Abstract: Structures for a tool surface of a downhole tool are constructed from a metal clay molded in a wet state. The wet state clay is a workable combination that can have a braze alloy grain, a tungsten carbide grain, and a binder. Additional cutting inserts can be embedded in the molded clay. Heat treatment applied to the molded metal clay causing the binder to be combusted and consumed. The braze alloy melts and then cools into a fused state with the tungsten carbide grain therein. The structure can affix to the tool surface of the tool by first being fused and then attached by brazing to the tool. Alternatively, the structure can be positioned in a fusible state adjacent the tool surface. When the heat treatment is applied, the structure fuses together and forms a metallurgical bond with the tool surface of the tool.

Abstract: Structures for a tool surface of a downhole tool are constructed from a metal clay molded in a wet state. The wet state clay is a workable combination that can have a braze alloy grain, a tungsten carbide grain, and a binder. Additional cutting inserts can be embedded in the molded clay. Heat treatment applied to the molded metal clay causing the binder to be combusted and consumed. The braze alloy melts and then cools into a fused state with the tungsten carbide grain therein. The structure can affix to the tool surface of the tool by first being fused and then attached by brazing to the tool. Alternatively, the structure can be positioned in a fusible state adjacent the tool surface. When the heat treatment is applied, the structure fuses together and forms a metallurgical bond with the tool surface of the tool.

Abstract: Methods and apparatus for releasing a downhole tool of a BHA from a whipstock in a wellbore include a latch release mechanism disposed on a whipstock. The latch release mechanism has a latch actuator and a latch member. The latch actuator has a switch and an actuator piston disposed in housing having an inlet. The inlet is in fluid communication with the actuator piston. The switch has first, intermediate, and second configurations. Fluid communication between the inlet and the actuator piston is blocked when the switch is in the first and intermediate configurations, and the fluid communication is unblocked when the switch is in the second configuration. The actuator piston is coupled to the latch member and configured to move the latch member out of engagement with a lock mechanism of the downhole tool in response to fluid communication from the inlet when the switch is in the second configuration.

Abstract: Methods and apparatus for releasing a downhole tool of a BHA from a whipstock in a wellbore include a latch release mechanism disposed on a whipstock. The latch release mechanism has a latch actuator and a latch member. The latch actuator has a switch and an actuator piston disposed in housing having an inlet. The inlet is in fluid communication with the actuator piston. The switch has first, intermediate, and second configurations. Fluid communication between the inlet and the actuator piston is blocked when the switch is in the first and intermediate configurations, and the fluid communication is unblocked when the switch is in the second configuration. The actuator piston is coupled to the latch member and configured to move the latch member out of engagement with a lock mechanism of the downhole tool in response to fluid communication from the inlet when the switch is in the second configuration.

Abstract: A wellbore tubular patch for patching a hole in a wellbore has been invented, the tubular patch in certain aspects having an expandable top member having a hollow tubular body and a top end and a bottom end, an expandable bottom member having a hollow tubular body and a top end and a bottom end, an expandable outer sleeve in which is secured a portion of the bottom end of the expandable top member, and a portion of the top end of the expandable bottom member inserted into and held within expandable outer sleeve. A method for making a tubular patch for patching a hole in a tubular in an earth wellbore has been invented, the method in certain aspects including securing a portion of a bottom end of an expandable top member in an expandable outer sleeve, the expandable top member having a hollow tubular body and a top end, and securing a portion of a top end of an expandable bottom member within the expandable outer sleeve, the expandable bottom emmber having a hollow tubular body.

Abstract: A stroke indicator has been invented for indicating that a movable inner member of an hydraulically activated wellbore tool or apparatus has moved, particularly that movement of such a member indicating that a stroke of the tool or apparatus has occurred. In one aspect such an indicator is used to indicate that the stroke of a wellbore tubular patch expander system has been completed. A tubular patch has been invented which includes two or more connected tubular patch members. A tubular patch system has been invented for patching operations which, in one aspect, is useful as a "through tubing" tubular patch system and has a body and a series of selectively expandable members which, once having passed through a tubular of a first diameter, are expandable in a tubular of a second diameter larger than the first diameter and then operable to expand a liner patch to seal a leak in the tubular of the second diameter.

Abstract: A tubular patch system has been invented for patching operations which, in one aspect, is useful as a "through tubing" tubular patch system and has a body and a series of selectively expandable members which, once having passed through a tubular of a first diameter, are expandable in a tubular of a second diameter larger than the first diameter and then operable to expand a liner patch to seal a leak in the tubular of the second diameter. Such a system may be used in a tubular disposed within a wellbore or in a tubular on the earth surface.