Patents by Inventor Robert P. Badrak

Robert P. Badrak has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Patent number: 10539518
    Abstract: Using an X-ray diffractometer, a processing device, and memory, a database models estimates of a number of cycles to failure for each of a plurality of materials. The model estimates are performed on the material at a plurality of applied fatigues up to a failure point and are based on parameters including residual stress, the micro-strain, and the ratio between X-Ray peak intensity and background intensity of the component material. To inspect a component, the material of the component is selected in the database, and measurements are obtained at two or more different depths of at least a portion of the component. Information about current residual stress, micro-strain, and ratio between X-Ray peak intensity and background intensity are determined from the obtained measurements. Then, a fatigue life of the portion of the component is estimated by matching the information to at least one of the modelled estimates of the number of cycles to failure in the database for the selected material.
    Type: Grant
    Filed: May 15, 2017
    Date of Patent: January 21, 2020
    Assignee: Weatherford Technology Holdings, LLC
    Inventors: Robert P. Badrak, Sergey Kolesov
  • Publication number: 20190299326
    Abstract: A method is disclosed of manufacturing a side pocket mandrel for use with a gas lift valve downhole on a tubing string. A plurality of separate components of the mandrel are manufactured. A face on at least one end of each of the separate components is configured for solid-state joining with a face on another of the separate components. Joints are then formed between the separate components by moving the face of at least one of the separate components in a solid state joining process relative to the face of at least one other of the separate components. For example, linear friction, rotary friction, or spin friction welding can be used by moving one of the faces against another. Also, an induction heater can preheat the ends to a suitable temperature to reduce the need for friction heating.
    Type: Application
    Filed: March 27, 2018
    Publication date: October 3, 2019
    Inventors: Robert P. Badrak, Brian M. Sternaman
  • Publication number: 20190211630
    Abstract: A sucker rod for use in a subterranean well and a method of producing same, in which the method can include air quenching a martensitic stainless steel material of the sucker rod. An artificial lift system and a method of flowing a fluid from a well, in which the method can include connecting multiple air quenched and tempered sucker rods in a rod string connected to a downhole pump, and operating the downhole pump, thereby flowing the fluid from the well. A sucker rod can include a stainless steel sucker rod composition in which a carbon content is restricted to the range of 0.08% to 0.15%, and in which the sucker rod composition includes up to 0.20% vanadium content, up to 0.10% niobium content, up to 0.05% titanium content, up to 0.99% nickel content and/or up to 1.0% molybdenum content.
    Type: Application
    Filed: August 11, 2017
    Publication date: July 11, 2019
    Inventors: Oscar E. MARTINEZ, John STACHOWIAK, Jr., Robert P. BADRAK
  • Publication number: 20190211633
    Abstract: A sucker rod for use in a subterranean well can include a martensitic stainless steel material with a chromium content in the range of 11.5 to 13%, and a carbon content in the range of 0.08 to 0.15%, and a length of the sucker rod being at least 60 meters. A method of producing a sucker rod for use in a subterranean well can include producing a martensitic stainless steel material of the sucker rod, the material including chromium in the range of 11.5 to 13%, and carbon in the range of 0.08 to 0.15%, heat treating the material, and winding the material for storage.
    Type: Application
    Filed: November 28, 2017
    Publication date: July 11, 2019
    Inventor: Robert P. BADRAK
  • Publication number: 20180328870
    Abstract: Using an X-ray diffractometer, a processing device, and memory, a database models estimates of a number of cycles to failure for each of a plurality of materials. The model estimates are performed on the material at a plurality of applied fatigues up to a failure point and are based on parameters including residual stress, the micro-strain, and the ratio between X-Ray peak intensity and background intensity of the component material. To inspect a component, the material of the component is selected in the database, and measurements are obtained at two or more different depths of at least a portion of the component. Information about current residual stress, micro-strain, and ratio between X-Ray peak intensity and background intensity are determined from the obtained measurements. Then, a fatigue life of the portion of the component is estimated by matching the information to at least one of the modelled estimates of the number of cycles to failure in the database for the selected material.
