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 be 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 method for forming a dissolvable cast magnesium composite that includes in situ precipitation of galvanically-active intermetallic phases; said method comprising the step of:
 a. providing a magnesium material;   b. providing a first additive material; said first additive material includes one or more metals selected from the group consisting of aluminum, boron, bismuth, zinc, zirconium, and manganese;   c. providing a second additive material; said second additive includes one or more metals selected from the group consisting of nickel, cobalt, copper, lead, antimony, indium, gold, and gallium;   d. providing a third additive material; said third additive material calcium, strontium, barium, potassium, sodium, lithium, yttrium, samarium, europium, gadolinium, terbium, holmium, and ytterbium;   e. heating said magnesium material to a temperature so that said magnesium material is at least at or above a solidus temperature of said magnesium material;   f. introducing one or more of said first, second and third additive materials to said magnesium material while said magnesium material is above said solidus temperature;   g. mixing one or more of said first, second and third additive materials in said magnesium material while said magnesium material is above said solidus temperature to form a magnesium mixture; and   h. cooling said magnesium mixture to form said dissolvable cast magnesium composite below a solidus temperature of said dissolvable cast magnesium composite; and   wherein said dissolvable cast magnesium composite includes in situ precipitation of galvanically-active intermetallic phases that at least partially formed during said step of cooling; and   wherein said dissolvable cast magnesium composite includes greater than 50 wt. % magnesium; and   wherein said dissolvable cast magnesium composite includes no more than 10 wt. % aluminum; and   wherein said dissolvable cast magnesium composite has a dissolution rate of at least 5 mg/cm 2 -hr. in 3% KCl at 90° C.   
     
     
         19 . The dissolvable cast magnesium composite as defined in  18 , wherein said magnesium material includes one or more of said first, second and third additive materials prior to said step of heating said magnesium material. 
     
     
         20 . The dissolvable cast magnesium composite as defined in  18 , wherein said second additive includes one or more metals selected from the group consisting of copper, nickel, cobalt, bismuth, silver, and gallium. 
     
     
         21 . The dissolvable cast magnesium composite as defined in  19 , wherein said second additive includes one or more metals selected from the group consisting of copper, nickel, cobalt, bismuth, silver, and gallium. 
     
     
         22 . The dissolvable cast magnesium composite as defined in  18 , wherein said third additive includes one or more metals selected from the group consisting of calcium, strontium, and barium. 
     
     
         23 . The dissolvable cast magnesium composite as defined in  21 , wherein said third additive includes one or more metals selected from the group consisting of calcium, strontium, and barium. 
     
     
         24 . The dissolvable cast magnesium composite as defined in  claim 18 , wherein said magnesium composite includes at least 85 wt. % magnesium. 
     
     
         25 . The dissolvable cast magnesium composite as defined in  claim 23 , wherein said magnesium composite includes at least 85 wt. % magnesium. 
     
     
         26 . The dissolvable cast magnesium composite as defined in  claim 18 , wherein said second additive includes one or more of nickel, antimony and/or gallium; said second additive constitutes about 0.05-45 wt. % of said dissolvable cast magnesium composite. 
     
     
         27 . The dissolvable cast magnesium composite as defined in  claim 25 , wherein said second additive includes one or more of nickel, antimony and/or gallium; said second additive constitutes about 0.05-45 wt. % of said dissolvable cast magnesium composite. 
     
     
         28 . The dissolvable cast magnesium composite as defined in  claim 18 , wherein said first additive includes copper; said copper constitutes about 0.05-45 wt. % of said dissolvable cast magnesium composite. 
     
     
         29 . The dissolvable cast magnesium composite as defined in  claim 25 , wherein said first additive includes copper; said copper constitutes about 0.05-45 wt. % of said dissolvable cast magnesium composite. 
     
     
         30 . The dissolvable cast magnesium composite as defined in  claim 18 , wherein first additive includes cobalt; said cobalt constitutes about 0.05-45 wt. % of said dissolvable cast magnesium composite. 
     
     
         31 . The dissolvable cast magnesium composite as defined in  claim 25 , wherein first additive includes cobalt; said cobalt constitutes about 0.05-45 wt. % of said dissolvable cast magnesium composite. 
     
     
         32 . The dissolvable cast magnesium composite as defined in  claim 18 , wherein said second additive includes calcium; said calcium constitutes about 0.05-35 wt. % of said dissolvable cast magnesium composite. 
     
     
         32 . The dissolvable cast magnesium composite as defined in  claim 25 , wherein said second additive includes calcium; said calcium constitutes about 0.05-35 wt. % of said dissolvable cast magnesium composite. 
     
     
         33 . A method for forming a component for use in downhole operations comprising:
 providing a dissolvable cast magnesium composite; said dissolvable cast magnesium composite formed by:
 a. providing a magnesium material; 
 b. providing a first additive material; said first additive material includes one or more metals selected from the group consisting of aluminum, boron, bismuth, zinc, zirconium, and manganese; 
 c. providing a second additive material; said second additive includes one or more metals selected from the group consisting of nickel, cobalt, copper, lead, antimony, indium, gold, and gallium; 
 d. providing a third additive material; said third additive material calcium, strontium, barium, potassium, sodium, lithium, yttrium, samarium, europium, gadolinium, terbium, holmium, and ytterbium; 
 e. heating said magnesium material to a temperature so that said magnesium material is at least at or above a solidus temperature of said magnesium material; 
 f. introducing one or more of said first, second and third additive materials to said magnesium material while said magnesium material is above said solidus temperature; 
 g. mixing one or more of said first, second and third additive materials in said magnesium material while said magnesium material is above said solidus temperature to form a magnesium mixture; and 
 h. cooling said magnesium mixture to form said dissolvable cast magnesium composite below a solidus temperature of said dissolvable cast magnesium composite; and 
 wherein said dissolvable cast magnesium composite includes in situ precipitation of galvanically-active intermetallic phases that at least partially formed during said step of cooling; and 
 wherein said dissolvable cast magnesium composite includes greater than 50 wt. % magnesium; and 
 wherein said dissolvable cast magnesium composite includes no more than 10 wt. % aluminum; and 
 wherein said dissolvable cast magnesium composite has a dissolution rate of at least 5 mg/cm 2 -hr. in 3% KCl at 90° C.; and 
   forming said dissolvable cast magnesium composite into a portion or all of said component for use in downhole operations; said component for use in downhole operations is selected from the group consisting of a sleeve, afrac ball, hydraulic actuating tooling, a mandrel, a slip, a grip, a ball, a dart, a carrier, a tube, a valve, a valve component, and a plug.