Abstract: Methods of manufacturing monolithic components with complex design features and functionally graded properties in any spatial direction may include forming of outer shell with an additive manufacturing process, loading the shell with bulk material and exposing the loaded shell to a hot isostatic pressing (HIP) process. The combination of the additive manufacturing process and the HIP process forms a diffusion bond between the outer shell and the bulk material resulting in a monolithic component with functionally graded properties. The outer shell may include an exterior surface and an inner passage formed with relatively hard surfaces to accommodate fluids in a wellbore.

Abstract: A rotary valve can include a seat and a rotary actuator, each with a surface, the rotary actuator rotatably mounted to a housing. The surfaces can form a seal due to their engagement with an engagement force used to maintain the engagement. One biasing device can elevate pressure in a sealed volume in the valve at a constant level above an external pressure. The elevated pressure can produce a pressure differential across the rotary actuator, thereby producing at least a portion of the engagement force. Another biasing device can act between a splined hub and a mated splined shaft, thereby applying at least a portion of the engagement force through the shaft to the rotary actuator. Fluid flowing through a screen can create a pressure drop, thereby causing a pressure differential across the rotary actuator and applying at least a portion of the engagement force to the surfaces.

Abstract: A rotary valve can include a housing, a manifold with multiple flow paths can be fixedly mounted to the housing. A rotary actuator with a first surface can be rotatably mounted within the housing, and a valve seat with a second surface can be fixedly attached to the manifold, where the second surface can sealingly engage the first surface. The rotary actuator can include a gap that selectively aligns with respective ones of valve seat ports as the rotary actuator rotates relative to the valve seat, thereby selectively pressurizing one or more actuators. A system and method can include a rotary valve that selectively causes pads to extend at a predetermined orientation in the wellbore to steer a drill bit. The azimuthal orientation of a rotary actuator of the valve can determine which pads are extended and which are retracted as the drill bit rotates.

Abstract: Methods of manufacturing monolithic components with complex design features and functionally graded properties in any spatial direction may include forming of outer shell with an additive manufacturing process, loading the shell with bulk material and exposing the loaded shell to a hot isostatic pressing (HIP) process. The combination of the additive manufacturing process and the HIP process forms a diffusion bond between the outer shell and the bulk material resulting in a monolithic component with functionally graded properties. The outer shell may include an exterior surface and an inner passage formed with relatively hard surfaces to accommodate fluids in a wellbore.

Abstract: A rotary valve can include a housing, a manifold with multiple flow paths can be fixedly mounted to the housing. A rotary actuator with a first surface can be rotatably mounted within the housing, and a valve seat with a second surface can be fixedly attached to the manifold, where the second surface can sealingly engage the first surface. The rotary actuator can include a gap that selectively aligns with respective ones of valve seat ports as the rotary actuator rotates relative to the valve seat, thereby selectively pressurizing one or more actuators. A system and method can include a rotary valve that selectively causes pads to extend at a predetermined orientation in the wellbore to steer a drill bit. The azimuthal orientation of a rotary actuator of the valve can determine which pads are extended and which are retracted as the drill bit rotates.

Abstract: A rotary valve can include a housing, a manifold with multiple flow paths can be fixedly mounted to the housing. A rotary actuator with a first surface can be rotatably mounted within the housing, and a valve seat with a second surface can be fixedly attached to the manifold, where the second surface can sealingly engage the first surface. The rotary actuator can include a gap that selectively aligns with respective ones of valve seat ports as the rotary actuator rotates relative to the valve seat, thereby selectively pressurizing one or more actuators. A system and method can include a rotary valve that selectively causes pads to extend at a predetermined orientation in the wellbore to steer a drill bit. The azimuthal orientation of a rotary actuator of the valve can determine which pads are extended and which are retracted as the drill bit rotates.

Abstract: A rotary valve with increased resistance to degradation that can include, a manifold with multiple flow paths, a rotary actuator rotatably mounted within the valve, and a valve seat that is fixedly attached to the manifold, with an end (or component) of the rotary actuator made from silicon carbide diamond (ScD) and the end having a first surface. The valve seat can have a second surface that sealingly engages the first surface. Manufacturing a rotary valve can include combining diamond particles in a press with silicon and applying temperature and pressure to produce a piece of ScD. Interposing a compound between the piece and a structure and brazing them by heating the compound between 700-1200 degrees Celsius. Forming ports and flow paths in the piece by machining the piece with an Electrical Discharge Machining (EDM) tool.

Abstract: A rotary valve can include a seat and a rotary actuator, each with a surface, the rotary actuator rotatably mounted to a housing. The surfaces can form a seal due to their engagement with an engagement force used to maintain the engagement. One biasing device can elevate pressure in a sealed volume in the valve at a constant level above an external pressure. The elevated pressure can produce a pressure differential across the rotary actuator, thereby producing at least a portion of the engagement force. Another biasing device can act between a splined hub and a mated splined shaft, thereby applying at least a portion of the engagement force through the shaft to the rotary actuator. Fluid flowing through a screen can create a pressure drop, thereby causing a pressure differential across the rotary actuator and applying at least a portion of the engagement force to the surfaces.

Abstract: A rotary valve can include a housing, a manifold with multiple flow paths can be fixedly mounted to the housing. A rotary actuator with a first surface can be rotatably mounted within the housing, and a valve seat with a second surface can be fixedly attached to the manifold, where the second surface can sealingly engage the first surface. The rotary actuator can include a gap that selectively aligns with respective ones of valve seat ports as the rotary actuator rotates relative to the valve seat, thereby selectively pressurizing one or more actuators. A system and method can include a rotary valve that selectively causes pads to extend at a predetermined orientation in the wellbore to steer a drill bit. The azimuthal orientation of a rotary actuator of the valve can determine which pads are extended and which are retracted as the drill bit rotates.

Abstract: A rotary valve with increased resistance to degradation that can include, a manifold with multiple flow paths, a rotary actuator rotatably mounted within the valve, and a valve seat that is fixedly attached to the manifold, with an end (or component) of the rotary actuator made from silicon carbide diamond (ScD) and the end having a first surface. The valve seat can have a second surface that sealingly engages the first surface. Manufacturing a rotary valve can include combining diamond particles in a press with silicon and applying temperature and pressure to produce a piece of ScD. Interposing a compound between the piece and a structure and brazing them by heating the compound between 700-1200 degrees Celsius. Forming ports and flow paths in the piece by machining the piece with an Electrical Discharge Machining (EDM) tool.

Abstract: Polyols useful in the manufacture of polyurethanes are disclosed. The polyols are prepared by reacting a vegetable oil based (hydroxymethyl containing) monomer with a polyol, polyamine or aminoalcohol under vacuum.