Addressing Corrosion Stress Cracking Issue of Magnesium Frac Plugs Used in Ultra HPHT Shale Well Development

2021 ◽  
Author(s):  
Timothy Ryan Dunne ◽  
Wenhan Yue ◽  
Lei Zhao ◽  
Damon Nettles ◽  
Peng Cheng ◽  
...  
Keyword(s):  
High Temperature ◽  
Magnesium Alloy ◽  
Material Selection ◽  
Tap Water ◽  
High Strength ◽  
Secondary Phase ◽  
Dissolution Testing ◽  
Secondary Phases ◽  
Component Level ◽  
Premature Failure

Abstract The paper discusses the unrecognized issue of accelerated cracking and dissolution of stressed high strength dissolvable magnesium components at elevated temperature. A high strength dissolvable magnesium alloy was selected for inclusion in a frac plug designed for 125°C to 175°C service after thorough tensile, compression, and dissolution testing of the alloy. After a 125°C plug field test, the plug exhibited catastrophic, premature failure. Laboratory plug testing of two magnesium alloys for the slips replicated the failure at 140°C in tap water. Dissolution testing of coupons in a more aggressive media showed inadequate mass loss to compromise functionality. It was theorized that the passivating magnesium layer was unable to form due to the stress applied to the components with magnesium's inherent reactivity with water. Slow strain rate testing was used to study the potential mechanism causing stress corrosion cracking. Two high temperature high strength alloys, DM-1 and DM-2, were tested at 4 x 10^-6 in/in/s in 140°C tap water. DM-1 demonstrated a decrease in yield from 52.4 ksi to 33 ksi, a 37% reduction as well as a decrease in ductility from 10.9% to 0.8%, a 93% decrease. DM-2 demonstrated a decrease in yield from 59.3 ksi to 32.3 ksi, a 46% reduction as well as a decrease in ductility from 10.3% to 0.7%, a 93% decrease. A scanning electron microscope evaluation showed both materials possessed a highly developed secondary phase surrounding the grain boundaries. The development and subsequent investigation of an alternative magnesium alloy, DM-3, showed semi-continuous secondary phases and was investigated for a substitute at a component level. While the ultimate tensile strength decreased minimally, the ductility decreased by 36%. Laboratory testing of the plug in identical conditions with the DM-3 slips was still successful. It is imperative for high temperature magnesium plug material selection to ensure the alloy does not have highly interconnected secondary phases which may cause sudden failure during field operation.

ELEKTRON EQ2

Alloy Digest ◽  
2015 ◽  
Vol 64 (9) ◽  
Keyword(s):  
Corrosion Resistance ◽  
Rare Earth ◽  
High Temperature ◽  
Magnesium Alloy ◽  
North America ◽  
Earth Element ◽  
High Strength ◽  
Heat Treating ◽  
Bend Strength ◽  
Temperature Performance

Abstract Elektron EQ21 is a casting high strength magnesium alloy developed as a heat treatable alloy with rare earth element additions. This datasheet provides information on composition, physical properties, hardness, elasticity, tensile properties, and compressive, shear, and bend strength as well as creep. It also includes information on high temperature performance and corrosion resistance as well as casting, forming, heat treating, machining, joining, and surface treatment. Filing Code: Mg-80. Producer or source: Magnesium Elektron Wrought Products, North America.

Material Selection and Sizes Optimization of Casing Material for High-Temperature Natural Gas Well

2013 ◽  
Vol 700 ◽  
pp. 213-216
Author(s):  
Ling Feng Li
Keyword(s):  
High Temperature ◽  
Natural Gas ◽  
Material Selection ◽  
High Strength ◽  
Gas Production ◽  
Material Strength ◽  
Production Engineering ◽  
Gas Well ◽  
Strength Material ◽  
High Temperature Gas

In natural gas production engineering for high-temperature gas well, material selection and sizes optimization of casing material are one of the important phases. This paper presents the effect of high temperature on material strength of casing, performance matching requirements of high-strength material, sizes optimization of casing material for high-temperature gas well and examples for application.By testing, the study above is good and easy for on-the-spot application.

The Effect on Dynamic Steel Tube Umbilical Fatigue Performance Associated With Designing for Elevated Temperature

2017 ◽  
Author(s):  
Jamie Fletcher-Woods ◽  
Jake Noble ◽  
Lewis Balfour
Keyword(s):  
High Temperature ◽  
Elevated Temperature ◽  
Material Selection ◽  
Steel Tube ◽  
Fatigue Performance ◽  
Contact Load ◽  
Component Level ◽  
Steel Tubes ◽  
The Coefficient Of Friction ◽  
Design Case

