CN103518032A - 功能梯度复合物件 - Google Patents
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Abstract
公开了一种复合井下物件。该物件可在井筒流体中选择性地腐蚀。该物件包括至少一个可腐蚀的芯构件，其含有第一材料，第一材料可在井筒流体中以第一腐蚀速度腐蚀。该物件还包括至少一个外构件，其设置在芯构件上并含有第二材料，第二材料可在井筒流体中以第二腐蚀速度腐蚀，其中，可腐蚀的芯构件具有成分梯度或密度梯度或组合的成分梯度和密度梯度，第一腐蚀速度基本上大于第二腐蚀速度。
Description
相关申请的交叉参考
本申请请求享有美国申请13/096413号的优先权，该美国申请于2011年4月28日提交，该美国申请的全部内容引入文中作为参考。
本申请含有的主题与同时待审的、与本申请的同日提交的代理人案号为WBI4-51865-US的专利申请的主题相关；该申请与本申请转让给同一受让人，即位于德克萨斯州休斯顿的贝克休斯公司，该专利申请的全部内容引入文中作为参考。
背景技术
井下钻井、完井和生产操作通常使用一些井筒部件或工具，这些井筒部件或工具由于其功能缘故，仅要求具有有限的使用寿命，必须从井筒中被去除掉或处置掉以恢复流体通道的原始尺寸以便使用，包括油气开采、CO2封存等。处置掉这些部件或工具的传统操作方式是，磨碾或钻这些部件或工具以将它们从井眼中去除掉；但是，这些操作通常耗时、成本高昂。
已经有人提出，通过采用各种井筒流体分解可降解的聚乳酸聚合物来去除掉这些部件或工具。但是，这些聚合物不具有在井筒的操作温度范围内实现井筒部件或工具的功能所必要的机械强度、断裂韧性或其它机械属性，这些聚合物的应用也受到限制。
已经有人提出采用其它可降解材料，包括某些可降解的金属合金，这些金属合金由占主要部分的某些活性金属（如铝）以及占少数部分的其它合金成分（如，镓、铟、铋、锡、以及这些金属的混合物和组合）形成，但不排除含有某些二次合金元素（如锌、铜、银、镉、铅、以及这些金属的混合物和组合）。可以采用下述方式来形成这些材料：熔化所述这些成分的粉末，然后固化该熔化体以形成合金，或者，采用粉末冶金方法来形成这些材料，即，对所述量的活性金属和其它合金成分的粉末混合物进行挤压、压制、烧结及类似处理。这些材料包括很多利用重金属（如，铅、镉以及类似金属）的化合物，这些重金属不适于随着材料的降解而排放到外界环境中。另外，这些材料的形成过程会出现各种熔化现象，这会导致合金结构，合金结构会受各合金成分的相平衡和固化特性影响，从而不会达到最优或合适的合金微观结构、机械属性或溶解属性。
因此，迫切需要开发一些材料用于形成井下物件（如部件或工具），其具有实现它们的预定功能所需的机械属性，然后通过使用井筒流体可控地溶解以将物件从井筒中去除掉。
发明内容
在一示例实施例中，公开了一种复合井下物件。该物件可在井筒流体中选择性地腐蚀。该物件包括至少一个可腐蚀的芯构件，其含有第一材料，第一材料可在井筒流体中以第一腐蚀速度腐蚀。该物件还包括至少一个外构件，其设置在芯构件上并含有第二材料，第二材料可在井筒流体中以第二腐蚀速度腐蚀，其中，可腐蚀的芯构件具有成分梯度或密度梯度或组合的成分梯度和密度梯度，第一腐蚀速度远远大于第二腐蚀速度。
在另一示例实施例中，公开了另一种复合井下物件。该物件也可在井筒流体中选择性地腐蚀。该物件包括至少一个芯构件，其含有第一材料，第一材料可在井筒流体中可以第一腐蚀速度腐蚀。该物件还包括至少一个可腐蚀的外构件，其设置在芯构件上并含有第二材料，第二材料可在井筒流体中以第二腐蚀速度腐蚀，其中，可腐蚀的外构件具有成分梯度或密度梯度或组合的成分梯度和密度梯度，第二腐蚀速度远远大于第一腐蚀速度。
附图说明
现在请参照附图，附图中的类似元件用类似标记表示：
图1是文中公开的井下物件的一示例实施例的横截面图；
图2是图1中的截面2的横截面图，示出了文中公开的梯度部分的实施例；
图3是文中公开的梯度部分的另一实施例的横截面图；
图4是文中公开的井下物件的第二示例实施例的横截面图；
图5是文中公开的井下物件的第三示例实施例的横截面图；
图6是文中公开的井下物件的第四示例实施例的横截面图；
图7是文中公开的井下物件的第五示例实施例的横截面图；
图8是文中公开的井下物件的第六示例实施例的横截面图；
图9是文中公开的井下物件的第七示例实施例的横截面图；
图10是文中公开的井下物件的第八示例实施例的横截面图；
图11是文中公开的井下物件的第九示例实施例的横截面图；
图12是文中公开的井下物件的第十示例实施例的横截面图；
图13是制造文中公开的井下物件的制造方法的流程图；
图14是制造文中公开的井下物件的第二方法的流程图；
图15是使用文中公开的井下物件的方法的流程图；
图16是涂层金属粉末的横截面图，该涂层金属粉末用于制造文中公开的纳米基体复合粉末压块；
图17是文中公开的纳米基体复合粉末压块的横截面图；
图18是文中公开的前体纳米基体复合粉末压块的横截面图。
具体实施方式
参照图1至12，公开了一种复合井下物件10。复合井下物件10可包括各种井下工具和部件中的任一种。这些井下工具和部件可包括各种分流球12、球座14、封堵器16、封堵器支座18、盘20、镖形物（dart）21、套筒22、管状部分23和类似构件。复合井下物件10可在预定井筒流体24中选择性地腐蚀。可采用预定井筒流体24选择性地去除掉复合井下物件10。可选择地，可采用预定井筒流体24选择性地腐蚀物件10的一部分，从而，将物件10从一种形状或尺寸重新构造为另一种形状或尺寸。这些方式也可以组合，例如，采用预定井筒流体24或多种预定井筒流体24的组合，先将物件从一种形状或尺寸重新构造为另一种形状或尺寸，之后，从井筒中去除掉物件10。这里描述的复合井下物件10包括功能梯度复合材料，该复合材料包括可迅速腐蚀的金属部分26和更耐腐蚀的部分28，更耐腐蚀的部分28在预定井筒流体24中的腐蚀速度要慢得多。在某些实施例中，复合井下物件10可包括坚韧的、可选择的、可迅速腐蚀的金属芯构件30或基底，金属芯构件30或基底含有第一材料32，第一材料32包括可腐蚀的金属部分26并被耐腐蚀的硬质外构件40保护，该外构件40含有第一材料42，第二材料42包括更耐腐蚀的部分28。在其他实施例中，可以颠倒这种布置，即，复合井下物件10包括坚韧的、可选择的、可快速腐蚀的金属外构件50或基体，外构件50或基体含有第一材料32，第一材料32包括可腐蚀的金属部分26，可腐蚀的金属部分26包围耐腐蚀的硬质芯构件60，硬质芯构件60含有第二材料42，第二材料42包括更耐腐蚀的部分28。可腐蚀的金属部分26可包括功能梯度部分70，功能梯度部分70包括功能梯度材料70，功能梯度材料70布置在可腐蚀金属部分26的第一材料32和更耐腐蚀部分28的第二材料42之间。这种结构可让工具在使用物件期间（如工具操作期间）耐腐蚀，同时，当芯材料暴露在预定井筒流体中时，也允许迅速重新构造或去除。由于第一材料32和第二材料42的冶金性能和机械性能完全不同，因此，例如，梯度部分70可用于在第一材料32和第二材料42之间提供微结构过渡。可腐蚀的金属部分26可由这里公开的纳米基体（nanomatrix）复合材料形成。相对更耐腐蚀的部分28可由比可腐蚀金属部分26更耐腐蚀的任何合适材料形成，优选地，该材料的耐腐蚀性比可腐蚀金属部分26要强得多，更具体而言，更耐腐蚀的部分28例如可含有硬度高、耐磨性强的材料。
