Degradable high-strength zinc compositions and method of manufacture

Abstract

A degradable, high-strength zinc composition suitable for use in producing degradable tools and components for in use in oil and gas and related application fields.

1 - 24 . (canceled) 
     
     
         25 . A method for forming the degradable tool including the steps of:
 a. providing a degradable high-strength zinc alloy, said degradable high-strength zinc alloy which includes more than 50 wt. % zinc and one or more additives selected from the group consisting of aluminum, copper, magnesium, calcium, lead, tin, gallium, lithium, sodium, and strontium, said degradable high-strength zinc alloy having a shear strength of greater than 25,000 psig, said degradable high-strength zinc alloy having a degradation rate of one or more of a) about 10-150 mg/cm2/hr. in a 3 wt. % KCl fluid at a temperature of 90° C., b) 0.1-75 mm/day at 50-135° C. in fresh water, c) 0.1-75 mm/day at 50-135° C. in salt water, d) no more than 2 mg/cm2/hr. in salt water, and e) no more than 2 mg/cm2/hr. in fresh water; and   b. shaping said degradable high-strength zinc alloy to at least partially form said degradable tool.   
     
     
         26 . The method as defined in  claim 25 , wherein said step of shaping includes one or more processes selected from the group consisting of molding, casting, extruding, heat treating, cutting, welding, forging, plastically deforming, and machining. 
     
     
         27 . A method for using a degradable alloy including the steps of:
 a. providing a tool, device, shape, or component formed from the degradable high-strength zinc alloy, said degradable high-strength zinc alloy includes more than 50 wt. % zinc, said degradable high-strength zinc alloy having a degradation rate of at least 5 mg/cm 2 /hr. in a 3 wt. % KCl fluid at a temperature of 90° C., said degradable high-strength zinc alloy having a shear strength of greater than 25,000 psig.;   b. placing said tool, device, shape, or component into a wellbore;   c. allowing said tool, device, shape, or component to contact a wellbore fluid; and   d. allowing said tool, shape, component, or device to at least partially degrade in said wellbore fluid.   
     
     
         28 . A degradable tool that is at least partially formed from a degradable high-strength zinc alloy, said degradable high-strength zinc alloy which includes more than 50 wt. % zinc and one or more additives selected from the group consisting of aluminum, copper, magnesium, calcium, lead, tin, gallium, lithium, sodium, and strontium, said degradable high-strength zinc alloy having a shear strength of greater than 25,000 psig, said degradable high-strength zinc alloy having a degradation rate of one or more of a) about 10-150 mg/cm2/hr. in a 3 wt. % KCl fluid at a temperature of 90° C., b) 0.1-75 mm/day at 50-135° C. in fresh water, c) 0.1-75 mm/day at 50-135° C. in salt water, d) no more than 2 mg/cm2/hr. in salt water, and e) no more than 2 mg/cm2/hr. in fresh water. 
     
     
         29 . The degradable tool as defined in  claim 28 , wherein said additive in three or more of aluminum, copper, magnesium, calcium, lead, tin, and gallium. 
     
     
         30 . The degradable tool as defined in  claim 28 , wherein said degradable high-strength zinc alloy includes at least 2 wt. % of one or more elements selected from the group of aluminum, magnesium, calcium, lithium, sodium, and strontium, said degradable high-strength zinc alloy further alloyed with 0.5-15 wt. % of an electronegative alloying additive, said electronegative alloying additive having an electronegativity greater than 1.75. 
     
     
         31 . The degradable tool as defined in  claim 28 , wherein said degradable high-strength zinc alloy alloyed includes 0.5-15 wt. % of one or more electropositive additives, said electropositive additives having an electronegativity of less than or equal to 1.65. 
     
     
         32 . The degradable tool as defined in  claim 28 , wherein said degradable high-strength zinc alloy is formed using a molding or casting process. 
     
     
         33 . The degradable tool as defined in  claim 28 , wherein said degradable high-strength zinc alloy has a shear strength of at least 35,000 psi, and a tensile ultimate strength of at least 50 KSI. 
     
     
         34 . The degradable tool as defined in  claim 28 , wherein said degradable high-strength zinc alloy includes 1-15 wt. % calcium, and one or more of magnesium, aluminum, copper, lead, tin, zinc and gallium. 
     
     
         35 . The degradable tool as defined in  claim 28 , wherein said degradable high-strength zinc alloy includes 1-15 wt. % calcium, and two or more of magnesium, aluminum, copper, lead, tin, zinc and gallium. 
     
     
         36 . The degradable tool as defined in  claim 28 , wherein said degradable high-strength zinc alloy includes 1-15 wt. % calcium, 0.1-5 wt. % tin, and two or more of magnesium, aluminum, copper, lead, zinc and gallium. 
     
     
         36 . The degradable tool as defined in  claim 28 , wherein said degradable high-strength zinc alloy includes 1-15 wt. % calcium, 0.1-5 wt. % tin, 0.1-5 wt. % gallium, and one or more of magnesium, aluminum, copper, lead, and zinc.