Methods of manufacturing degradable tools using a galvanic carrier and tools manufactured thereof
View Patent ↗A method of manufacturing a degradable article comprises: forming a mixture comprising composite particles dispersed in a metallic matrix material; the composite particles comprising a carrier and a disintegration agent coated on the carrier or embedded in the carrier, or a combination thereof and having a density that is about 0.2 to about 2.5 equivalents to that of the metallic matrix material when measured under the same testing conditions; and molding or casting the mixture to form a degradable article. The disintegration agent forms a plurality of galvanic cells with the metallic matrix material, or the carrier, or a combination thereof, in the degradable article.
1. A method of manufacturing a degradable article, the method comprising:
forming a mixture comprising composite particles dispersed in a metallic matrix material; the composite particles comprising a carrier and a disintegration agent coated on the carrier or embedded in the carrier, or a combination thereof and the composite particles having a density that is about 0.2 to about 2.5 equivalents to that of the metallic matrix material when measured under the same testing conditions;
releasing the disintegrating agent from the composite particles; and
molding or casting the mixture to form a degradable article;
wherein the disintegration agent forms a plurality of galvanic cells with the metallic matrix material, with the carrier, or with a combination of the metallic matrix material and the carrier, in the degradable article.
2. The method of claim 1 wherein the composite particles have a density that is about 0.5 to about 1.5 equivalents to that of the metallic matrix material when measured under the same testing conditions.
3. The method of claim 1 , further comprising forming the composite particles by one or more of the following: physical vapor deposition; chemical vapor deposition; milling; or mechanical mixing.
4. The method of claim 1 , wherein forming a mixture comprising composite particles dispersed in a metallic matrix material comprises:
mixing the metallic matrix material in a solid form with the composite particles to provide a blend; and
heating the blend to a temperature to selectively melt the metallic matrix material.
5. The method of claim 4 , wherein the carrier is at least partially melted at the temperature.
6. The method of claim 1 , wherein forming a mixture comprising composite particles dispersed in a metallic matrix material comprises:
heating the metallic matrix material in a solid form to provide a molten metallic matrix material; and
introducing the composite particles to the molten matrix material.
7. The method of claim 6 , wherein heating the metallic matrix material is to a temperature of about 450° C. to about 850° C.
8. The method of claim 1 , wherein molding the mixture comprises pressure molding or vacuum molding.
9. The method of claim 1 , wherein molding the mixture comprises applying a superatmospheric pressure of about 500 psi to about 30,000 psi to the mixture.
10. The method of claim 1 , further comprising extruding the molded article.
11. The method of claim 1 , wherein the carrier comprises one or more of the following: a magnesium-based alloy; an aluminum-based alloy; or a zinc-based alloy.
12. The method of claim 1 , wherein the carrier comprises particles have an average particle size of about 1 micron to about 10 millimeters.
13. The method of claim 1 , wherein the disintegration agent comprises 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.
14. The method of claim 1 , wherein the disintegration agent comprises particles having an average particle size of about 200 nanometers to about 10 microns.
15. 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.
16. The method of claim 1 , wherein the mixture comprises about 0.001 wt. % to about 10 wt. % of the disintegration agent, based on the total weight of the mixture.
17. A degradable article produced by the method of claim 1 .
18. A degradable article comprising:
a metallic matrix comprising a plurality of grains formed from a metallic matrix material, a carrier, or a combination thereof; and
a disintegration agent disposed on grain boundaries of the grains formed from the metallic matrix material, the carrier, or a combination thereof; the disintegration agent comprising particles having an aspect ratio greater than about 2;
wherein the metallic matrix and the disintegration agent form a plurality of galvanic cells in the article; and
the disintegration agent comprises 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.
19. The degradable article of claim 18 , wherein the disintegration agent comprises particles having an aspect ratio greater than about 5.
20. The degradable article of claim 18 , wherein the disintegration agent is further disposed inside the grains formed from the metallic matrix material.
21. The method of claim 1 , wherein releasing the disintegration agent comprises partially or completely melting the carrier.
22. The method of claim 1 , wherein the composite particles comprise the carrier and the disintegration agent coated on the carrier.
23. The method of claim 1 , wherein the composite particles comprise the carrier and the disintegration agent embedded in the carrier.
24. The method of claim 1 , further comprising selectively melting the matrix material and the carrier but not the disintegration agent.