参照图1，在一示例实施例中，复合井下物件包括至少一个可腐蚀的芯构件30，芯构件30含有第一材料32，第一材料32可在井筒流体中以第一腐蚀速度腐蚀。复合井下物件10还包括至少一个外构件40，外构件40设置在芯构件30上并含有第二材料42，第二材料42可在井筒流体中以第二腐蚀速度腐蚀，其中可腐蚀的芯构件30具有梯度部分70，梯度部分70具有成分梯度或密度梯度或组合的成分梯度和密度梯度，并且第一腐蚀速度远远大于第二腐蚀速度。
外构件40可以具有任何合适的形式或厚度。在一个实施例中，外构件40包括以以下方式设置在芯构件30上的层，所述方式包括：将第二材料42直接沉积在芯构件30的梯度部分70的外部分或表面36上；或可选择地，单独形成的梯度部分70设置在芯构件30上，第二材料42直接沉积在该单独形成的梯度部分70的外部分或表面上。可采用各种沉积方法，例如，这里所述的电镀、溅射和其它薄膜沉积技术、包层、压制粉末、热喷涂或激光熔化粉末。外构件40还可以被形成为单独构件，然后通过任何合适的连接方法（包括这里所述的那些）连接到芯构件30的外部分36上。例如，外构件40可形成为粉末压块（包括这里所述的纳米基体粉末压块），然后通过合适的连接方法连接到芯构件30的外部分上。合适的连接方法包括等静压制、扩散结合、热塑、焊接、钎焊、粘附以及类似方法。外构件40还可形成为一个部分，或形成为相互连接以包围芯构件30的多个部分或节段，可以直接或不直接连接到芯构件30上。在一示例实施例中，外构件40可形成为两个薄半球部分33，它们围绕基本上为球形的芯构件30布置，使它们压在芯构件40上，然后，例如通过它们相互邻接的外围周围的连接件（如焊缝35）将它们连接起来，从而包围住芯构件30。外构件40可以具有任何合适的厚度，能满足执行井筒操作或与物件10相关的操作的必须要求。在一示例实施例中，外构件40包括设置在芯构件30上的相对薄的层，更具体而言，该层的厚度最大大致为10mm，更具体而言，大致为1mm至5mm，进一步具体而言，大致为0.1mm至2mm。外构件还可以包括沉积薄膜，其厚度可以是500微米或更小，更具体而言，为100微米或更小，进一步具体而言，为10微米或更小。
在某些实施例中，芯构件30可由外构件40完全或局部包围，例如在某些实例中，外构件40包括的外层完全或局部包围住芯构件30。在其它实施例中，外构件40可仅应用到芯构件30的一部分或多个部分上，例如，应用到暴露在井筒流体24中的部分上。在一个实施例中，物件10包括基本上为球形的分流球12，如图1所示。如图1所示，可腐蚀的芯构件30基本上为球形，外构件40是设置在芯构件上的基本上为球形的层，梯度部分70设置在外构件和芯构件之间。在另一实施例中，物件10包括圆柱形封堵器16，如图4所示。可腐蚀的芯构件30基本上为圆柱形，外构件40包括设置在芯构件30上的包覆层。但是，在另一实施例中，物件10包括中空的圆柱形套筒22，如图5所示。芯构件30包括围绕纵轴线设置的中空圆柱体，外构件40包括设置在芯构件30和梯度部分70上的层。套筒22的一端或两端上还包括支座，例如，图7所示的锥形球座14或封堵器支座18。在又一实施例中，物件10包括图6所示的圆柱形盘20。芯构件30包括圆柱形盘，外构件40包括设置在芯构件30和梯度部分70上的层。在另一实施例中，物件10可包括镖形构件21，镖形构件21包括圆柱形盘部分27和截头圆锥体尾端部分29，如图8所示。截头圆锥体尾端部分29可包括多个锥形翅片31，这些翅片31绕纵轴线33径向间隔。芯构件30包括圆柱形盘，外构件40包括设置在芯构件30和梯度部分70上的层。但是，在另一实施例中，物件10包括圆柱形管状部分23，例如，管状部分23可用来形成井筒套管的一部分，如图9所示。本领域的普通技术人员将能意识到，包括上述的物件10形状的井下工具或部件可用于各种钻井、完井和生产操作，并且这些形式还可包括并入的、与管状部分23结合的各种特征25，例如，各种孔、缝、肩部、凹槽、肋以及类似结构，如图9所示。这些形状形式还可相互嵌套，即多个上述球形球或圆柱或套筒嵌套在彼此中，并具有逐渐增大或变小的整体尺寸。具有这里所述的不同形状形式的这里公开的物件10可以嵌套在彼此内，例如，如图11所示，更小的球体12嵌套在更大的球体12中；如图12所示，更小的球体12嵌套在更大的封堵器16中，或者，反之亦然。
可腐蚀的芯构件30包括可选择性腐蚀的第一材料32。第一材料32可包括金属材料，预定井筒流体可选择性地快速腐蚀该金属材料。更具体而言，可选择性腐蚀的金属材料可以包括各种金属纳米基体复合材料，同属于本申请人的同样待审的2009年12月8日提交的美国专利申请12/633,682和2010年10月27日提交的美国专利申请12/913,310中描述了这类复合材料，这些美国专利申请的全部内容引入文中作为参考。参照图16，纳米基体复合材料是由金属粉末110形成的压块，金属粉末110包括多个金属涂层粉末颗粒112。可以形成粉末颗粒112来提供粉末110，包括自由流动的粉末，其可被注入或以其它方式布置在具有各种形状或尺寸的各种模具或模子（未示出）中，粉末110可用来制成这里所述的前体粉末压块100（图19）和粉末压块200（图18），前体粉末压块100和粉末压块200可用作或用于制造各种制造物件，包括各种井筒工具和部件。
粉末110的每个金属涂层粉末颗粒112包括粒芯114和设置在粒芯114上的金属涂层116。粒芯114包括芯材料118。芯材料118可包括用于形成粒芯114的任何合适材料，能让粉末颗粒112被烧结形成轻质、高强度粉末压块200，使压块200具有可选择性和可控制的分解特性。在一个实施例中，合适的芯材料包括电化学活性金属，其标准氧化电位高于或等于Zn，在另一实施例中，合适的芯材料包括Mg、Al、Mn、Fe或Zn，或这些金属的合金或组合。芯材料118还可包括其电化学活性低于Zn的其它金属或非金属材料，或上述两种材料的组合。合适的非金属材料包括陶瓷、复合物、玻璃或碳，或这些材料的组合。可选择在预定井筒流体中的分解速度高的芯材料118，但是也可选择分解速度相对低（包括零分解）的芯材料118，其中纳米基体材料的分解会迅速破坏粒芯114，使粒芯114在与井筒流体的交界面上从颗粒压块上释放下来，从而，即使芯材料118本身分解速度低（包括芯材料120完全不能溶解在井筒流体中的情况），对于采用这些芯材料118的粒芯114制成的颗粒压块而言，其有效溶解速度也较高。
