Methods of manufacturing dissolvable tools via liquid-solid state molding

1. A method of manufacturing a dissolvable article, the method comprising:

forming a liquid-solid mixture comprising secondary particles dispersed in a molten metallic matrix material;

disposing the liquid-solid mixture in a mold;

agitating the liquid-solid mixture in the mold;

molding the liquid-solid mixture under agitation to form a molded dissolvable article, wherein molding the liquid-solid mixture comprises applying a superatmospheric pressure of about 500 psi to about 30,000 psi to the liquid-solid mixture under agitation;

cooling the molded dissolvable article; and

applying an agitating force to the molded dissolvable article during cooling thus forming the dissolvable article;

wherein the secondary particles have an original shape and an original composition before being dispersed in the molten metallic matrix material, and greater than about 90 wt. % of the secondary particles remain in the original shape and the original composition in the dissolvable article; and

the secondary particles and the metallic matrix material form a plurality of micro- or nano-sized galvanic cells in the dissolvable article.

2. The method of claim 1 wherein less than 10 wt. % of the secondary particles form a solid solution, an intermetallic compound, or a combination thereof with the metallic matrix material, based on the total weight of the secondary particles.

3. The method of claim 1 , wherein forming the liquid-solid mixture comprises:

mixing the metallic matrix material in a solid form with the secondary particles to provide a blend; and

heating the blend under agitation to selectively melt the metallic matrix material.

4. The method of claim 1 , wherein forming the liquid-solid mixture comprises:

heating the metallic matrix material in a solid form to provide a molten metallic matrix material; and

introducing the secondary particles to the molten matrix material under agitation.

5. The method of claim 4 , wherein heating the metallic matrix material is to a temperature of about 600° C. to about 700° C.

6. The method of claim 1 , wherein agitating the liquid-solid mixture comprises applying an agitation force to the mixture by mechanical means, electromagnetic means, acoustic means, or a combination comprising at least one of the foregoing.

7. The method of claim 1 , further comprising extruding the article.

8. The method of claim 1 , wherein the metallic matrix material comprises one or more of the following: a magnesium-based alloy; an aluminum-based alloy; or a zinc-based alloy.

9. The method of claim 1 , wherein the secondary particles comprise one or more of the following: a metal; an oxide of the metal; a nitride of the metal; or a cermet of the metal; wherein the metal is one or more of the following: W; Co; Cu; Ni; or Fe.

10. The method of claim 1 , wherein the liquid-solid mixture comprises about 1 wt % to about 10 wt % of secondary particles, based on the total weight of the liquid solid mixture.

11. The method of claim 1 , wherein the dissolvable article has a microstructure comprising a plurality of grains formed from the metallic matrix material.

12. The method of claim 11 , wherein the secondary particles are disposed on grain boundaries of the grains formed from the metallic matrix material.

13. The method of claim 12 , wherein the secondary particles are further disposed inside the grains.

14. The method of claim 1 , wherein less than about 10 wt. % of the secondary particles form an intermetallic compound with the metallic matrix material, based on the total weight of the secondary particles.

15. The method of claim 14 , wherein less than about 5 wt. % of the secondary particles form an intermetallic compound with the metallic matrix material, based on the total weight of the secondary particles.

16. The method of claim 1 , wherein the secondary particles comprise one or more of the following: a metal; an oxide of the metal; a nitride of the metal; or a cermet of the metal; and the metal is W, Co, or a combination thereof.

17. The method of claim 1 , wherein greater than about 95 wt. % of the secondary particles remain in the original form shape and the original composition in the dissolvable article.

18. The method of claim 1 , wherein greater than about 98 wt. % of the secondary particles remain in the original shape and the original composition in the dissolvable article.

19. The method of claim 1 , wherein the secondary particles comprise W, Co, or a combination thereof.

20. A method of manufacturing a dissolvable article, the method comprising:

forming a liquid-solid mixture comprising 0.1 to 6 wt. % of secondary particles homogeneously dispersed in a molten metallic matrix material based on the total weight of the liquid-solid mixture, the metallic matrix material comprising one or more of the following: a magnesium-based alloy; an aluminum-based alloy; or a zinc-based alloy, and the secondary particles comprising a metal; an oxide of the metal; a nitride of the metal; or a cermet of the metal; wherein the metal is one or more of the following: W; Co; Cu; Ni; or Fe;

disposing the liquid-solid mixture in a mold;

agitating the liquid-solid mixture in the mold;

molding the liquid-solid mixture under agitation to form a dissolvable molded article, wherein molding the liquid-solid mixture comprises applying a superatmospheric pressure of about 1,000 psi to about 5,000 psi to the liquid solid mixture under agitation;

cooling the molded dissolvable article; and

applying an agitating force to the molded dissolvable article during cooling thus forming the dissolvable article;

wherein the secondary particles have an original shape and an original composition before being dispersed in the molten metallic matrix material, and greater than about 98 wt. % of the secondary particles remain in the original shape and the original composition in the dissolvable article; and

the secondary particles and the metallic matrix material form a plurality of micro- or nano-sized galvanic cells in the dissolvable article.

21. The method of claim 20 , wherein the secondary particles comprise W, Co, or a combination thereof.