Composite expandable metal elements with reinforcement
Methods for forming a seal in a wellbore. An example method includes positioning an expandable metal sealing element in the wellbore; wherein the expandable metal sealing element comprises a composite material of expandable metal and a reinforcement material. The expandable metal forms a matrix and the reinforcement material is distributed within the matrix. The method further includes contacting the expandable metal sealing element with a fluid that reacts with the expandable metal to produce a reaction product having a volume greater than the expandable metal.
1. A method for forming a seal in a wellbore comprising:
positioning an expandable metal sealing element in the wellbore; wherein the expandable metal sealing element comprises:
a composite material comprising an expandable metal and a reinforcement material; wherein the expandable metal forms a matrix and the reinforcement material is distributed within the matrix;
contacting the expandable metal sealing element with a fluid that reacts with the expandable metal to produce a metal hydroxide reaction product having a volume greater than the expandable metal; and
forming a seal with the reaction product.
2. The method of claim 1 , wherein the expandable metal comprises a metal selected from the group consisting of magnesium, calcium, aluminum, and any combination thereof.
3. The method of claim 1 , wherein the expandable metal comprises a metal alloy selected from the group consisting of magnesium-zinc, magnesium-aluminum, calcium-magnesium, aluminum-copper, and any combination thereof.
4. The method of claim 1 , wherein the reinforcement material comprises a material selected from the group consisting of metals, ceramics, glass, plastics, and any combination thereof.
5. The method of claim 1 , wherein the reinforcement material comprises a shape selected from the group consisting of a rod, a ball, a mesh, and any combination thereof.
6. The method of claim 1 , wherein the expandable metal sealing element further comprises a bonding agent.
7. The method of claim 1 , wherein the expandable metal sealing element further comprises a removable barrier coating.
8. The method of claim 1 , wherein the expandable metal sealing element further comprises a feed-through.
9. The method of claim 1 , wherein the expandable metal sealing element is disposed on a conduit.
10. The method of claim 9 , wherein the conduit comprises a profile variance on its exterior surface; wherein the expandable metal sealing element is positioned over the profile variance.
11. The method of claim 1 , wherein the expandable metal sealing element is a component of a swell packer.
12. The method of claim 11 , wherein the swell packer further comprises a swellable non-metal sealing element.
13. The method of claim 1 , wherein the expandable metal sealing element was produced by compaction of discrete pieces of the expandable metal with the reinforcement material in a mold.
14. An expandable metal sealing element for forming a seal, the expandable metal sealing element comprising:
a composite material comprising an expandable metal and a reinforcement material; wherein the expandable metal forms a matrix and the reinforcement material is distributed within the matrix; wherein the expandable metal is a reactive metal that reacts with a fluid to form a metal hydroxide reaction product; wherein the reaction product is configured to form the seal.
15. The expandable metal sealing element of claim 14 , wherein the expandable metal comprises a metal selected from the group consisting of magnesium, calcium, aluminum, and any combination thereof.
16. The expandable metal sealing element of claim 14 , wherein the reinforcement material comprises a material selected from the group consisting of metals, ceramics, glass, plastics, and any combination thereof.
17. The expandable metal sealing element of claim 14 , wherein the expandable metal sealing element further comprises a bonding agent.
18. A system for forming a seal in a wellbore:
an expandable metal sealing element comprising:
a composite material comprising an expandable metal and a reinforcement material; wherein the expandable metal forms a matrix and the reinforcement material is distributed within the matrix; wherein the expandable metal is a reactive metal that reacts with a fluid to form a metal hydroxide reaction product; wherein the reaction product is configured to form the seal; and
a conduit with the expandable metal sealing element disposed thereon.
19. The system of claim 18 , wherein the expandable metal sealing element is a component of a swell packer.
20. The system of claim 18 , wherein the conduit comprises a profile variance on its exterior surface; wherein the expandable metal sealing element is positioned over the profile variance.