Homogeneous shaped charge liner and fabrication method

Abstract

A shaped charged liner for oil well perforating is made from composite metal powder of clusters of pre-agglomerated particles of a denser metal with an agglutinating metal which is press-molded or tap-molded into a near net-shape liner preform which is then sintered to form a sintered body which is hot-coined or forged to form the final shape liner. The powder is formed by different density metal particles which are preclustered.

What is claimed is:  
     
         1 . A process for manufacturing to a desired shape and dimensions, a homogeneous shaped charge liner which comprises: 
 selecting a free-flowing powder of agglomerated nodules of a first metal and of a second metal having a higher specific gravity and a higher melting point than said first metal, wherein each of said nodules comprises an agglutination of sub-nodules wherein each of said sub-nodules include at least one particle of said first metal and at least one particle of said second metal bonded together;    pressing a volume of said powder into a compact;    sintering said compact at a temperature sufficient to melt said first metal to form a sintered body; and    coining said sintered body into a composite body having said desired shape and dimensions.    
     
     
         2 . The process of  claim 1 , wherein said step of pressing comprises shaping said compact to a near net-shape of said desired shape.  
     
     
         3 . The process of  claim 1 , wherein said pressing comprises tap-molding said volume.  
     
     
         4 . The process of  claim 1 , wherein said pressing comprises compacting said volume into a mold at room temperature.  
     
     
         5 . The process of  claim 1 , wherein said selecting comprises selecting said second metal from a group consisting of metals and alloys having a specific gravity of at least 10 grams/cm 3 .  
     
     
         6 . The process of  claim 5 , wherein said second metal is selected from the group consisting of tungsten, molybdenum, and alloys thereof.  
     
     
         7 . The process of  claim 5 , wherein said first metal is selected from the group consisting of copper and alloys thereof.  
     
     
         8 . The process of  claim 1 , wherein: 
 said selecting comprises selecting copper as said first metal and tungsten as said second metal; and    said sintering comprises sintering at a temperature between about 1090° C. and 1230° C.    
     
     
         9 . The process of  claim 1 , wherein said step of selecting comprises selecting a aggregate powder consisting of particles of the first and second metals, breakably bonded together into nodules and sub-nodules.  
     
     
         10 . In the process of manufacturing a shaped charge liner for use in perforating wells by pressing a volume of powdered metal particles of different densities, an improvement which comprises: 
 using a free-flowing powder of preclustered nodules of said metal particles of different densities.    
     
     
         11 . A process for fabricating a shaped charge liner for perforating a well comprises: 
 selecting a free-flowing powder of pre-agglomerated particles of different density metals; and    forming a volume of said powder into a shaped charge liner.    
     
     
         12 . The process of  claim 11 , wherein said forming comprises press-molding said volume into a compact.  
     
     
         13 . The process of  claim 11 , wherein said forming comprises tap-molding said volume into a compact.