additional powder matching 30 which is different from powder 10, either due to the difference in composition in the particle core 34 or in the coating layer 36, or both, and may include any of the materials described here, in this patent application to be used as a second powder 30 which is different from the powder 10 which is selected for the formation of the compacted powder 200. In one embodiment, for example, the second dispersed particles 234 they may include Ni, Fe, Cu, Co, W, Al, Zn, Mn, or Si, or an oxide, nitrite, carbide, intermetallic compound or ceramic metal comprising at least one of the above, or a combination thereof.
    [0023] Nanomatrix 216 is a substantially continuous cellular network of layers of metallic coating 16 which are sintered with each other. The thickness of the nanomatrix 216 will depend on the nature of the powder 10 or the powders 10 used to form the compacted powder 200, as well as the incorporation of any second powder 30, specifically the thickness of the coating layers associated with these particles. And, as an example, the thickness of the nanomatrix 216 is substantially uniform across the entire microstructure of the compacted powder 200, and comprises
    Petition 870180132562, of 9/20/2018, p. 24/38
    21/25 about twice the thickness of the coating layers 16 of the powder particles 12. In another embodiment, for example, the network of cells 216 in a substantially uniform average thickness between the dispersed particles 214 of about 50 nm to about 5000 nm. The compacted powder 200 formed through extrusion can have much smaller thicknesses, and can become non-uniform and substantially discontinuous as described here, in this patent application.
    [0024] Nanomatrix 216 is formed by sintering layers of metallic coating 16 of adjacent particles with each other through inter-diffusion and creating a bonding layer as described here, in this patent application. The metallic cladding layers 16 can be a single-layer or multilayered structures, and they can be selected to promote or inhibit diffusion or both, within the layer or between the layers of the metallic cladding layer 16 or between the metallic coating layer 16 and the particle core 14, or between the metallic coating layer 16 and the metallic coating layer 16 and an adjacent powder particle, the degree of interdiffusion of the metallic coating layers 16 during sintering can be limited or extensive depending on the coating thickness of the selected coating material or materials, the sintering conditions and other factors. Given the potential complexity of interdiffusion and component interaction, the description of the chemical composition resulting from nanomatrix 216 and material from nanomatrix 220 can be understood simply as a combination of the constituents of the coating layers 16, which can also include one or more more constituents of the scattered particles 214, depending on the degree of inter-diffusion, if any, that occurs between the scattered particles and 214 and the nanomatrix 216.
    Petition 870180132562, of 9/20/2018, p. 25/38
    22/25 similarly, the chemical composition of the dispersed particles 214 and the core material 218 can be understood simply as a combination of particle core constituents 14 which may also include one or more constituents of the nanomatrix 216 and the nanomatrix 220, depending on the degree of interdiffusion, if any, that occurs between dispersed particles 214 and nanomatrix 216. [0025] In one embodiment, for example, the material of nanomatrix 200 has a chemical composition and the core material particle 218 has a chemical composition that is different from that of the material of nanomatrix 220, and differences in chemical compositions can be configured to provide a selectable and controllable dissolution rate, which includes a transition form selectable from a rate very low dissolution to a very fast dissolution rate in response to a controlled change in a property or condition of well drilling, in the vicinity of compact 200, including a change in property of a well fluid which is in contact with compact powder 200, as described herein, in this patent application. Nanomatrix 216 can be formed from powder particles 12 having a single layer or multiple layers of coating 16. This design flexibility provides a large number of material combinations, especially in the case of multilayer coating layers 16 , which can be used to adapt cell nanomatrix 216 and the composition of nanomatrix materials 220 by controlling the interaction of the constituents of the coating layer, both within a given layer, as well as between the coating layer 16 and the core of the particles 14 with which it is associated, or a coating layer 16, of adjacent powder particles 12.
    [0026] In one modality, for example, the nanomatrix 216
    Petition 870180132562, of 9/20/2018, p. 26/38
    23/25 may comprise a nanomatrix material 220 comprising Ni, Fe, Cu, Co, W, Al, Zn, Mn, Mg or Si, or an alloy thereof, or an oxide, nitrite, carbide, intermetallic compound or metal ceramic tile that includes at least one of the precedents, or a combination of them.
    [0027] The compact metal powder 200 described here, in this patent application can be configured to provide selectively and controllably disposable, degradable, soluble, corrosion or otherwise removable from a well with a predetermined well fluid , which includes those described here, in this patent application. These materials can be configured to provide a corrosion rate of up to about 400 mg / cm 2 / hour, and more specifically a wax corrosion rate of 0.2 to about 50 mg / cm 2 / hour. These compacted powders 200 can also be configured to provide a high resistance, including a final compression resistance of up to 150 ksi, and more specifically from 60 ksi to about 150 ksi, and even more specifically from more than about 60 ksi to about 120 ksi.
