Reconfigurable downhole article

Abstract

A reconfigurable downhole article is disclosed. The article comprises a base material. The article also comprises a removable material disposed on or within the base material that is configured for removal from the base material in response to a wellbore condition, wherein the base material and the removable material define a base article that is configured to perform a first function, and wherein upon removal of the removable material, the base material defines a modified article that is configured to perform a second function that is different than the first function.

1 . A reconfigurable downhole article, comprising:
 a base material; and   a removable material disposed on or within the base material that is configured for removal from the base material in response to a wellbore condition, wherein the base material and the removable material define a base article that is configured to perform a first function, and wherein upon removal of the removable material, the base material defines a modified article that is configured to perform a second function that is different than the first function.   
     
     
         2 . The reconfigurable downhole article of  claim 1 , wherein the removable material comprises a plurality of corrodible metal powder particles dispersed within the base material. 
     
     
         3 . The reconfigurable downhole article of  claim 1 , wherein each removable metal powder particle comprises: a particle core, the particle core comprises a core material comprising Mg, Al, Zn, Fe or Mn, or alloys thereof, or a combination thereof, and a nanoscale metallic coating layer disposed on the particle core. 
     
     
         4 . The reconfigurable downhole article of  claim 3 , wherein the metallic coating layer comprises Al, Zn, Mn, Mg, Mo, W, Cu, Fe, Si, Ca, Co, Ta, Re or Ni, or an oxide, carbide or nitride thereof, or a combination of any of the aforementioned materials, and wherein the metallic coating layer has a chemical composition and the particle core material has a chemical composition that is different than the chemical composition of the metallic coating material. 
     
     
         5 . The reconfigurable downhole article of  claim 1 , wherein at least a portion of the removable particles are in touching contact with one another. 
     
     
         6 . The reconfigurable downhole article of  claim 1 , wherein the removable material comprises a sintered or unsintered powder compact disposed on the base material. 
     
     
         7 . The reconfigurable downhole article of  claim 1 , wherein the plurality of removable metal powder particles comprise a sintered or unsintered powder compact disposed within the base material. 
     
     
         8 . The reconfigurable downhole article of  claim 1 , wherein the removable material comprises a powder compact having a shape and comprising a plurality of removable metal powder particles disposed within the base material, wherein the powder compact is substantially enclosed within the base material. 
     
     
         9 . The reconfigurable downhole article of  claim 1 , wherein upon removal of the removable material, the modified article comprises a substantially closed cavity having a shape corresponding to the shape of the powder compact. 
     
     
         10 . The reconfigurable downhole article of  claim 1 , wherein the modified article comprises a surface having predetermined surface texture, and wherein the surface texture comprises a friction control surface. 
     
     
         11 . The reconfigurable downhole article of  claim 1 , wherein upon removal of the removable material, the modified article comprises a predetermined porosity in the base material that was not present in the base article, the predetermined porosity extends from a first surface through a wall section to a second surface, and the wall section defines a screen, filter, or porous barrier. 
     
     
         12 . The reconfigurable downhole article of  claim 1 , wherein the base material comprises a cross-linked polymer and the removable material comprises a salt. 
     
     
         13 . The reconfigurable downhole article of  claim 12 , wherein the cross-linked polymer comprises cross-linked polyethersulfone and the salt comprises an inorganic salt or an organic salt. 
     
     
         14 . The reconfigurable downhole article of  claim 12 , wherein the base article comprises an open cell network of cell walls comprising the cross-linked polymer, and wherein the salt is disposed within the cell walls. 
     
     
         15 . The reconfigurable downhole article of  claim 1 , wherein the modified article comprises an open cell foam of the cross-linked polymer. 
     
     
         16 . The reconfigurable downhole article of  claim 1 , wherein the base material comprises a concrete and the removable material comprises a plurality of removable metal powder particles dispersed within the concrete. 
     
     
         17 . The reconfigurable downhole article of  claim 1 , wherein the modified article comprises a porous concrete comprising a plurality of dispersed pores corresponding to spaces previously occupied by the removable metal powder particles dispersed within the concrete. 
     
     
         18 . The reconfigurable downhole article of  claim 17 , wherein the plurality of dispersed pores comprise an open cell network of interconnected pores dispersed within the concrete. 
     
     
         19 . The reconfigurable downhole article of  claim 18 , wherein the modified article comprises a fluid permeable concrete. 
     
     
         20 . The reconfigurable downhole article of  claim 16 , wherein the concrete comprises a cement and an aggregate. 
     
     
         21 . The reconfigurable downhole article of  claim 1 , wherein the base article comprises a downhole tool or component and the modified article comprises a downhole tool or component. 
     
     
         22 . The reconfigurable downhole article of  claim 21 , wherein the modified article has a feature that is not found in the base article. 
     
     
         23 . The reconfigurable downhole article of  claim 22 , wherein the feature comprises a through-hole, opening, blind hole, blind opening, conduit, passage, groove, protruding rib, or shoulder. 
     
     
         24 . The reconfigurable downhole article of  claim 21 , wherein the downhole tool or component comprises a well drilling, completion or production tool or component. 
     
     
         25 . The reconfigurable downhole article of  claim 21 , wherein the downhole tool or component comprises a screen, sieve, porous wall, filter, clutch, bearing, bushing, brake, shaft, sleeve, tubular, casing, seal, plug, packing, or liner. 
     
     
         26 . A reconfigurable downhole article, comprising:
 a base article, the base article comprising a base material and a removable material, the removable material comprising a substantially-continuous, cellular nanomatrix comprising a nanomatrix material, a plurality of dispersed particles comprising a particle core material that comprises Mg, Al, Zn, Fe or Mn, or a combination thereof, dispersed in the cellular nanomatrix; and a bond layer extending throughout the cellular nanomatrix between the dispersed particles; and   a modified article comprising the base material, wherein the base article is configured for irreversible transformation to the modified article by removal of the removable material.   
     
     
         27 . The reconfigurable downhole article of  claim 26 , wherein upon removal of the removable material, the modified article comprises at least one of a predetermined surface texture in the base material, a predetermined porosity in the base material or a substantially closed cavity in the base material that was not present in the base article. 
     
     
         28 . The reconfigurable downhole article of  claim 26 , wherein the metallic coating layer comprises Al, Zn, Mn, Mg, Mo, W, Cu, Fe, Si, Ca, Co, Ta, Re or Ni, or an oxide, carbide or nitride thereof, or a combination of any of the aforementioned materials, and wherein the metallic coating layer has a chemical composition and the particle core material has a chemical composition that is different than the chemical composition of the metallic coating material. 
     
     
         29 . The reconfigurable downhole article of  claim 26 , wherein the base article comprises a downhole tool or component and the modified article comprises a downhole tool or component. 
     
     
         30 . The reconfigurable downhole article of  claim 29 , wherein the modified article has a feature that is not found in the base article. 
     
     
         31 . The reconfigurable downhole article of  claim 30 , wherein the feature comprises a through-hole, opening, blind hole, blind opening, conduit, passage, groove, protruding rib, or shoulder. 
     
     
         32 . The reconfigurable downhole article of  claim 26 , wherein the downhole tool or component or tool comprises a well drilling, completion or production tool or component. 
     
     
         33 . The reconfigurable downhole article of  claim 26 , wherein the downhole tool or component comprises a screen, sieve, porous wall, filter, clutch, bearing, bushing, brake, shaft, sleeve, tubular, casing, seal, plug, packing, or liner.