粉末110的每个金属涂层粉末颗粒112还包括设置在粒芯114上的金属涂层116。金属涂层116包括金属涂层材料120。金属涂层材料120能使粉末颗粒112和粉末110具有金属属性。金属涂层116是纳米级涂层。在一示例实施例中，金属涂层116的厚度大致为25nm至2500nm。金属涂层116的厚度在粒芯114的表面上可以是变化的，但是，优选地，其厚度在粒芯114的表面上基本一致。金属涂层116可以包括单层或作为多层涂覆结构的多层。金属涂层材料120可以包括任何合适的金属涂层材料，其用于提供可烧结外表面121，外表面121被构造成烧结到相邻的粉末颗粒112上，相邻的粉末颗粒112也具有金属涂层116和可烧结的外表面121。在粉末110的一示例实施例中，粒芯114包括Mg、Al、Mn、Fe或Zn或这些金属的合金或组合作为芯材料118，更具体而言，粒芯114可以包括纯Mg和Mg合金，金属涂层116包括Al、Zn、Mn、Mg、Mo、W、Cu、Fe、Si、Ca、Co、Ta、Re或Ni或这些金属的合金或这些金属的氧化物、氮化物或碳化物，或上述材料的任何组合，作为涂层材料120。粉末110还可以包括散布在多个粉末颗粒112中的附加或第二粉末30，如图16所示。在一示例实施例中，第二粉末130包括多个第二粉末颗粒132。可选择这些第二粉末颗粒132来改变由粉末110和第二粉末130形成的粉末颗粒压块200的物理、化学、机械或其它属性，或这些属性的组合。在一示例实施例中，属性变化可包括梯度部分70中的成分梯度或密度梯度或组合的成分梯度和密度梯度。第二粉末颗粒132可以没有涂覆或涂覆有金属涂层136。如果有涂层（包括单层或多层涂层），第二粉末颗粒132的涂层136可包括与粉末颗粒112的涂层材料120相同的涂层材料140，或者涂层材料140与涂层材料120不同。第二粉末颗粒132（未涂覆）或粒芯134可以包括任何合适材料（包括许多金属）来实现所需益处。在一示例实施例中，如果采用含有Mg、Al、Mn、Fe或Zn，或上述金属的合金或组合的涂覆的粉末颗粒112，那么，合适的第二粉末颗粒132例如可以包括Ni、W、Cu、Co或Fe，或上述金属的合金或组合。
这里使用的术语“基本连续的细胞状纳米基体216”并不表示粉末压块的主要组分，而相反是指少数组分，不论是按重量计还是按体积计。这与大多数基体复合材料不同，在大多数基体复合材料中，按重量或体积计，基体构成大多数的组分。术语“基本上连续的细胞状纳米基体”用来描述纳米基体材料220在粉末压块200内广泛、规则、连续、相互连接的分布特性。这里使用的术语“基本上连续”描述纳米基体材料在整个粉末压块200中的范围，即纳米基体材料分布在所有分散颗粒214之间并基本上包围所有分散颗粒214。“基本上连续”用来表示不需要每个分散颗粒214周围的纳米基体的完全连续性和规则次序。例如，在一些粉末颗粒112上，覆盖在粒芯114上的涂层116中的瑕疵会在烧结粉末压块200的过程中使粒芯114之间连接起来，从而，会引起细胞状纳米基体216中的局部部分不连续，但是，在粉末压块的其他部分中，纳米基体基本上连续并具有这里所述的结构。这里使用的术语“细胞状”用来表示：纳米基体限定纳米基体材料220的基本重复的、相互连接的格室或小室的网络，所述网络包围分散颗粒214并与分散颗粒214相互连接。这里使用的术语“纳米基体”用来描述基体的尺寸或级别，特别地，表示相邻的分散颗粒214之间的基体的厚度。被烧结在一起形成纳米基体的金属涂层本身是纳米级厚度涂层。由于大多数位置（除了两个以上分散颗粒214相交的位置以外）上的纳米基体通常包括相邻的纳米级厚度粉末颗粒112的两个涂层116的相互扩散和结合，形成的基体也具有纳米级厚度（例如，大致为这里所述涂层厚度的两倍），因而可描述为纳米基体。另外，使用的术语“分散颗粒214”并不表示粉末压块200的少数组分，而相反是指大多数组分，不论是按重量计还是按体积计。使用的术语“分散颗粒”用来表示粒芯材料218在粉末压块200内的分布不连续、离散。
在粉末颗粒112被压紧并相互扩散和变形以填充粒间空间115时，粉末颗粒112的烧结和变形会使分散颗粒214呈现等轴形态、使颗粒层形成细胞状网状结构216。可选择烧结温度和压力以确保粉末压块200的密度基本上达到完全的理论密度。参照图17，烧结粉末压块200可以包括烧结的前体粉末压块100，烧结的前体粉末压块100包括多个如这里所述的变形的、机械连接的粉末颗粒。可以通过下述方式形成前体粉末压块100：压紧粉末110以至粉末颗粒112彼此相互被压入对方中，从而让它们变形，在粒间形成机械结合或与这种变形相关的其它结合，能足以使变形的粉末颗粒112相互结合，形成生坯态粉末压块，部分由于粒间空间115的缘故，生坯态粉末压块的生坯密度是可变的并小于粉末110的完全致密压块的理论密度。例如，可通过下述方式进行压制：在室温下均衡挤压粉末110，以提供形成前体粉末压块100所需的粉末颗粒112的变形和颗粒之间相互结合。
烧结并动态锻造的粉末压块200包括含Mg的分散颗粒214以及纳米基体216，纳米基体216含有这里所述的各种纳米基体材料，这种粉末压块200机械强度优、密度低。这里使用的术语“动态锻造”意为：在一段时间内在一定温度下动态施加载荷，足以促使相邻粉末颗粒12的金属涂层16的烧结，并优选地可包括在一定温度下在一段时间内以预定加载速度施加动态锻造载荷，从而足以形成烧结并完全致密的粉末压块200。在一示例实施例中，其中粒芯14含有Mg，金属涂层16含有这里所述的各种单层和多层涂层，如，含有Al的各种单层或多层涂层，可通过如下方式执行动态锻造过程：在不施加锻造压力的情况下，在为约450℃至约470℃的温度Ts下，大致烧结1个小时，之后，通过以约0.5ksi/秒至约2ksi/秒的升压速度施加等静压，直至达到最大压力Ps（其为约30ksi至约60ksi），从而进行动态锻造，这导致大致为15秒至120秒的锻造循环。
粉末压块200包括含Mg的分散颗粒214以及纳米基体216，纳米基体216含有这里所述的各种纳米基体材料220，这种粉末压块200的室温抗压强度至少为约37ksi，并且进一步室温抗压强度超过约50ksi。这里公开的这类粉末压块200能够实现的实际密度基本上等于基于粉末110成分的压块材料的预定理论密度，包括相对量的粒芯114和金属涂层116的成分，这类粉末压块200也是这里所述的完全致密粉末压块。包括含Mg的分散颗粒和含有这里所述的各种纳米基体材料的多纳米基体216的粉末压块200的实际密度大致为1.738g/cm3至2.50g/cm3，基本上等于预定理论密度，最多与预定理论密度相差4%。包括含Mg的分散颗粒214和含有这里所述的各种纳米基体材料的细胞状纳米基体216的粉末压块200在15%HCl中的腐蚀速度大致为4750mg/cm2/hr至7432mg/cm2/hr。这种响应范围例如能够通过在少于一小时的时间内改变井筒流体而从井筒中去除掉由这种材料制成的、直径为3英寸的球体。