    Type: Application
    Filed: May 15, 2017
    Publication date: November 15, 2018
    Inventors: Robert P. Badrak, Sergey Kolesov
  • Patent number: 9739105
    Abstract: A slip component for a downhole tool has a bearing surface that is hard surface treated. The slip component, which can be a slip or other component of a slip mechanism used on a packer, bridge plug, or other downhole tool, is composed of a non-metallic base material, such as plastic, composite, or ceramic. To hard surface treat the slip component, at least the bearing surface is positioned relative to an ion sputtering apparatus. An intermediate layer is first bonded onto the bearing surface by ion sputtering an intermediate material onto the non-metallic base material of the slip component. Then, the bearing surface of the slip component is positioned relative to an electrosparking apparatus, which has an electrode composed of a selected external material for depositing on the slip component. Using the electrosparking apparatus, an external layer is bonded at least on the bearing surface.
    Type: Grant
    Filed: July 20, 2015
    Date of Patent: August 22, 2017
    Assignee: Weatherford Technology Holdings, LLC
    Inventor: Robert P. Badrak
  • Patent number: 9631157
    Abstract: A bearing surface of an oilfield component is treated by applying a surface treatment having a low coefficient of friction to the bearing surface of the oilfield component by weld fusing an overlay of a Cu—Ni—Sn alloy material to the bearing surface. Weld fusing the overlay of the Cu—Ni—Sn alloy material to the bearing surface can involve laser surface cladding the overlay of the Cu—Ni—Sn alloy material to the bearing surface, gas tungsten arc welding the overlay of the Cu—Ni—Sn alloy material to the bearing surface, or plasma tungsten arc welding the overlay of the Cu—Ni—Sn alloy material to the bearing surface.
    Type: Grant
    Filed: October 14, 2014
    Date of Patent: April 25, 2017
    Assignee: Weatherford Technology Holdings, LLC
    Inventors: Robert P. Badrak, William R. Howie
  • Patent number: 9273527
    Abstract: A slip component for a downhole tool has a bearing surface hard surface treated. The slip component, which can be a slip or other component of a slip mechanism used on a packer, bridge plug, or other downhole tool, is composed of a metallic base material such as magnesium, aluminum, an aluminum alloy, or a magnesium alloy. To hard surface treat the slip component, at least the bearing surface is positioned relative to an electro sparking apparatus. Using the electrosparking apparatus, an external layer is bonded at least on the bearing. In a further embodiment, an intermediate layer can be first bonded onto at least the bearing surface by ion sputtering an intermediate material onto the metallic base material of the slip component. Then, an external layer can be bonded at least on the intermediate layer by electrospark deposition.
    Type: Grant
    Filed: February 7, 2013
    Date of Patent: March 1, 2016
    Assignee: Weatherford Technology Holdings, LLC
    Inventor: Robert P. Badrak
  • Patent number: 9212527
    Abstract: A pipe handling system for locating a pipe joint in a joining assembly that includes an internal joining tool and an external joining tool is provided. The system includes a gripper configured to grip a surface of the pipe joint; an elevator configured to pick up the pipe joint and position the pipe joint adjacent a string of pipe disposed in the external joining tool; and a deployment assembly coupled to the gripper, wherein the deployment assembly includes a cable that is used to position the internal joining tool inside the pipe joint.
    Type: Grant
    Filed: September 15, 2014
    Date of Patent: December 15, 2015
    Assignee: Weatherford Technology Holdings, LLC
    Inventors: Karsten Heidecke, Michael Hayes, Frederick T. Tilton, Doyle Fredric Boutwell, Jr., Robert P. Badrak, Joseph Ross Rials, David J. Havens
  • Publication number: 20150322741
    Abstract: A slip component for a downhole tool has a bearing surface that is hard surface treated. The slip component, which can be a slip or other component of a slip mechanism used on a packer, bridge plug, or other downhole tool, is composed of a non-metallic base material, such as plastic, composite, or ceramic. To hard surface treat the slip component, at least the bearing surface is positioned relative to an ion sputtering apparatus. An intermediate layer is first bonded onto the bearing surface by ion sputtering an intermediate material onto the non-metallic base material of the slip component. Then, the bearing surface of the slip component is positioned relative to an electrosparking apparatus, which has an electrode composed of a selected external material for depositing on the slip component. Using the electrosparking apparatus, an external layer is bonded at least on the bearing surface.
