Downhole tool and method of use

Abstract

A downhole tool for use in a wellbore having a mandrel, a bearing plate, a composite slip, and a metal slip. The metal slip has a metal slip body having a one-piece configuration, an outer metal slip surface, an inner metal slip surface, and a plurality of metal slip grooves disposed therein. At least one of metal slip groove forms a lateral opening in the metal slip body. The metal slip is made of a reactive metal-based material.

What is claimed is: 
     
         1 . A downhole tool for use in a wellbore, the downhole tool comprising:
 a mandrel made of a composite material, the mandrel further comprising:
 a distal end; a proximate end; and an outer surface; 
   a bearing plate disposed around the mandrel;   a composite slip disposed around the mandrel proximate to the proximate end, the composite slip further comprising:
 a composite slip body having a one-piece configuration, an outer slip surface, 
 an inner slip surface, and a plurality of grooves disposed therein, 
 wherein at least one of the plurality of grooves forms a lateral opening in the composite slip body that is defined by a first portion of slip material at a first slip end, a second portion of slip material at a second slip end, and a depth that extends from the outer slip surface to the inner slip surface; 
   a metal slip disposed around the mandrel proximate to the distal end, the metal slip further comprising:
 a metal slip body having a one-piece configuration, an outer metal slip surface, an inner metal slip surface, and a plurality of metal slip grooves disposed therein, 
 wherein at least one of the plurality of metal slip grooves forms a lateral opening in the metal slip body that is defined by a first portion of metal slip material at a first metal slip end, a second portion of metal slip material at a second metal slip end, and a metal slip depth that extends from the outer metal slip surface to the inner metal slip surface; 
   a first cone disposed around the mandrel, and proximate to the composite slip;   a sealing element disposed around the mandrel; and   a lower sleeve coupled to the mandrel, and proximate to a second side of the metal slip,   wherein the metal slip is made of a reactive metal-based material.   
     
     
         2 . The downhole tool of  claim 1 , the downhole tool further comprising a second cone disposed around the mandrel, and proximate to the metal slip, and wherein the lower sleeve is threadingly coupled with the mandrel. 
     
     
         3 . The downhole tool of  claim 1 , wherein the composite material comprises filament wound material, wherein the mandrel is configured with a ball seat configured receive a ball that restricts fluid flow in at least one direction through the flowbore, wherein the ball seat has a radius configured with a rounded edge. 
     
     
         4 . The downhole tool of  claim 3 , wherein the reactive metal-based material comprises one of dissolvable aluminum-based material, dissolvable magnesium-based material, and dissolvable aluminum-magnesium-based material. 
     
     
         5 . The downhole tool of  claim 4 , wherein the composite slip comprises a first inner surface having a first angle with respect to an axis, wherein each of the composite slip and the metal slip comprise a plurality of inserts disposed therein. 
     
     
         6 . The downhole tool of  claim 1 , wherein the reactive metal-based comprises one of dissolvable aluminum-based material, dissolvable magnesium-based material, and dissolvable aluminum-magnesium-based material. 
     
     
         7 . The downhole tool of  claim 1 , wherein a circumferential taper is formed on the outer surface near the proximate end, wherein the circumferential taper is formed at an angle φ of about 5 degrees with respect to a longitudinal axis of the mandrel, and a length of the circumferential taper is about 0.5 inches to about 0.75 inches. 
     
     
         8 . The downhole tool of  claim 7 , wherein the downhole tool is selected from the group consisting of a frac plug, a bridge plug, a bi-directional bridge plug, and a kill plug. 
     
     
         9 . A downhole tool for use in a wellbore, the downhole tool comprising:
 a mandrel made of a composite material, the mandrel further comprising:
 a distal end; a proximate end; and an outer surface; 
   a bearing plate disposed around the mandrel;   a composite slip disposed around the mandrel proximate to the proximate end, the composite slip further comprising:
 a composite slip body having a one-piece configuration, an outer slip surface, an inner slip surface, and a plurality of grooves disposed therein, 
 wherein at least one of the plurality of grooves forms a lateral opening in the composite slip body that is defined by a first portion of slip material at a first slip end, a second portion of slip material at a second slip end, and a depth that extends from the outer slip surface to the inner slip surface; 
   a metal slip disposed around the mandrel proximate to the distal end, the metal slip further comprising:
 a metal slip body having a one-piece configuration, an outer metal slip surface, an inner metal slip surface, and a plurality of metal slip grooves disposed therein, 
 wherein at least one of the plurality of metal slip grooves forms a lateral opening in the metal slip body that is defined by a first portion of metal slip material at a first metal slip end, a second portion of metal slip material at a second metal slip end, and a metal slip depth that extends from the outer metal slip surface to the inner metal slip surface; 
   a composite member comprising:
 a resilient portion; and 
 a deformable portion having at least one member groove formed therein, 
 wherein the resilient portion and the deformable portion are made of a first material, and wherein a second material is bonded to the deformable portion and at least partially fills into the at least one member groove, 
   wherein the metal slip is made of a reactive metal-based material.   
     
     
         10 . The downhole tool of  claim 9 , wherein each of the composite slip body and the metal slip body comprises a respective plurality of inserts disposed therein, and wherein at least one of the respective plurality of inserts comprises a flat surface. 
     
     
         11 . The downhole tool of  claim 10 , wherein a lower sleeve is threadingly coupled with the mandrel. 
     
     
         12 . The downhole tool of  claim 11 , wherein the composite material comprises filament wound material, wherein the mandrel is configured with a ball seat configured receive a ball that restricts fluid flow in at least one direction through the flowbore, wherein the ball seat has a radius configured with a rounded edge. 
     
     
         13 . The downhole tool of  claim 11 , wherein the reactive metal-based material comprises one of dissolvable aluminum-based material, dissolvable magnesium-based material, and dissolvable aluminum-magnesium-based material. 
     
     
         14 . The downhole tool of  claim 9 , wherein the composite material comprises filament wound material, wherein the mandrel is configured with a ball seat configured receive a ball that restricts fluid flow in at least one direction through the flowbore, wherein the ball seat has a radius configured with a rounded edge. 
     
     
         15 . The downhole tool of  claim 9 , wherein the reactive metal-based comprises one of dissolvable aluminum-based material, dissolvable magnesium-based material, and dissolvable aluminum-magnesium-based material. 
     
     
         16 . The downhole tool of  claim 15 , wherein a circumferential taper is formed on the outer surface near the proximate end, wherein the circumferential taper is formed at an angle φ of about 5 degrees with respect to a longitudinal axis of the mandrel, and a length of the circumferential taper is about 0.5 inches to about 0.75 inches. 
     
     
         17 . The downhole tool of  claim 9 , wherein a circumferential taper is formed on the outer surface near the proximate end, wherein the circumferential taper is formed at an angle φ of about 5 degrees with respect to a longitudinal axis of the mandrel, and a length of the circumferential taper is about 0.5 inches to about 0.75 inches. 
     
     
         18 . The downhole tool of  claim 17 , wherein the downhole tool is selected from the group consisting of a frac plug, a bridge plug, a bi-directional bridge plug, and a kill plug.