外构件40设置在芯构件30上并包括第二材料42，第二材料42可在预定井筒流体24中以第二腐蚀速度腐蚀。如这里所述，第一材料32的第一腐蚀速度远远大于第二材料42的第二腐蚀速度。外构件40的第二材料42可以是任何合适材料，包括各种金属、聚合物或陶瓷、或上述材料的复合物或其他组合。合适的金属包括通常用于管状制品（其在井筒环境下使用）的合金，包括各种等级的钢，尤其是各种等级的不锈钢。其它的合适合金包括铁基合金、镍基合金、钴基合金以及超级合金。合适的聚合物可以包括在足以起到这里所述的第二材料42的作用的时间内对预定井筒流体24提供低渗透率的任何聚合物。合适的聚合物包括各种含氟聚合物和聚氨酯。合适的陶瓷可以包括金属碳化物、氧化物或氮化物或它们的组合，包括碳化钨、碳化硅、碳化硼、氧化铝、氧化锆、氧化铬、氮化硅或氮化钛。
在一个实施例中，第一材料32和第二材料42的腐蚀速度的差异使得选择性腐蚀的井下物件10在存在预定井筒流体24的情况下可用于其预定目的，例如用于特定井筒操作，并使得在预定井筒流体24中的工作寿命或临界使用时间足以执行井筒操作。在另一示例实施例中，腐蚀速度的差异使得在井下物件10不暴露在预定井筒流体24中的情况下可用于其预定目的，例如用于特定井筒操作，并且一旦完成井筒操作，可将预定流体引入以选择性腐蚀该物件10。上面提供了第一材料32的快速腐蚀速度的例子。第二材料42在井筒流体中的第二腐蚀速度可以是低于第一腐蚀速度的任何合适速度，更具体而言，第二腐蚀速度可以低约1至约10个数量级，更具体而言，低约1至约3个数量级。这可包括约0.001mg/cm2/hr至约1.0mg/cm2/hr的腐蚀速率。
如图所示，更具体而言，如图2和3所示，可腐蚀的芯构件32具有梯度部分70，梯度部分70具有成分梯度或密度梯度或组合的成分梯度和密度梯度。在一个实施例中，梯度部分70具有成分梯度或密度梯度或成分及密度梯度，梯度部分70包括设置在可腐蚀的芯构件和外构件之间的一个或多个过渡层。所述一个或所述多个过渡层可用于任何合适目的，例如，如果第一和第二材料具有不同属性（如，晶体结构、热膨胀系数或类似属性不同），过渡层可提供在这两种材料之间进行过渡，从而减小这两种材料交界处的应力，并促进外构件40到芯构件30上的附着。该层或所述多层也可通过以下方式用于控制物件10的密度，即，提供一区域，在该区域中通过添加受控量的另一种材料（如，一定量的第二材料42）可调节芯构件的第一材料32，从而为物件10提供预定密度。该层或所述层还可通过以下方式用于控制物件10的腐蚀速度，即，提供腐蚀速度与芯构件30的第一材料32或外构件40的第二材料42不同（例如，在第一材料32和第二材料42之间的腐蚀速度）的一层或多层。尽管上面描述梯度部分70为芯构件30的成分或密度梯度部分或组合的成分梯度和密度梯度部分，但是，应该理解为，梯度部分70还可以与外构件40相关，并且梯度部分70可以认为是设置在外构件40和芯构件30之间的单独的梯度构件72。尽管成分梯度部分或密度梯度部分或组合的成分梯度和密度梯度部分可以包括均匀地布置在芯构件30周围的一层或多层，但是，其也可以是不均匀地布置在芯构件30和外构件40之间的部分70或区域，例如，可用于在物件10内提供变化的重量分布，包括各种非轴对称重量分布。同样地，成分梯度部分或密度梯度部分或组合的成分梯度和密度梯度部分例如可通过不均匀地加重物件10的特定部分而在物件通过井筒流体在井筒中下降时用于定向或预先定位该物件。
可以采用任何合适方式来形成梯度部分70及其相关的成分梯度或密度梯度、或成分和密度梯度。在一示例实施例中，将包括第一材料32和另一种材料（如第二材料42）的粉末混合物的粉末压块的层设置在芯构件和外构件之间，而形成成分梯度。即使是在芯构件30和包括成分梯度的梯度部分70或层被压紧至完全理论密度的情况下，只要第一材料和其它材料是密度不同的不同材料，这种布置也提供成分梯度和密度梯度。例如，通过压紧含有镁合金粒芯（其具有铝或铝合金纳米层）的粉末以形成纳米基体复合物（该纳米基体复合物如这里所述含有分散在铝或铝合金纳米基体中的镁颗粒）而形成芯构件，那么，通过压紧与用来形成芯构件30相同的由涂覆铝的镁粉末颗粒和另一种金属或金属合金的纳米颗粒或微颗粒（如，第二材料42的颗粒）组成的混合物，可在梯度部分70中形成成分梯度。尽管可通过采用外构件40的第二材料42来形成成分梯度，但是，也可采用任何其他材料（包括其密度不同于第一材料32的第二材料42）来形成密度梯度。用来形成成分梯度的其它材料可以是任何合适材料，包括各种金属和金属合金、陶瓷、玻璃以及类似材料。在成分梯度也用来提供密度梯度的情况下，使用原子量高的各种金属是有利的，这些金属包括元素周期表中的IVB-VIIB族。
可以采用任何合适方式来形成密度梯度，包括上述方式，即，第一材料32的粉末与另一种材料（如，第二材料42）的粉末混合，然后将它们压紧至达到预定密度（如，所述材料混合物的完全理论密度），以形成粉末压块。还可以通过下述方式在梯度部分70中形成密度梯度：压紧第一材料32的粉末至不同于芯构件30的第一材料32的密度，包括大于或小于芯构件30的密度。在一个实施例中，芯构件30可以包括被压紧至达到完全理论密度的第一材料32的粉末的粉末压块；梯度部分70的层可以包括被压紧至小于完全理论密度的第一材料32的粉末的粉末压块。在另一实施例中，芯构件30可以包括被压紧至小于完全理论密度的第一材料32的粉末的粉末压块；梯度部分70或层可以包括被压紧至更高密度（包括为完全理论密度）的第一材料32的粉末的粉末压块。
第一材料32的梯度部分70（其具有成分或密度梯度或组合的成分梯度和密度梯度）可以从靠近外构件40的外部分35朝远离外构件40的内部分37伸展，作为图2所示的单层或区域，或者图3所示的多个离散层或成分梯级。在一个实施例中，梯度部分70可包含第一材料32从内部分37至外部分35数量减小或密度减小、或数量和密度均减小。例如，在图2中，芯构件30包含100重量百分比的第一材料32，如，其中散布有镁或镁合金颗粒的铝纳米基体。梯度部分70包括三个离散层，这些离散层具有不同组分。第一层80例如可以包括均质粉末混合物的基本上为球体的粉末压块，该均质粉末混合物含有75%重量的第一材料32和25%重量的第二材料42。第二层82例如含有50%重量的第一材料32和50%重量的第二材料42。第三层84例如可包括25%重量的第一材料32和75%重量的第二材料42。外构件40含有100%重量的第二材料。在该实施例中，成分梯度或密度梯度或成分和密度梯度从内部分37至外部分35在离散的梯级中变化，这些梯级对应于提供多个离散的成分和密度梯级的层，如上所述各层具有不同的成分和密度。
在另一实施例中，芯构件中的第一材料的成分梯度或密度梯度或组合的成分梯度和密度梯度从内部分至外部分连续变化，如图2所示。第一构件的量可以例如从芯构件30的内部分37中第一材料的100%重量变化至外部分35中的0%重量。相应地，另一材料（如第二材料42）的量可以例如从外部分35中第二材料的100%重量变化至内部分37中的0%重量。在该实例中，可腐蚀的芯构件30还包括从靠近外构件40的外部分35朝内部分37的、可腐蚀的芯构件30中的第二材料42的梯度部分70，其具有成分梯度或密度梯度或组合的成分梯度和密度梯度。