    Type: Application
    Filed: July 20, 2015
    Publication date: November 12, 2015
    Inventor: Robert P. Badrak
  • Patent number: 9097076
    Abstract: A slip component for a downhole tool has a bearing surface that is hard surface treated. The slip component, which can be a slip or other component of a slip mechanism used on a packer, bridge plug, or other downhole tool, is composed of a non-metallic base material, such as plastic, composite, or ceramic. To hard surface treat the slip component, at least the bearing surface is positioned relative to an ion sputtering apparatus. An intermediate layer is first bonded onto the bearing surface by ion sputtering an intermediate material onto the non-metallic base material of the slip component. Then, the bearing surface of the slip component is positioned relative to an electrosparking apparatus, which has an electrode composed of a selected external material for depositing on the slip component. Using the electrosparking apparatus, an external layer is bonded at least on the bearing surface.
    Type: Grant
    Filed: February 7, 2013
    Date of Patent: August 4, 2015
    Assignee: Weatherford Technology Holdings, LLC
    Inventor: Robert P. Badrak
  • Publication number: 20150111793
    Abstract: A bearing surface of an oilfield component is treated by applying a surface treatment having a low coefficient of friction to the bearing surface of the oilfield component by weld fusing an overlay of a Cu—Ni—Sn alloy material to the bearing surface. Weld fusing the overlay of the Cu—Ni—Sn alloy material to the bearing surface can involve laser surface cladding the overlay of the Cu—Ni—Sn alloy material to the bearing surface, gas tungsten arc welding the overlay of the Cu—Ni—Sn alloy material to the bearing surface, or plasma tungsten arc welding the overlay of the Cu—Ni—Sn alloy material to the bearing surface.
    Type: Application
    Filed: October 14, 2014
    Publication date: April 23, 2015
    Inventor: Robert P. Badrak
  • Publication number: 20150060045
    Abstract: A pipe handling system for locating a pipe joint in a joining assembly that includes an internal joining tool and an external joining tool is provided. The system includes a gripper configured to grip a surface of the pipe joint; an elevator configured to pick up the pipe joint and position the pipe joint adjacent a string of pipe disposed in the external joining tool; and a deployment assembly coupled to the gripper, wherein the deployment assembly includes a cable that is used to position the internal joining tool inside the pipe joint.
    Type: Application
    Filed: September 15, 2014
    Publication date: March 5, 2015
    Inventors: Karsten HEIDECKE, Michael HAYES, Frederick T. TILTON, Doyle Fredric BOUTWELL, JR., Robert P. BADRAK, Joseph Ross RIALS, David J. HAVENS
  • Publication number: 20140375167
    Abstract: Embodiments of the present invention provide methods for manufacturing an even-wall rotor or stator that do not suffer from drawbacks of the prior art. Even-wall rotors or stators produced according to those methods are also provided. In one embodiment, a method for manufacturing a rotor or stator for use in a mud motor is provided. The method includes providing a vacuum chamber; providing a metal electrode at least partially disposed in the vacuum chamber; providing a mold disposed in the vacuum chamber; and melting a portion of the electrode with a direct current arc, the molten metal flowing into the mold ring.
    Type: Application
    Filed: August 27, 2014
    Publication date: December 25, 2014
    Inventors: David W. TEALE, Robert P. BADRAK
  • Publication number: 20140216722
    Abstract: A slip component for a downhole tool has a bearing surface that is hard surface treated. The slip component, which can be a slip or other component of a slip mechanism used on a packer, bridge plug, or other downhole tool, is composed of a non-metallic base material, such as plastic, composite, or ceramic. To hard surface treat the slip component, at least the bearing surface is positioned relative to an ion sputtering apparatus. An intermediate layer is first bonded onto the bearing surface by ion sputtering an intermediate material onto the non-metallic base material of the slip component. Then, the bearing surface of the slip component is positioned relative to an electrosparking apparatus, which has an electrode composed of a selected external material for depositing on the slip component. Using the electrosparking apparatus, an external layer is bonded at least on the bearing surface.
