Galvanically-Active In Situ Formed Particles for Controlled Rate Dissolving Tools

Abstract

A castable, moldable, and/or extrudable structure using a metallic primary alloy. One or more additives are added to the metallic primary alloy so that in situ galvanically-active reinforcement particles are formed in the melt or on cooling from the melt. The composite contains an optimal composition and morphology to achieve a specific galvanic corrosion rate in the entire composite. The in situ formed galvanically-active particles can be used to enhance mechanical properties of the composite, such as ductility and/or tensile strength. The final casting can also he enhanced by heat treatment, as well as deformation processing such as extrusion, forging, or rolling, to further improve the strength of the final composite over the as-cast material.

1 - 17 . (canceled) 
     
     
         18 . A magnesium composite that includes in situ precipitation of galvanically-active intermetallic phases comprising a magnesium or a magnesium alloy and an additive constituting about 0.05-45 wt. % of said magnesium composite, said magnesium having a content in said magnesium composite that is greater than 50 wt. %, said additive forming metal composite particles or precipitant in said magnesium composite, said metal composite particles or precipitant forming said in situ precipitation of said galvanically-active intermetallic phases, said additive including one or more first additives having an electronegativity of greater than 1.5. 
     
     
         19 . The magnesium composite as defined in  claim 18 , further including one or more second additives having an electronegativity of less than 1.25. 
     
     
         20 . The magnesium composite as defined in  claim 18 , wherein said first additive has an electronegativity of greater than 1.8, 
     
     
         21 . The magnesium composite as defined in  18 , wherein said first additive includes one or more metals selected from the group consisting of copper, nickel, cobalt, bismuth, silver, gold, lead, tin, antimony, indium, arsenic, mercury, and gallium. 
     
     
         22 . The magnesium composite as defined in  18 , wherein said second additive includes one or more metals selected from the group consisting of calcium, strontium, barium, potassium, sodium, lithium, cesium, and the rare earth metals such as yttrium, lanthanum, samarium, europium, gadolinium, terbium, dysprosium, holmium, and ytterbium. 
     
     
         23 . The magnesium composite as defined in  claim 18 , wherein said magnesium alloy includes over 50 wt. % magnesium and one or more metals selected from the group consisting of aluminum, boron, bismuth, zinc, zirconium, and manganese. 
     
     
         24 . The magnesium composite as defined in  claim 18 , wherein said additive includes about 0.05-45 wt. % nickel. 
     
     
         25 . The magnesium composite as defined in  claim 18 , wherein said first additive includes about 0.05-45 wt. % copper. 
     
     
         26 . The magnesium composite as defined in  claim 18 , wherein said first additive includes about 0.05-45 wt. % cobalt. 
     
     
         27 . The magnesium composite as defined in  claim 18 , wherein said first additive includes about 0.05-45 wt. % antimony. 
     
     
         28 . The magnesium composite as defined in  claim 18 , wherein said first additive includes about 0.05-45 wt. % gallium. 
     
     
         29 . The magnesium composite as defined in  claim 18 , wherein said first additive includes about 0.05-45 wt. % tin. 
     
     
         30 . The magnesium composite as defined in  claim 18 , wherein said first additive includes about 0.05-45 wt. % bismuth. 
     
     
         31 . The magnesium composite as defined in  claim 18 , wherein said second additive includes 0.05-35 wt. % calcium. 
     
     
         32 . The magnesium composite as defined in  claim 18 , wherein said magnesium composite has a dissolution rate of at least 5 mg/cm2-hr, in 3% KCl at 90° C. 
     
     
         33 . A dissolvable component for use in downhole operations that is fully or partially formed of a magnesium composite, said dissolvable component including a component selected from the group consisting of sleeve, frac ball, hydraulic actuating tooling, mandrel, slip, grip, ball, dart, carrier, tube, valve, valve component, plug, or other downhole well component, said magnesium composite includes in situ precipitation of galvanically-active intermetallic phases comprising a magnesium or a magnesium alloy and an additive constituting about 0.05-45 wt. % of said magnesium composite, said magnesium having a content in said magnesium composite that is greater than 50 wt. %, said additive forming metal composite particles or precipitant in said magnesium composite, said metal composite particles or precipitant forming said in situ precipitation of said galvanically-active intermetallic phases, said additive including one or more first additives having an electronegativity of greater than 15. 
     
     
         34 . A dissolvable component for use in downhole operations that is fully or partially formed of a magnesium composite, said magnesium composite including in situ precipitation of galvanically-active intermetallic phases comprising a magnesium alloy, said magnesium alloy including over 50 wt. % magnesium and one or more metals selected from the group consisting of aluminum, boron, bismuth, zinc, zirconium, and manganese, said magnesium composite including additive, said additive including first additive and second additive, said first additive including one or more elements having an electronegativity of greater than 1.5, said second additive including one or more elements having an electronegativity of less than 1.25, said second additive including calcium, said additive constituting about 0.05-45 wt. % of said magnesium composite, said magnesium composite having a dissolution rate of at least 5 mg/cm 2 -hr. in 3% KCl at 90° C. 
     
     
         35 . The dissolvable component as defined in  claim 34 , wherein said first additive includes one or more metals selected from the group consisting of calcium, copper, nickel, cobalt, bismuth, silver, gold, lead, tin, antimony, indium, arsenic, mercury, and gallium. 
     
     
         36 . The dissolvable component as defined in  claim 34 , wherein said second additive includes one or more metals selected from the group consisting of strontium, barium, potassium, sodium, lithium, cesium, and the rare earth metals such as yttrium, lanthanum, samarium, europium, gadolinium, terbium, dysprosium, holmium, and ytterbium, 
     
     
         37 . The dissolvable component as defined in  claim 35 , Wherein said second additive includes one or more metals selected from the group consisting of strontium, barium, potassium, sodium, lithium, cesium, and the rare earth metals such as yttrium, lanthanum, samarium, europium, gadolinium, terbium, dysprosium, holmium, and ytterbium,