外构件40可被构造成具有均匀或变化的厚度，其厚度足以提供井下物件10的预定工作时间（包括在预定井筒流体24中的预定工作时间），因此，第二材料42在预定井筒流体中的腐蚀速度使外构件能充分变薄，从而预定井筒流体接触第一材料32并开始迅速腐蚀芯构件30（包括外构件和芯构件之间的梯度部分70）。例如，外构件40的腐蚀在外构件40的表面44的所有部分或一部分上以第二腐蚀速度基本上均匀地进行，直到预定井筒流体24破坏外构件40，并接触芯构件30的第一材料32，包括接触设置在外构件和芯构件之间的梯度部分70。在另一实施例中，外构件40可以包括入口点90或多个入口点90，其被构造成让预定井筒流体24通过外构件40进入芯构件30中，以响应于预定井筒条件腐蚀该可腐蚀的芯构件30的第一材料32，如图4-12所示。井筒条件可包括任何合适条件，这些条件可用于让预定井筒流体24进入可腐蚀的芯构件30中。在一个实施例中，入口点90可以包括外构件40和第二材料42的局部变薄部分，这可以通过提供外构件的表面44中凹陷或在可腐蚀芯构件30的突起来实现，如图4所示，井筒条件可以包括使预定井筒流体与入口点90接触一段时间，足以能让预定井筒流体24在入口点90处腐蚀掉第二材料42的厚度。在另一实施例中，入口点90还可以包括不同的入口点材料92，其可响应于井筒条件或井筒条件的变化（而不是预定井筒流体24）提供通过外构件40的入口。例如，井筒条件可以包括热或压力、或热和压力，其足以改变入口点90的属性，例如，通过相变（包括熔化）或机械属性的变化，足以让预定井筒流体24进入芯构件40中。在另一实施例中，入口点90可以包括止回阀94，其能响应于井筒条件（包括压力变化）让预定井筒流体24进入。还可利用任何合适的井筒条件让井筒流体24通过入口点90经过外构件40而进入芯构件30中。在一示例实施例中，入口点90可包括外构件40的第二材料40的厚度差异、成分差异或密度差异中的至少一种，其足以响应于井筒条件或井筒条件的变化使预定井筒流体24进入芯构件30中。
在一示例实施例中，所述的至少一个可腐蚀的芯构件30和所述的至少一个外构件42可以包括多个芯构件，相应的多个外构件设置在该多个芯构件上，其中各芯构件30与相关的外构件40相互嵌套，以形成芯构件30和外构件40交替布置，如图11和12所示。在图11所示的实施例中，多个中空球形芯构件30相互嵌套，以形成包括带有芯构件30的分流球12与外构件40交替布置的结构。可使用这里所述的方法顺序形成各芯构件30和相应的外构件40，使最内侧的外构件40/芯构件30被一个或多个相继的更大的外构件40/芯构件30包围。尽管相同形状可以相互嵌套布置，例如，图11所示的多个分流球12以及多个圆柱形封堵器（未示出）或多个嵌套的套筒22或球座14（未示出），但是，也可以使不同的形状相互嵌套。在图12所示的示例实施例中，圆柱形封堵器16中可以具有嵌套在内的另一形状的物件10（如分流球12）。同样地，圆柱形封堵器16可以具有嵌套在内的一个分流球12或多个分流球12（未示出）。这些配置可使物件10被选择性地腐蚀，从而可将该物件重新配置成另一种物件10以用于随后的井筒操作，而不需要插入第二或随后的物件10。例如，可采用多个嵌套球12，从而，井筒中特定高度位置上的井筒操作一完成，最外侧的外构件40/芯构件30就可被去除掉，例如，可选择直径使剩余物件10能穿过球座，到达井筒高度更低的位置上。当然，本领域的普通技术人员将能理解到，也可采用相反的布置，从而，通过去除掉最外侧的外构件40/芯构件30，能让球向上移动，穿过球座到达更靠近地面的井筒部分。
尽管上述布置结构在许多应用场合（包括上述的应用场合）中是有利的，但是，也可采用图10所示的第一材料32和第二材料42的相反布置，其中，第一材料构成外构件50，第二材料42构成芯构件60，从而外构件50可在预定井筒流体24中迅速腐蚀以露出芯构件60，芯构件60的腐蚀速度要低得多。同样地，复合井下物件10可以包括至少一个可腐蚀的外构件50以及至少一个芯构件60，外构件50含有在此所述的第一材料32，第一材料32在预定井筒流体24中以第一腐蚀速度腐蚀，芯构件设置在外构件50内，并含有第二材料42，第二材料42在预定井筒流体24中以第二腐蚀速度可腐蚀，其中可腐蚀的外构件50具有梯度部分70，梯度部分70具有成分梯度或密度梯度或组合的成分梯度和密度梯度，如文中所述，第一腐蚀速度基本上大于第二腐蚀速度。例如这种结构可能是理想的，其将物件10定位在井筒中的某位置上，这是通过利用外构件将物件10定位在井筒中，之后，使物件10暴露在预定井筒流体24中以去除掉外构件50，将芯构件留在特定位置或方位上。
参照图13，公开了一种方法300，用于制造文中所述的复合井下物件10。方法300通常包括：形成步骤310，用于形成至少一个可腐蚀的芯构件30，芯构件30含有第一材料32，第一材料32可在井筒流体24中以第一腐蚀速度腐蚀；设置步骤220，用于在芯构件30上设置至少一个外构件40，外构件40含有第二材料42，第二材料42可在井筒流体中以第二腐蚀速度腐蚀，其中可腐蚀的芯构件30具有成分梯度或密度梯度或组合的成分梯度和密度梯度，第一腐蚀速度远远大于第二腐蚀速度。
可腐蚀的芯构件30可以具有文中所述的任何合适结构（包括尺寸和形状）。可采用任何合适的成型方法来执行用于形成可腐蚀芯构件30的步骤310，所述成型方法包括，压制和动态锻造各种粉末压块（尤其是文中所述的各种涂层金属粉末的粉末压块）。
形成步骤310可包括形成用作为可腐蚀芯构件30的未烧结粉末压块100或前体粉末压块100。例如，可采用各种粉末压制方法（如，压紧、锻造、挤出、等静压成型以及类似方法）来形成未烧结粉末压块100（图18）。通常，可通过下述方式来执行用于形成未烧结粉末压块或前体粉末压块100的粉末压制过程：压制期间不需要提供外部热源用于加热粉末颗粒；或者，可供选择地，在压制期间加热粉末到基本上低于选作金属涂层的材料的熔化温度的温度，从而使相邻粉末颗粒之间基本上没有固态相互扩散。未烧结粉末压块100例如可在相邻粉末颗粒的金属涂层之间形成机械结合，能足以保持可腐蚀芯构件30的压紧形状。未烧结粉末压块100通常具有预定孔隙率或密度，孔隙率或密度大小由与压制相关的因素决定，如，压制压力和时间、用于形成压块的金属粉末的属性。在一个实施例中，可通过压紧含有多个金属粉末颗粒的粉末来形成未烧结粉末压块100，每个粉末颗粒含有粒芯和金属涂层，粒芯包括芯材料，芯材料包括Mg、Al、Zn、Fe或Mn，或这些金属的合金或组合，金属涂层设置在粒芯上，其中，压制操作使相邻颗粒的金属涂层相互之间形成机械结合，能足以形成和保持图18所示的粉末压块的形状。
