Abstract: Disclosed herein are systems and methods of using a coating solution such as an aromatic copolyester thermoset (ACT) to improve the wear, galling, and corrosion resistances of downhole tools and their sub-components. Aromatic copolyester thermoset may be reinforced with filler material. Further, the aromatic copolyester thermoset reinforced with filler material may be used in a borehole as a composite hollow profile, for example. In some examples, the systems may comprise a substrate for downhole applications coated with an aromatic thermosetting copolyester mixed with polytetrafluoroethylene (PTFE).

Abstract: HIC-resistant materials may include sensors embedded within or otherwise coupled thereto for use in a hydrogen service environment. In an example, a diagnostic system includes a first sensor embedded within a structural metal for exposure to hydrogen for generating a signal response to both the hydrogen and one or more parameter. A second sensor is embedded within the structural metal for generating another signal response to the one or more parameter. A hydrogen-suppressing layer is provided to suppress any response of the second sensor to the hydrogen. A controller in communication with the first and second sensors distinguishes the signal response of the first sensor from the signal response of the second sensor to characterize the hydrogen and the one or more other parameter.

Abstract: A variety of methods and apparatus are disclosed, including, in one embodiment, a downhole tool for use in a borehole, comprising: a mandrel; and a sealing element disposed about the mandrel, wherein the sealing element comprises bulk metallic glass (BMG).

Abstract: A variety of methods and apparatus are disclosed, including, in one embodiment, a downhole tool for use in a borehole, comprising: a mandrel; and a sealing element disposed about the mandrel, wherein the sealing element comprises bulk metallic glass (BMG).

Abstract: A variety of methods and apparatuses are disclosed, including, a downhole tool for a wellbore, the downhole tool having a spring comprising bulk metallic glass (BMG), and a method of positioning the downhole tool having the spring comprising BMG in the wellbore.

Abstract: A syntactic foam including a matrix material and a filler material. The filler material may include microspheres of metallic glass material, the microspheres may be hollow microspheres.

Abstract: Manufacturing a dissolvable downhole hydraulic frac tool member, including providing water-soluble bulk metallic glass (BMG) particles, providing water-soluble thermoplastic polymer particles and mixing together to form a BMG-polymer blend. Heating the BMG-polymer blend to a temperature where the BMG particles are superplastic, the water-soluble thermoplastic polymer particles are moldable, and the BMG particles have a temperature of superplastic flowability that is in a moldability temperature range of the water-soluble thermoplastic polymer and are embedded in a matrix of the thermoplastic polymer to thereby form a BMG-polymer composition; and then; forming the BMG-polymer composition into the frac tool member.

Abstract: A metal can include a metallic substrate and an alloy coating. The alloy coating may have a higher entropy than the entropy of the metallic substrate. The alloy coating may coat an external surface of the metallic substrate. The metal coated by the higher entropy alloy on an external surface of the metallic substrate may serve to increase resistance of the metal to hydrogen-induced cracking in a downhole environment.

Abstract: The present disclosure provides elastomer blends comprising mixtures of partially fluorinated elastomers, such as tetrafluoroethylene propylene elastomers (FEPM or TFEP) and fluorocarbon rubbers, such as vinylidene fluoride-based elastomers (FKM or FEP). The elastomer blends can be prepared using two-roll mills, internal mixers, or other mixing technique and can be molded into seals, gaskets, o-rings or other articles using extrusion, injection molding, compression molding or the like. The resultant elastomeric articles can provide good sealing performance, including at moderate or low temperatures, and exhibit good chemical compatibility and resistance when exposed to common wellbore environments. In some cases, the elastomer blends can provide performance characteristics previously only available from perfluorinated elastomers (FFKM), but without requiring the complex processing conditions associated with preparing perfluorinated elastomers.

Abstract: A downhole hydraulic frac tool for use in a hydraulic fracturing system, the frac tool comprising a dissolvable frac tool member that includes a water-dissolvable composition, the composition including: a water-soluble thermoplastic polymer; and water-soluble bulk metallic glass (BMG) particles, wherein: the BMG particles are embedded within a matrix of the water-soluble thermoplastic polymer, the BMG particles have a greater tensile strength than a tensile strength the water-soluble thermoplastic polymer, and the BMG particles have a higher fracture toughness than a fracture toughness the water-soluble thermoplastic polymer. A method of manufacturing a dissolvable downhole hydraulic frac tool member and, a hydraulic fracturing system associated with a wellbore in which dissolvable downhole hydraulic frac tools of the disclosure can be used, are also disclosed.

