Cast flapper with hot isostatic pressing treatment

Abstract

Components of a subsurface safety valve are cast instead of machined for dramatic cost savings. In particular, the flapper is cast from a 718 nickel alloy and treated with the HIP process to increase strength and corrosion resistance while reducing porosity. Other downhole valve components are contemplated to be produced by the same technique and the materials can also be varied. Depending on the specific alloys, the resulting HIP components are either superior in performance (e.g. strength, corrosion resistance) or considerably cheaper to manufacture than their wrought counterparts.

1 . A method of manufacturing components for a downhole tool, comprising: 
 casting the component;    subjecting the component to a HIP process;    finish machining said component to a desired dimension.    
   
   
       2 . The method of  claim 1 , comprising: 
 producing engaging components of the downhole tool.    
   
   
       3 . The method of  claim 1 , comprising: 
 producing a flapper for a safety valve.    
   
   
       4 . The method of  claim 1 , comprising: 
 producing a seat for a flapper in a safety valve.    
   
   
       5 . The method of  claim 1 , comprising: 
 producing a flow tube for a safety valve.    
   
   
       6 . The method of  claim 1 , comprising: 
 using a nickel alloy for the material for said casting.    
   
   
       7 . The method of  claim 1 , comprising: 
 using 718 nickel alloy for the material for said casting.    
   
   
       8 . The method of  claim 1 , comprising: 
 reducing porosity of said casting with said HIP process.    
   
   
       9 . The method of  claim 1 , comprising: 
 improving corrosion resistance of said casting by said HIP process.    
   
   
       10 . The method of  claim 1 , comprising: 
 increasing strength of said casting by said HIP process.    
   
   
       11 . The method of  claim 3 , comprising: 
 using a nickel alloy for the material for said casting.    
   
   
       12 . The method of  claim 10 , comprising: 
 using 718 nickel alloy for the material for said casting.    
   
   
       13 . The method of  claim 11 , comprising: 
 reducing porosity of said casting with said HIP process.    
   
   
       14 . The method of  claim 12 , comprising: 
 improving corrosion resistance of said casting by said HIP process.    
   
   
       15 . The method of  claim 13 , comprising: 
 increasing strength of said casting by said HIP process.    
   
   
       16 . The method of  claim 14 , comprising: 
 producing engaging components of the downhole tool.    
   
   
       17 . The method of  claim 15 , comprising: 
 producing a seat for a flapper in a safety valve.    
   
   
       18 . The method of  claim 16 , comprising: 
 producing a flow tube for a safety valve.