形成步骤310还可包括，形成用作为可腐蚀芯构件30的烧结粉末压块200。烧结粉末压块200可以包括：烧结以基本上达到粉末压块的完全理论密度；以及局部烧结达到小于粉末压块的完全理论密度，包括局部烧结达到预定孔隙率或密度。通常，烧结粉末压块的特征在于：相邻粉末颗粒的金属涂层之间相互扩散（如，固态相互扩散），使得它们之间形成化学或机械结合。例如通过采用各种粉末压制方法来形成烧结粉末压块，如压紧、轧制、锻造（包括动态锻造）、挤出或等静压成型（包括热等静压成型）、或这些方法的组合方法，或类似方法。通常，形成烧结粉末压块的粉末压制结合在压制期间提供外部热源来加热粉末颗粒来执行，可包括在压制期间加热粉末至接近选择用于金属涂层的材料的熔化温度的温度。在某些实施例中，这可包括将粉末加热至刚好低于金属涂层材料的熔化温度的温度，在其它实施例中，甚至可包括将粉末加热至稍高于金属涂层材料的熔化温度的温度。在一示例实施例中，形成烧结粉末压块和可腐蚀芯构件30的步骤310包括：形成基本上连续、细胞状的纳米基体，纳米基体含有纳米基体材料，纳米基体包括多个分散颗粒，分散颗粒包括粒芯材料，粒芯材料包括镁、铝、锌、铁或锰或它们的合金或组合，并散布在细胞状纳米基体中，和形成结合层，该结合层在整个细胞状纳米基体中在分散颗粒之间延伸，如图17所示。
可通过任何合适方法，使梯度部分70及其相关的成分或密度梯度或组合的成分梯度和密度梯度布置在可腐蚀的芯构件30和外构件40之间。梯度部分可与可腐蚀芯构件30一体形成；或者，梯度部分可形成为单独的梯度部分70或构件，在外构件40设置在可腐蚀芯构件30之前，该单独的梯度部分70或构件设置在可腐蚀芯构件30和外构件40之间；或者，例如，在将外构件40沉积在可腐蚀芯构件30上之前，将具有成分梯度或密度梯度或组合的成分梯度和密度梯度的层沉积在可腐蚀的芯构件30上。形成可腐蚀芯构件30的形成步骤310例如可以包括：从靠近外构件40的芯构件30的外部分35朝远离外构件40的芯构件30的内部分37，形成第一材料32的成分梯度或密度梯度或组合的成分梯度和密度梯度，例如如图2和3所示。
在一个实施例中，形成步骤310包括：通过从靠近外构件40的外部分37朝远离外构件40的内部分35，连续改变第一材料32的成分梯度或密度梯度或组合的成分梯度和密度梯度，而从外部分37朝内部分35形成第一材料32的成分梯度或密度梯度或组合的成分梯度和密度梯度，如图2所示。例如，这可以通过连续改变梯度部分70中的第一材料32的密度来实现。可采用各种形式的喷射成型和熔化第一材料32的粉末来连续改变密度，例如激光烧结前体压块100、激光直接沉积或涂覆、立体光刻以及熔融沉积模制沉积方法。例如，这可包括以连续变化能量或功率逐步激光熔合具有单个粒径的第一材料32的粉末，以为粉末颗粒提供更大和更小程度的熔融和结合，以及连续变化的密度。在另一示例实施例中，从内部分37到外部分35，第一材料32的成分或密度、或成分和密度可以连续变化。可采用第一材料32的至少两种粒径的各种形式的喷射成型和熔融，以通过使用固定或变化能量或功率密度而连续改变提供的这两种粒径粉末的量，从而可改变第一材料的密度或成分、或密度和成分。但是，在另一示例实施例中，通过在梯度部分70的第一材料32中加入连续变化量的另一种材料（如第二材料42），而可改变梯度部分70中的第一材料32的成分，从而进行该操作。例如，连续变化量为在靠近外构件40的外部分35中，第二材料42的100%重量/第一材料32为0%重量，到在内部分37中，第二材料42为0%重量/第一材料32为100%重量。可采用第一材料和其他材料（如第二材料）的粉末的各种形式的喷射成型和熔化，以连续改变成分，例如，当使用固定或变化的能量或功率密度以连续变化的比例同时供应粉末时，激光熔化粉末。可采用各种公知方法来确保一种或多种材料的沉积覆盖面均匀，包括在沉积和激光熔化喷射粉末期间，旋转基底或使基底光栅化；或者，可供选择地，沉积期间，在基底表面上使喷射粉末和激光光栅化。
在另一实施例中，形成步骤310包括：通过从内部分37朝外部分35在离散的梯级或层中改变成分梯度或密度梯度或组合的成分梯度和密度梯度，从而可从靠近外构件40的外部分35朝远离外构件40的内部分37形成第一材料32的成分梯度或密度梯度或组合的成分梯度和密度梯度，如图3所示。可采用任何合适方法（如，如上所述使用激光熔化粉末的方法），使用第一材料32、或第一材料32和另一种材料（如第二材料42）的组合来改变每一梯级中的密度或成分、或密度和成分。在每一梯级区域或层中，密度或成分、或密度和成分可以保持不变或连续变化。
将至少一个外构件40设置在芯构件30上的设置步骤320可通过任何合适方法执行。在一个实施例中，将外构件40设置在芯构件30上的设置步骤320可以包括将第二材料42的粉末压块设置在芯构件30上。这例如可以如下方式进行，即压紧一种形态或多种形态的第二材料42，该第二材料42可用于包围可腐蚀的芯构件30。例如，如果可腐蚀芯构件30基本上为球形，那么，外构件40可以包括两个中空的半球形粉末压块构件40，其尺寸设置成将其内表面设置在可腐蚀芯构件的外表面上，并通过接头沿它们的邻接周边边缘相互连接，如图1所示。在另一个实施例中，将外构件40设置在芯构件30上的设置步骤320可以包括将一层第二材料42沉积在芯构件30上。可通过任何合适的沉积方法来沉积一层第二材料42，这些沉积方法包括浸入在熔融金属池中、镀（包括电镀和无电镀）、溅镀和其它薄膜沉积技术、涂覆、压制粉末、热喷射，或将第二材料42的粉末激光熔化在可腐蚀芯构件的外表面或一部分上，或这些方法的组合。
参照图13，方法300还可选地包括在外构件上形成入口点90的形成步骤330，入这里所述，入口点90配置成可响应于井筒条件的变化使井筒流体进入芯构件中。可通过任何合适的形成方法来执行将入口点90形成在外构件40上的形成步骤330。可以结合设置步骤320（用于外构件40设置在芯构件30上）来整体执行形成步骤330，或者通过另外的一个或多个形成操作来执行形成步骤330。例如，在入口点90包括第二材料42局部细薄的情况下，这可通过芯构件30和/或外构件40的设计来实现。可供选择地，这可通过化学、机械或其它去除方法将第二材料42从外构件40上去除掉而执行。可通过化学或电化学铣削、蚀刻或其它化学去除方法来实现化学去除，可以包括采用光刻掩膜或图形技术来界定入口点90的结构形式或形状，之后，通过蚀刻或其它材料去除技术进行合适的材料去除以形成入口点。可通过机器切削加工、钻、研磨或其他材料去除方法来完成机械去除。
如上所述，也可以大致如图10和14中所示相反布置第一材料32和第二材料42，这可以通过制造复合井下物件10的方法400来形成，方法400包括以下步骤：用于形成至少一个芯构件60的形成步骤410，芯构件60含有第二材料42，第二材料42可在井筒流体中以第二腐蚀速度腐蚀；用于将至少一个可腐蚀的外构件50设置在芯构件60上的设置步骤420，外构件50含有第一材料32，第一材料32可在预定井筒流体24中以第一腐蚀速度腐蚀；其中，可腐蚀外构件50具有成分梯度或密度梯度或组合的成分梯度和密度梯度；第一腐蚀速度远远大于第二腐蚀速度。在这种结构中，第二材料42的芯构件60可以通过任何合适的制造方法制成，包括铸造、锻造、切削加工或各种粉末压制方法、或上述方法的组合。
