Method of controlling the corrosion rate of alloy particles, alloy particle with controlled corrosion rate, and articles comprising the particle
A composite particle comprises a core, a shielding layer deposited on the core, and further comprises an interlayer region formed at an interface of the shielding layer and the core, the interlayer region having a reactivity less than that of the core, and the shielding layer having a reactivity less than that of the interlayer region, a metallic layer not identical to the shielding layer and deposited on the shielding layer, the metallic layer having a reactivity less than that of the core, and optionally, an adhesion metal layer deposited on the metallic layer, wherein the composite particles have a corrosion rate of about 0.1 to about 450 mg/cm 2 /hour using an aqueous 3 wt % KCl solution at 200° F. An article comprises composite particles, wherein has a corrosion rates of about 0.1 to about 450 mg/cm 2 /hour using an aqueous 3 wt % KCl solution at 200° F.
1. A composite particle, comprising:
a core,
a shielding layer deposited on the core, and further comprising an interlayer region formed at an interface of the shielding layer and the core, the interlayer region having a reactivity less than that of the core, and the shielding layer having a reactivity less than that of the interlayer region,
a metallic layer not identical to the shielding layer and deposited on the shielding layer, the metallic layer having a reactivity less than that of the core, and
optionally, an adhesion metal layer deposited on the metallic layer;
wherein the shielding layer, the metallic layer, and the optional adhesion metal layer are discontinuous; the core and shielding layer, shielding layer and metallic layer, and metallic layer and optional adhesion metal layer, are each in mutual partial contact and are inter-dispersed such that components of the core, the shielding layer, and the metallic layer are present at an exposed surface of the composite particle; and
wherein the shielding layer is cathodic relative to the core, and anodic relative to the metallic layer.
2. The composite particle of claim 1 , wherein the core comprises magnesium, the shielding layer comprises aluminum and, optionally, oxides of aluminum, magnesium, or a combination comprising at least one of the foregoing, and the interlayer region comprises an intermetallic compound.
3. The composite particle of claim 2 , wherein the intermetallic compound is γ-Mg 17 Al 12 .
4. The composite particle of claim 1 , wherein the metallic layer comprises a group 6-11 transition metal.
5. The composite particle of claim 4 , wherein the group 6-11 transition metal comprises one or more of the following: Ni; Fe; Cu; Co; W; or alloys thereof.
6. The composite particle of claim 1 , wherein the core comprises an inner core of a first core material and an outer core of a second core material, the inner core material having a lower activity than that of the outer core.
7. The composite particle of claim 6 , wherein the inner core comprises aluminum, and the outer core comprises magnesium.
8. The composite particle of claim 1 , wherein the core comprises a magnesium-aluminum alloy.
9. A composite particle, comprising:
a magnesium-aluminum alloy core,
a shielding layer comprising an aluminum-containing layer deposited on the core, further comprising an interlayer region comprising γ-Mg 17 Al 12 formed at the interface between the magnesium alloy core and the aluminum-containing layer, and further comprising inclusions of alumina, magnesia, or a combination comprising at least one of these oxides,
a metallic layer deposited on the shielding layer, the metallic layer comprising one or more of the following: Ni; Fe; Cu; Co; W; or alloys thereof,
and
optionally, an aluminum-containing adhesion metal layer,
wherein the shielding layer, the metallic layer, and the optional adhesion metal layer are discontinuous, the core and shielding layer, shielding layer and metallic layer, and metallic layer and optional adhesion metal layer, are each in mutual partial contact and are inter-dispersed such that components of the core, the shielding layer, and the metallic layer are present at an exposed surface of the composite particle; and wherein the shielding layer is cathodic relative to the core, and anodic relative to the metallic layer.
10. A method of forming an article, comprising compressing or shaping the composite particles of claim 1 .
11. An article comprising the composite particles of claim 1 .
12. The article of claim 11 , wherein the article is a single component; and wherein the article has a corrosion rate of about 0.1 to about 450 mg/cm 2 /hour using an aqueous 3 wt. % KCl solution at 200° F.
13. The article of claim 12 , wherein the article comprises a flapper, a hold down dog and spring, a screen protector, a seal bore protector, an electric submersible pump space out sub, a full bore gun, a chemical encapsulation, a slip, a dog, a spring and collet restraint, a liner setting sleeve, a timing actuation device, an emergency grapple release, a chemical encapsulation container, a screen protector, a beaded screen protector, a whipstock lug, a whipstock coating, a pin, a set screw, an emergency release tool, a gas generator, a mandrel, a release mechanism, a staging collar, a C-ring, a component of perforating gun system, a disintegrable whipstock for casing exit tool, a shear pin, a dissolvable body locking ring, a mud motor stator, a progressive cavity pump stator, or a shear screw.
14. The article of 11 , wherein the article inhibits flow; and wherein the article has a corrosion rate of about 0.1 to about 450 mg/cm 2 /hour using an aqueous 3 wt. % KCl solution at 200° F.
15. The article of claim 14 , wherein the article comprises a seal, a high pressure beaded frac screen plug, a screen basepipe plug, a coating for balls and seats, a compression packing element, an expandable packing element, an O-ring, a bonded seal, a bullet seal, a sub-surface safety valve seal, a sub-surface safety valve flapper seal, a dynamic seal, a V-ring, a back-up ring, a drill bit seal, a liner port plug, an atmospheric disc, an atmospheric chamber disc, a debris barrier, a drill in stim liner plug, an inflow control device plug, a flapper, a seat, a ball seat, a direct connect disk, a drill-in linear disk, a gas lift valve plug, a fluid loss control flapper, an electric submersible pump seal, a shear out plug, a flapper valve, a gaslift valve, or a sleeve.
16. The article of claim 14 , wherein the article is pumpable within a downhole environment; and wherein the article has a corrosion rate of about 0.1 to about 450 mg/cm 2 /hour using an aqueous 3 wt. % KCl solution at 200° F.
17. The article of claim 16 , wherein the article comprises a plug, a direct connect plug, a bridge plug, a wiper plug, a frac plug, a component of frac plug, a drill in sand control beaded screen plug, an inflow control device plug, a polymeric plug, a disappearing wiper plug, a cementing plug, a ball, a diverter ball, a shifting and setting ball, a swabbing element protector, a buoyant recorder, a pumpable collet, a float shoe, or a dart.
18. A coating comprising the composite particles of claim 1 .
19. The composite particle of claim 1 , wherein each of the shielding layer, the metallic layer, and the optional adhesion layer has a thickness of about 0.05 to about 0.15 micron.
20. The composite particle of claim 9 , wherein each of the shielding layer, the metallic layer, and the optional adhesion layer has a thickness of about 0.05 to about 0.15 micron.
21. The composite particle of claim 9 , wherein each of the shielding layer, the metallic layer, and the optional adhesion layer has a thickness of about 0.07 to about 0.13 micron.