    [0028] The terms one and one here, in this patent application, do not indicate a quantity limit, but instead indicate the presence of at least one of the items mentioned. The modifier used in connection with a quantity is inclusive of all declared values, and has the meaning dictated by the context (as, for example, it includes the degree of error associated with the measurement of the determined quantity). In addition, unless otherwise limited all ranges described here, in this patent application are inclusive and can be combined (such as ranges of up to about 25 weight percent (p%) more specifically about 5% by weight up to about 20% by weight and even more specifically about 10% by weight up to about 15% by weight are inclusive of end points and
    Petition 870180132562, of 9/20/2018, p. 27/38
    24/25 all intermediate values of the ranges, for example, about 5% by weight to about 25% by weight, about 5% by weight to about 15% by weight, etc.). The use of fence in conjunction with a constituent ratio of an alloy composition is applied to all related constituents, and in conjunction with a strip at both end points of the strip. Finally, unless otherwise defined, the technical and scientific terms used here in this patent application have the same meaning as they are commonly understood by a person skilled in the technique to which the invention belongs. Q suffix (s) in the form used here, in this patent application is intended to include both the singular and the plural of the term it modifies, therefore including one or more of that term (such as the metal (s) ( (i) include one or more metals). The reference throughout the specification to a modality another modality, a modality and so on, means that the specific element (such as, for example, characteristic, structure and / or other characteristics) described in connection with the modality are included in at least a modality described here, in this patent application, and may or may not be present in other modalities.
    [0029] It should be understood that the use of comprising in conjunction with the alloy compositions described herein, in this patent application, describe specifically and include the modalities in which the alloy composition essentially consists of the indicated components (i.e., contains the indicated components and no other components that adversely affect the described basic and new characteristics), and modalities in which the alloy compositions consist of the indicated components (that is, it contains only the indicated components except with respect to the contaminants that are naturally and inevitably present in each of the indicated components). Although one or more
    Petition 870180132562, of 9/20/2018, p. 28/38
    25/25 modalities have been shown and described, modifications and substitutions can be made the same without departing from the spirit and scope of the invention. Accordingly, it should be understood that the present invention has been described by way of illustration and not by way of limitation.
    权利要求:
    Claims (28)
    [1]
    1. Compacted metal powder characterized by the fact that it comprises:
    a cellular nanomatrix comprising a nanomatrix material in which the nanomatrix material comprises Mg, or an oxide, nitride, carbide, intermetallic compound or ceramic metal provided, or a combination of Mg and at least one of Ni, Fe, Cu, Co , W, Al, Zn, Mn or Si; and;
    a plurality of dispersed particles comprising a particle core material comprising an Al-CuMg, Al-Mn, Al-Si, Al-Mg, Al-Mg-Si, Al-Zn, Al-Zn-Cu alloy, Al-Zn-Mg, Al-Zn-Cr, Al-Zn-Zr, or Al-Sn-Li, or a combination thereof, dispersed in the cell nanomatrix.
    [2]
    2. Compacted metal powder according to claim 1, characterized in that the particle core material comprises, in percentage by weight of the alloy, from 0.05% to 2.0% Mg; from 0.1% to 0.8% Si; from 0.7% to 6.0% Cu; from 0.1% to 1.2% Mn; from 0.1% to 0.8% Zn; from 0.05% to 0.25% Ti; and 0.1% - 1.2% Fe; and the remainder of Al and incidental impurities.
    [3]
    3. Compacted metal powder according to claim 1, characterized by the fact that the particle core material comprises, in weight percent of the alloy from 0.5% to 6.0% Mg; from 0.05% to 0.30% Zn; from 0.10% to 1.0% of Mn, from 0.08% to 0.75% of Si and the rest of Al and incidental impurities.
    [4]
    4. Compacted metal powder according to claim
    1, characterized by the fact that the particle core material or the nanomatrix material, or a combination thereof, comprises a nano structured material.
    [5]
    5. Compacted metal powder according to claim
    4, characterized by the fact that the nano structured material has a
    Petition 870180132562, of 9/20/2018, p. 30/38
    2/4 grain size less than 200 nm.
    [6]
    6. Compacted metal powder according to claim 5, characterized by the fact that the nano structured material has a grain size from 10 nm to 200 nm.
    [7]
    7. Compacted metal powder according to claim 4, characterized by the fact that the nanostructured material has an average grain size less than about 100 nm.
    [8]
    8. Compacted metal powder according to claim
    I, characterized by the fact that the dispersed particle further comprises a subparticle.
