Method of forming a flexible carbon composite self-lubricating seal

1. A method of forming a flexible carbon composite self-lubricating seal comprising:

compressing a carbon composite mixture having a carbon microstructure including at least one of a micro-sized binder and a nano-sized binder into a mold forming a flexible carbon composite self-lubricating annular seal.

2. The method of claim 1 , further comprising: heating the carbon composite mixture in the mold to a selected temperature.

3. The method of claim 2 , wherein heating the carbon composite mixture includes passing an electrical current through the carbon composite mixture.

4. The method of claim 2 , wherein heating the carbon composite mixture includes melting metal binders in the carbon composite mixture forming a metal melt.

5. The method of claim 4 , further comprising: driving the metal melt into gaps between graphite basal planes in the carbon composite mixture forming an interlocked structure.

6. The method of claim 2 , wherein heating the carbon composite mixture includes inductively heating the carbon composite mixture.

7. The method of claim 1 , further comprising: forming the carbon composite mixture includes mixing expanded graphite with metal binders.

8. The method of claim 6 , wherein forming the carbon composite mixture includes grinding the carbon composite mixture into a powder.

9. The method of claim 1 , further comprising: removing the flexible carbon composite self-lubricating annular seal from the mold.

10. The method of claim 1 , further comprising: integrating a biasing member into the flexible carbon composite self-lubricating annular seal.

11. The method of claim 10 , wherein integrating the biasing member includes positioning a coil spring in the flexible carbon composite self-lubricating annular seal.

12. The method of claim 10 , wherein integrating the biasing member includes encapsulating the biasing member in the flexible carbon composite self-lubricating annular seal.

13. The method of claim 12 , wherein encapsulating the biasing member includes compressing the carbon composite mixture about the biasing member.

14. The method of claim 1 , further comprising: mounting the flexible carbon composite self-lubricating annular seal to a downhole tubular.

15. The method of claim 14 , further comprising: inhibiting flow at the flexible carbon composite self-lubricating annular seal on the downhole tubular.

16. The method of claim 1 , further comprising: machining the flexible carbon composite self-lubricating annular seal to establish a selected seal shape.