形成可腐蚀外构件50的形成步骤410可以包括：从靠近芯构件60的内部分37朝远离芯构件60的外部分35，形成第一材料32的成分梯度或密度梯度或组合的成分梯度和密度梯度。从靠近芯构件60的内部分37朝远离芯构件60的外部分35形成第一材料32的成分梯度或密度梯度或组合的成分梯度和密度梯度这一步骤可以包括：从内部分37朝外部分35，如文中所述那样连续地改变成分梯度或密度梯度或组合的成分梯度和密度梯度。可供选择地，或结合地，从靠近芯构件60的内部分37朝远离芯构件60的外部分35形成第一材料32的成分梯度或密度梯度或组合的成分梯度和密度梯度这一步骤可以包括：在从内部分37朝外部分35在离散梯级或层中改变成分梯度或密度梯度或组合的成分梯度和密度梯度。在每一梯级中，成分梯度或密度梯度可以是如文中所述那样不变的或者连续变化。如文中所述，梯度部分70（包括成分梯度或密度梯度或组合的成分梯度和密度梯度）可被形成为第一材料32的粉末压块、或第一材料和另一种材料（包括第二材料42）的合成物的粉末压块（如文中所述）。在一个实施例中，方法400和形成步骤410可以包括，从靠近芯构件的内部分37朝外部分35，在可腐蚀外构件50中形成另一种材料（包括芯构件60的第二材料42）的成分梯度或密度梯度或组合的成分梯度和密度梯度，这与文中其它部分描述的组合第一材料32和第二材料42类似。
在一个实施例中，将可腐蚀外构件50设置在芯构件30上的设置步骤420包括，将第一材料32的粉末压块设置在芯构件60上。可采用文中所述的任何粉末施加或压制方法第一材料32的粉末压块直接形成在芯构件60上，或者，可供选择地，可将第一材料32的粉末压块单独形成为单一件或多个件，然后通过任何合适的沉积方法（包括文中公开的方法）设置在芯构件60上，从而将第二材料42连接、接合、或以其它方式设置在第一材料32上。
在一示例实施例中，公开了一种使用复合井下物件的方法500，如图15所示。方法500包括用于形成复合井下物件的形成步骤510，该井下物件包括含有第一腐蚀材料32的第一构件30、50和含有第二材料42的第二可腐蚀构件40、60，第一腐蚀材料32可在预定井筒流体24中以第一腐蚀速度腐蚀，第二材料42可在井筒流体中以第二腐蚀速度腐蚀，其中第一腐蚀构件具有梯度部分70，梯度部分70具有成分梯度或密度梯度或组合的成分梯度和密度梯度，第一腐蚀速度远远大于第二腐蚀速度。形成步骤510例如包括或采用用于制造复合井下物件10的方法300或方法400。方法500还包括以下步骤：使用物件10来执行第一井筒操作的使用步骤520；将物件暴露在预定井筒流体24中的暴露步骤530；以及，选择性地腐蚀第一腐蚀构件30、50的腐蚀步骤540。方法500所采用的物件可以包括任何合适的井下物件10，尤其包括各种井下工具或构件。
在一个实施例中，井下物件10可以包括如文中所公开的分流球12、封堵器16或盘20的各种结构，使用物件来执行预定井筒操作的使用步骤520包括结合断裂、完井或生产操作完全或局部关闭孔口。井下物件10具有外构件40，外构件40包括第二材料42的薄层或涂层，足以在一段时间内关闭预定孔口并阻止预定井筒流体24，以执行预定井筒操作（如断裂地层操作）。可选择外构件40和预定井筒流体24，使得在一定条件情况下，如足以完成预定井筒操作的时间已过去，则预定井筒流体24充分溶解外构件40，以进入芯构件30中，因此，预定井筒流体24能迅速腐蚀芯构件30，使外构件的任何剩余部分瓦解或分解，从而去除掉分流球12、封堵器16或盘20，然后打开孔口。也可以组合使用其它井筒条件，包括增加井筒流体的温度和/或压力、加入另一种物质（如另一种井筒流体）以选择性地增加第二材料42的第二腐蚀速度，从而加快第二材料的腐蚀，使流体进入第一材料32中。
在另一实施例中，井下物件10可以包括管状部分23，其可用于形成井筒套筒的一部分，其管状壁的一个或多个部分包括一些特征25，所述特征25包括的芯构件30和外构件40，用于限定例如通孔91或开口、盲孔93或盲眼、管道、通道、凹槽95、突出肋、肩部99或其它特征的特征。使用物件10执行预定井筒操作的使用步骤520可以包括任何合适的井筒操作，例如，采用管状部分23作为流体管道、平直管道、测井电缆、工具、部件或其它井筒物件，利用管状部分可用于与断裂、完井或生产操作相关的各种目的。可选择外构件40和井筒流体24，使得在出现一定条件的情况下，如，完成预定井筒操作的充足时间已经过去，则井筒流体充分溶解外构件40，以进入芯构件30中，因此，预定井筒流体24迅速腐蚀芯构件30，使外构件的剩余部分瓦解或分解，从而露出管状部分中的特征。例如，这可用于穿过管状部分23形成开口或多个开口，类似于穿孔操作，或者用于打开管道，从而可用于一些完井或生产操作，包括断裂操作。露出内表面上的肩部95或突出肋97例如可用于为套筒、球或封堵器提供支座。
但是，在另一实施例中，井下物件10可以包括中空圆柱体，例如，可将中空圆柱体插入套管内用作为套筒22或支座（包括球座14或封堵器支座18），中空圆柱体的一个或多个部分包括文中所公开的芯构件30和外构件40。使用步骤520可以包括以任何合适方式使用中空圆柱体，包括：使用中空圆柱体作为用于套管内的各种固定或滑动套筒（例如，用于隐藏或暴露套管中的开口或管的套筒）；或者使用中空圆柱体用作为各种圆柱形支座，其可与球12或封堵器16一起使用以打开或关闭井筒，从而用于与断裂、完井或生产操作相关的各种目的。可选择外构件40和预定井筒流体24，使得在出现一定条件情况下，如，完成预定井筒操作的充足时间已经过去，预定井筒流体24已经充分溶解外构件40，以进入芯构件30中，因此，预定井筒流体24就能迅速腐蚀芯构件30，使外构件的任何剩余部分瓦解或分解，从而从井筒中去除掉中空圆柱体。
将物件暴露在就预定井筒流体24中的步骤530可以包括将物件10暴露在任何预定井筒流体24中，该预定井筒流体24适于腐蚀文中所述的可腐蚀的第一材料32和第二材料42。在一个实施例中，暴露步骤530可以包括：将第二材料42的暴露表面浸入井筒流体中一段时间，足以腐蚀穿过第二材料42以到达梯度部分70，其中梯度部分70中的第一材料32开始迅速腐蚀，并且第一构件（包括梯度部分70）可被迅速去除掉。合适的井筒流体24可以包括水、各种含水溶液、盐水或酸（包括有机或无机酸）或这些流体的组合。在另一实施例中，将井筒物件10暴露在井筒流体24中的步骤530包括响应于井筒条件打开第二构件40上的入口点，使得井筒流体进入第一腐蚀构件中，如文中所述。
选择性腐蚀步骤540可以包括：通过预定井筒流体24完全腐蚀第一可腐蚀构件30，从而，从井筒中完全去除掉井下物件10。可供选择地，选择性腐蚀步骤540可以包括去除掉井下物件10的一部分。例如，该步骤540可以包括，如文中所述，可以腐蚀第一腐蚀构件30以改变物件10的形状或尺寸。在一个实施例中，其中物件10包括多个嵌套物件，如文中所述的多个嵌套的球12，选择性腐蚀步骤540可以包括：去除掉最外层（如，最外侧的球12），使物件10的尺寸（如直径）减小，从而，剩余部分可经过支座到达更靠近地面或离地面更远的井筒另一部分，以被支撑在另一支座上。可重复执行选择性腐蚀步骤540，以连续去除掉嵌套物件10并减小其尺寸（如，球12的直径），从而，让剩余部分逐渐移动经过球座到达更靠近地面或离地面更远的井筒另一部分，以被支撑在另一支座上。
尽管已经示出和描述了优选实施例，但是，在不脱离本发明的实质范围的情况下，可进行改进或替换。因此，应该理解为，已经通过阐释而非限制的方式描述了本发明。