Abstract: Elastomer blends comprising mixtures of partially fluorinated elastomers, such as tetrafluoroethylene propylene elastomers (FEPM or TFEP) and fluorocarbon rubbers, such as vinylidene fluoride-based elastomers (FKM or FEP), can be prepared using two-roll mills, internal mixers, or other mixing technique and can be molded into seals, gaskets, o-rings or other articles using extrusion, injection molding, compression molding or the like. The resultant elastomeric articles can provide good sealing performance, including at moderate or low temperatures, and exhibit good chemical compatibility and resistance when exposed to common wellbore environments. In some cases, the elastomer blends can provide performance characteristics previously only available from perfluorinated elastomers (FFKM), but without requiring the complex processing conditions associated with preparing perfluorinated elastomers.

Abstract: A metal can include a metallic substrate and an alloy coating. The alloy coating may have a higher entropy than the entropy of the metallic substrate. The alloy coating may coat an external surface of the metallic substrate. The metal coated by the higher entropy alloy on an external surface of the metallic substrate may serve to increase resistance of the metal to hydrogen-induced cracking in a downhole environment.

Abstract: A tubing string may include a swellable metal material for providing a seal downhole. The swellable metal material may react with a silica material and a water-based fluid to cause the swellable metal material to swell and form a seal within a flow path defined in part by the tubing string.

Abstract: The disclosure provides for a layered metal with resistance to hydrogen induced cracking and method of production thereof, comprising a core metal alloy and a skin metal alloy. The core metal alloy comprises twinned boundaries. The core metal alloy has undergone plastic deformation and a heat treatment. The core metal alloy comprises nickel and cobalt. The skin metal alloy is disposed on the core metal alloy, wherein the skin metal alloy comprises an entropy greater than the core metal alloy. The core metal alloy comprises a greater density of twinned boundaries than the skin metal alloy. The skin metal alloy comprises a stacking fault energy of at least about 50 mJ/m2, and the skin metal alloy comprises iron, aluminum, and boron.

Abstract: A downhole hydraulic frac tool for use in a hydraulic fracturing system, the frac tool comprising a dissolvable frac tool member that includes a water-dissolvable composition, the composition including: a water-soluble thermoplastic polymer; and water-soluble bulk metallic glass (BMG) particles, wherein: the BMG particles are embedded within a matrix of the water-soluble thermoplastic polymer, the BMG particles have a greater tensile strength than a tensile strength the water-soluble thermoplastic polymer, and the BMG particles have a higher fracture toughness than a fracture toughness the water-soluble thermoplastic polymer. A method of manufacturing a dissolvable downhole hydraulic frac tool member and, a hydraulic fracturing system associated with a wellbore in which dissolvable downhole hydraulic frac tools of the disclosure can be used, are also disclosed.

Abstract: HIC-resistant materials may include sensors embedded within or otherwise coupled thereto for use in a hydrogen service environment. In an example, a diagnostic system includes a first sensor embedded within a structural metal for exposure to hydrogen for generating a signal response to both the hydrogen and one or more parameter. A second sensor is embedded within the structural metal for generating another signal response to the one or more parameter. A hydrogen-suppressing layer is provided to suppress any response of the second sensor to the hydrogen. A controller in communication with the first and second sensors distinguishes the signal response of the first sensor from the signal response of the second sensor to characterize the hydrogen and the one or more other parameter.

Abstract: A coated structure may be formed with a hydrogen-resistant coating for use in a corrosive service environment. The structure may include a ferrous base metal with sufficient structural strength, despite being susceptible to hydrogen degradation in an uncoated state. A hydrogen-resistant coating is formed on the base metal without increasing a temperature of the base metal beyond a tempering temperature of the base metal. A preferred coating method is cold spraying. The cold spraying may be performed at sufficiently high pressures to achieve a low porosity without requiring a post-coating heat treatment that may otherwise reduce the strength of the base metal.

Abstract: A syntactic foam including a matrix material and a filler material. The filler material may include microspheres of metallic glass material, the microspheres may be hollow microspheres.

Abstract: The disclosure provides for a layered metal with resistance to hydrogen induced cracking and method of production thereof, comprising a core metal alloy and a skin metal alloy. The core metal alloy comprises twinned boundaries. The core metal alloy has undergone plastic deformation and a heat treatment. The core metal alloy comprises nickel and cobalt. The skin metal alloy is disposed on the core metal alloy, wherein the skin metal alloy comprises an entropy greater than the core metal alloy. The core metal alloy comprises a greater density of twinned boundaries than the skin metal alloy. The skin metal alloy comprises a stacking fault energy of at least about 50 mJ/m2, and the skin metal alloy comprises iron, aluminum, and boron.

Abstract: A tubing string may include a swellable metal material for providing a seal downhole. The swellable metal material may react with a silica material and a water-based fluid to cause the swellable metal material to swell and form a seal within a flow path defined in part by the tubing string.