    Type: Application
    Filed: February 7, 2013
    Publication date: August 7, 2014
    Inventor: Robert P. Badrak
  • Publication number: 20140216723
    Abstract: A slip component for a downhole tool has a bearing surface hard surface treated. The slip component, which can be a slip or other component of a slip mechanism used on a packer, bridge plug, or other downhole tool, is composed of a metallic base material such as magnesium, aluminum, an aluminum alloy, or a magnesium alloy. To hard surface treat the slip component, at least the bearing surface is positioned relative to an electro sparking apparatus. Using the electrosparking apparatus, an external layer is bonded at least on the bearing. In a further embodiment, an intermediate layer can be first bonded onto at least the bearing surface by ion sputtering an intermediate material onto the metallic base material of the slip component. Then, an external layer can be bonded at least on the intermediate layer by electrospark deposition.
    Type: Application
    Filed: February 7, 2013
    Publication date: August 7, 2014
    Inventor: Robert P. Badrak
  • Publication number: 20140158295
    Abstract: A method of manufacturing or surface treating a wire wrapped screen for use in a wellbore improves the erosion resistance of the wire-wrapped screen. The wire-wrapped screen can be disposed on an axle positioned in a chamber containing a source of erosion resistant surface coating. The coating is then deposited on the exterior of the wire-wrapped screen using a deposition process, such as physical vapor deposition or thermal spraying. Alternatively, a spray system proximate the wire-wrapped screen can have a deposition nozzle to coat the exterior surface of the screen with an elastomer coating by spraying an elastomer. In additional embodiments, the wire for the wire-wrapped screen can first be treated for erosion resistance and then wound about a mandrel to form the wire-wrapped screen.
    Type: Application
    Filed: December 10, 2012
    Publication date: June 12, 2014
    Applicant: WEATHERFORD/LAMB, INC.
    Inventor: Robert P. Badrak
  • Patent number: 7887103
    Abstract: A tubular configured to mate with a second tubular so that sealing integrity is maintained between the tubulars before, during, and after expansion of the tubulars is disclosed. In one embodiment, a connector for connecting tubulars is provided. The connector includes a pin portion; a box portion, wherein the pin and the box portions are configured to mate; a sealing surface formed in an inner surface of the box portion; a seal disposed in a groove formed in an outer surface of the pin portion, wherein the seal is configured to engage with a sealing surface of the box portion upon mating of the pin and the box portions; and a bump formed on an inner surface of the pin portion, wherein the bump is substantially radially aligned with the groove and the bump is configured so that the seal remains engaged with the box portion during and after expansion of the pin and the box portions.
    Type: Grant
    Filed: February 7, 2007
    Date of Patent: February 15, 2011
    Assignee: Watherford/Lamb, Inc.
    Inventors: Merle E. Evans, Ghazi J. Hashem, John Richard Setterberg, Jr., Robert P. Badrak, Patrick G. Maguire
  • Publication number: 20090278419
    Abstract: Embodiments of the present invention provide methods for manufacturing an even-wall rotor or stator that do not suffer from drawbacks of the prior art. Even-wall rotors or stators produced according to those methods are also provided. In one embodiment, a method for manufacturing a rotor or stator for use in a mud motor is provided. The method includes providing a vacuum chamber; providing a metal electrode at least partially disposed in the vacuum chamber; providing a mold disposed in the vacuum chamber; and melting a portion of the electrode with a direct current arc, the molten metal flowing into the mold ring.
    Type: Application
    Filed: July 13, 2009
    Publication date: November 12, 2009
    Inventors: David W. Teale, Robert P. Badrak
  • Patent number: 7409758
    Abstract: Apparatus and methods are provided for reducing drilling vibration during drilling with casing. In one embodiment, an apparatus for reducing vibration of a rotating casing includes a tubular body disposed concentrically around the casing, wherein tubular body is movable relative to the casing. Preferably, a portion of the tubular body comprises a friction reducing material. In operation, the tubular body comes into contact with the existing casing or the wellbore instead of the rotating casing. Because the tubular body is freely movable relative to the rotating casing, the rotating casing may continuously rotate even though the tubular body is frictionally in contact with the existing casing.
    Type: Grant
    Filed: October 29, 2004
    Date of Patent: August 12, 2008
    Assignee: Weatherford/Lamb, Inc.
    Inventors: Tuong Thanh Le, Richard L. Giroux, Albert C. Odell, Gary Thompson, Deborah L. Banta, Robert P. Badrak, Gregory G. Galloway, Mark S. Fuller