Claims (24)
1.一种复合井下物件，包括：
至少一个可腐蚀的芯构件，其含有第一材料，该第一材料可在井筒流体中以第一腐蚀速度腐蚀；和
至少一个外构件，其设置在芯构件上并含有第二材料，该第二材料可在井筒流体中以第二腐蚀速度腐蚀，其中该可腐蚀的芯构件具有成分梯度或密度梯度或组合的成分梯度和密度梯度，并且该第一腐蚀速度远远大于第二腐蚀速度。
2.根据权利要求1的物件，其中，第一材料的成分梯度或密度梯度或组合的成分梯度和密度梯度从靠近外构件的外部分朝远离外构件的内部分延伸。
3.根据权利要求2的物件，其中，第一材料的成分梯度或密度梯度或组合的成分梯度和密度梯度包括第一材料从内部分朝外部分减小的量或密度或组合的量和密度。
4.根据权利要求3的物件，其中，芯构件中的第一材料的成分梯度或密度梯度或组合的成分梯度和密度梯度从内部分朝外部分连续变化。
5.根据权利要求3的物件，其中，第一材料的成分梯度或密度梯度或组合的成分梯度和密度梯度从内部分朝外部分以离散的梯级变化。
6.根据权利要求2的物件，其中，可腐蚀的芯构件还包括从靠近外构件的外部分朝内部分的、在可腐蚀的芯构件中的第二材料的成分梯度或密度梯度或组合的成分梯度和密度梯度。
7.根据权利要求1的物件，还包括入口点，该入口点被配置成可响应于井筒条件让井筒流体进入芯构件中。
8.根据权利要求1的物件，其中，入口点包括足以响应于井筒条件使井筒流体进入芯构件中的第二材料的厚度差异、成分差异或密度差异中的至少一种。
9.根据权利要求1的物件，其中，可腐蚀的芯构件基本上为球形，外构件是设置在芯构件上的基本上为球形的层。
10.根据权利要求1的物件，其中，可腐蚀的芯构件基本上为圆柱形，外构件包括设置在芯构件上的层。
11.根据权利要求9的物件，其中，芯构件包括绕纵轴线设置的中空套筒，外构件包括设置在芯构件上的层。
12.根据权利要求1的物件，其中，第一材料包括粉末金属压块，粉末金属压块包括：基本上连续的细胞状纳米基体，该基本上连续的细胞状纳米基体包括纳米基体材料；分散在细胞状纳米基体中的多个分散的颗粒，所述分散的颗粒包括颗粒芯构件材料，该颗粒芯构件材料包括Mg、Al、Zn、Fe或Mn或它们的合金或组合；和结合层，该结合层在整个细胞状纳米基体中在分散的颗粒之间延伸。
13.根据权利要求1的物件，其中，第二材料包括粉末压块。
14.根据权利要求1的物件，其中，第二材料包括金属、聚合物或陶瓷，或它们的组合。
15.根据权利要求1的物件，其中，所述至少一个可腐蚀芯构件和所述至少一个外构件包括设置有多个相应的外构件的多个芯构件，各芯构件及相关的外构件相互嵌套在彼此中，以形成芯构件和外构件交替布置。
16.一种复合井下物件，包括：
至少一个芯构件，其含有第二材料，该第二材料可在井筒流体中以第二腐蚀速度腐蚀；和
至少一个可腐蚀的外构件，其设置在芯构件上并含有第一材料，该第一材料可在井筒流体中以第一腐蚀速度腐蚀，其中，可腐蚀的外构件具有成分梯度或密度梯度或组合的成分梯度和密度梯度，并且第一腐蚀速度远远大于第二腐蚀速度。
17.根据权利要求16的物件，其中，可腐蚀的外构件具有从靠近外表面的外部分朝靠近芯构件的内部分的第一材料的成分梯度。
18.根据权利要求17的物件，其中，第一材料的成分梯度包括第一材料从外部分朝内部分减小的量。
19.根据权利要求18的物件，其中，第一材料的成分梯度从外部分朝内部分连续变化。
20.根据权利要求18的物件，其中，第一材料的成分梯度从外部分朝内部分以离散的梯级变化，每个梯级具有基本恒定量的第一材料。
21.根据权利要求17的物件，其中，外构件中还包括从靠近芯构件的内部分朝外部分的、外构件中的第二材料的成分梯度，并且第二材料的成分梯度包括第二材料从内部分朝外部分减小的量。
22.根据权利要求16的物件，其中，第一材料包括粉末金属压块，粉末金属压块包括：基本上连续的细胞状纳米基体，该基本上连续的细胞状纳米基体包括纳米基体材料；分散在细胞状纳米基体中的多个分散的颗粒，所述分散的颗粒包括颗粒芯构件材料，该颗粒芯构件材料包括Mg、Al、Zn、Fe或Mn或它们的合金或组合；和结合层，该结合层在整个细胞状纳米基体中在分散的颗粒之间延伸。
23.根据权利要求16的物件，其中，第二材料包括粉末压块。
24.根据权利要求16的物件，其中，第二材料包括金属、聚合物或陶瓷，或它们的组合。
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| CN106593358A (zh) * | 2017-02-09 | 2017-04-26 | 中国石油化工股份有限公司 | 一种抽油井中接力式释放药剂的装置 |
| CN106593358B (zh) * | 2017-02-09 | 2022-12-30 | 中国石油化工股份有限公司 | 一种抽油井中接力式释放药剂的装置 |
| CN111601947A (zh) * | 2018-02-27 | 2020-08-28 | 哈里伯顿能源服务公司 | 改进的密封元件 |
| CN111749667A (zh) * | 2020-06-04 | 2020-10-09 | 中国石油天然气股份有限公司 | 一种耐酸时间可调自主溶解的金属可溶球及其制作方法 |
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| AU2012249814A1 (en) | 2013-10-17 |
| US20150065401A1 (en) | 2015-03-05 |
| AU2017200486A1 (en) | 2017-02-16 |
| US20120276356A1 (en) | 2012-11-01 |
| CA2833981A1 (en) | 2012-11-01 |
| WO2012149007A3 (en) | 2013-01-17 |
| CA2833981C (en) | 2016-07-26 |
| WO2012149007A2 (en) | 2012-11-01 |
| GB2506022B (en) | 2018-05-23 |
| AU2012249814B2 (en) | 2016-11-24 |
| US9631138B2 (en) | 2017-04-25 |
| AU2017200486B2 (en) | 2017-04-06 |
| NO20131317A1 (no) | 2013-10-15 |
| US9080098B2 (en) | 2015-07-14 |
| GB2506022A (en) | 2014-03-19 |
| NO346719B1 (no) | 2022-12-05 |
| GB201318011D0 (en) | 2013-11-27 |
| CN103518032B (zh) | 2016-09-28 |
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