    [9]
    Compacted metal powder according to claim 8, characterized by the fact that the subparticle has an average particle size from 10 nm to 1 micron.
    [10]
    10. Compacted metal powder according to claim 8, characterized in that the subparticle comprises a preformed subparticle, a precipitate or a dispersoid.
    [11]
    Compacted metal powder according to claim 8, characterized by the fact that the subparticle is arranged inside or on the surface of the dispersed particle, or a combination thereof.
    [12]
    12. Compacted metal powder according to claim
    II, characterized by the fact that the subparticle is arranged on the surface of the dispersed particle and also comprises the material of the nanomatrix.
    [13]
    13. Compacted metal powder according to claim 1, characterized by the fact that the dispersed particles have an average particle size of 50 nm up to 500 pm.
    [14]
    14. Compacted metal powder according to claim
    1, characterized by the fact that the dispersed particles comprise a multimodal particle size distribution
    Petition 870180132562, of 9/20/2018, p. 31/38
    3/4 inside the cell nanomatrix.
    [15]
    15. Compacted metal powder according to claim 1, characterized in that the core material of the particles further comprises a rare earth element.
    [16]
    16. Compacted metal powder according to claim 1, characterized by the fact that the dispersed particles have an equiaxial particle shape and the nanomatrix is continuous.
    [17]
    17. Compacted metal powder according to claim 1, characterized by the fact that the nanomatrix and the dispersed particles are elongated in a predetermined direction.
    [18]
    18. Compacted metal powder according to claim 17, characterized by the fact that the nanomatrix is continuous.
    [19]
    19. Compacted metal powder according to claim 17, characterized by the fact that the nanomatrix is discontinuous.
    [20]
    20. Compacted metal powder according to claim 1, characterized by the fact that it further comprises a plurality of second dispersed particles, in which the second dispersed particles are also dispersed within the cellular nanomatrix and with respect to the dispersed particles.
    [21]
    21. Compacted metal powder according to claim
    20, characterized by the fact that the second dispersed particles comprise a metal, carbon, metal oxide, metal nitride, metal carbide, an intermetallic compound or ceramic metal, or a combination thereof.
    [22]
    22. Compacted metal powder according to claim
    21, characterized by the fact that the second dispersed particles comprise Ni, Fe, Cu, Co, W, Al, Zn, Mn, Mg or Si, or an oxide, nitride, carbide, intermetallic compound or ceramic metal comprising at least one precedents or a combination thereof.
    Petition 870180132562, of 9/20/2018, p. 32/38
    4/4
    [23]
    23. Compacted metal powder according to claim 1, characterized in that the material of the nanomatrix comprises a constituent of a grinding medium or a grinding fluid.
    [24]
    24. Compacted metal powder according to claim 1, characterized in that the nanomatrix material comprises a multilayer material.
    [25]
    25. Compacted metal powder according to claim 1, characterized in that the nanomatrix material has a chemical composition and the particle core material has a chemical composition that is different than the chemical composition of the nanomatrix material.
    [26]
    26. Compacted metal powder according to claim 1, characterized by the fact that the cell nanomatrix has an average thickness of 50 nm to 5000 nm.
    [27]
    27. Compacted metal powder according to claim 1, characterized in that it further comprises a bonding layer that extends through the cellular nanomatrix between the dispersed particles.
    [28]
    28. Compacted metal powder according to claim 27, characterized in that the bonding layer comprises a solid-state bonding layer.
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    同族专利:
    公开号 | 公开日
    US20180178289A1|2018-06-28|
    BR112014003726A2|2017-03-14|
    US9090956B2|2015-07-28|
    AP2014007460A0|2014-02-28|
    CA2842962C|2018-10-23|
    US11090719B2|2021-08-17|
    CA2842962A1|2013-03-07|
    US20130047784A1|2013-02-28|
    EP2751298A4|2015-02-18|
    CN103764858A|2014-04-30|
    WO2013032629A1|2013-03-07|
    US20160001366A1|2016-01-07|
    CN103764858B|2017-03-15|
    US9925589B2|2018-03-27|
    EP2751298A1|2014-07-09|
    AU2012301491B2|2017-01-05|
    AU2012301491A1|2014-01-30|
    MY171181A|2019-09-30|
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    法律状态:
    2018-06-26| B07A| Application suspended after technical examination (opinion) [chapter 7.1 patent gazette]|
    2019-01-22| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2019-03-12| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 03/08/2012, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    US13/220,822|2011-08-30|
    US13/220,822|US9090956B2|2011-08-30|2011-08-30|Aluminum alloy powder metal compact|
    PCT/US2012/049442|WO2013032629A1|2011-08-30|2012-08-03|Aluminum alloy powder metal compact|
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