The expansion of umbilical functionality to include power cables and high temperature fluid transportation (for applications such as gas lift) has led to the requirement for a high temperature steel tube riser umbilical, as shown in Figure 1. The combination of the elevated temperature and the dynamic service conditions create a unique design brief for steel tube umbilicals. The following paper presents a case study evaluating a steel tube riser umbilical capable of transporting hot gas at 70°C from an FPSO to a well head at approximately 800m water depth. The material selection for the steel tube is super duplex stainless steel (SDSS) and due to the high temperature, the corrosion resistant coating selected to ensure corrosion resistance in seawater at 70°C is fusion bonded epoxy protected with a bonded polypropylene outer layer (3LPP). The fatigue performance of the dynamic steel tube umbilicals is highly dependent on the frictional loads between the components developed due to tension and bending. This loading is most critical in the bend stiffener location at the riser umbilical’s interface with the FPSO structure. The fatigue critical component is usually determined to be one of the super duplex steel tubes within the umbilical. The frictional loads are a function of the coefficient of friction between the interacting components and the contact load developed between the layers of helically wound components. This contact load increases with tension. The paper considers the effects of the polypropylene material selection and the elevated operating temperature on the friction interface between the steel tubes. The work assesses the corresponding change in fatigue damage through the service life in comparison to more common temperatures and materials used in dynamic steel tube umbilicals. Changes in contact load between elements of a friction interface are known to affect the friction coefficient. The contact load across all interfaces has been varied to help understand how the coefficient of friction may be affected by different tensile loads or umbilical designs. Including this variable in the test program also ensures that the friction is quantified at a contact load relative to the design case considered. To assess the differences in friction a scope of component level friction testing is presented and the results are processed through umbilical local fatigue analysis software to establish the implications on fatigue performance. The umbilical structure is designed to free flood in between the components in service, and the bend stiffener region is submerged for the design case in question. Full scale flex-fatigue testing of the dynamic umbilical and the bend stiffener are however conducted in a dry environment. The impact of this on the severity of the test and in comparison to the in-service condition are assessed using component level wet and dry testing to provide changes in friction for sensitivity analysis. In addition to the loading on the tubes, the fatigue performance of the material being loaded is also considered. the fatigue performance of welded super duplex tubing has previously been tested and documented at ambient room temperature conditions and therefore the effect on the welded steel tube fatigue performance due to the increase in temperature for this application has been quantified to ensure the proposed design curve is suitable. cyclic bending stress experienced by the steel tubes during dynamic service (2).

scholarly journals Effects of High-Intensity Ultrasound on the Microstructure and Mechanical Properties of 2195 Aluminum Ingots

Metals ◽  
2021 ◽  
Vol 11 (7) ◽  
pp. 1050
Author(s):  
Yuqi Hu ◽  
Ripeng Jiang ◽  
Xiaoqian Li ◽  
Anqing Li ◽  
Ziming Xie
Keyword(s):  
Mechanical Properties ◽  
Aluminum Alloy ◽  
High Strength ◽  
Secondary Phase ◽  
Industrial Applications ◽  
Melt Processing ◽  
Secondary Phases ◽  
Large Area ◽  
Microstructural Refinement ◽  
Size And Morphology

The microstructural refinement of 2195 aluminum alloy ingots is particularly important for improving their industrial applications and mechanical properties. Combined with vacuum casting and inert gas protection, scalable high-strength ultrasonic melt processing (USMT) technology was used to manufacture 2195 aluminum alloy cylindrical ingots. Then, the influence of USMT on the main microstructural components (primary α-Al grains, secondary phase network, and precipitated particles) was studied. Our experiments show that the main microstructure of the ingot was improved after the introduction of ultrasound. Compared to the ingot formed without USMT, the size and morphology of the primary α-Al phase were optimized. The agglomeration of coarsening secondary phases can be alleviated, and the large layered secondary phase network becomes discontinuous throughout the ingot under USMT. At the same time, the mechanical properties of the solidified aluminum alloy ingots were also tested, and comparisons were made between samples formed with and without USMT. The results show that the stress concentration caused by the large area of coarse secondary phase in the ingot leads to the decrease of mechanical properties.

Effect of Addition of Nano-Al2O3 and Copper Particulates and Heat Treatment on the Tensile Response of AZ61 Magnesium Alloy

2013 ◽  
Vol 135 (3) ◽  
Author(s):  
Q. B. Nguyen ◽  
Y. H. D. Chua ◽  
K. S. Tun ◽  
J. Chan ◽  
R. Kwok ◽  
...  
Keyword(s):  
Heat Treatment ◽  
Magnesium Alloy ◽  
Mechanical Response ◽  
Hot Extrusion ◽  
Secondary Phase ◽  
Secondary Phases ◽  
Microstructural Characteristics ◽  
Tensile Response ◽  
Az61 Magnesium Alloy ◽  
Melt Deposition

In this paper, AZ61 magnesium alloy composites containing nanoalumina and micron-sized copper particulates are synthesized using the technique of disintegrated melt deposition followed by hot extrusion. The simultaneous addition of nano-Al2O3 and copper particulates led to an overall improvement in both microstructural characteristics in terms of distribution and morphology of secondary phases and mechanical response of AZ61. The presence of nanoalumina particulates broke down and dispersed the secondary phase Mg17Al12. The 0.2% yield strength increased from 216 MPa to 274 MPa. The ductility increased from 8.4% to 9.3% in the case of the AZ61-1.5Al2O3 sample. The results of aging heat treatment in the case of the AZ61-1.5Al2O3-1Cu sample showed significant improvement in both tensile strength, ductility, and work of fracture (54% increment). An attempt is made to correlate the tensile response of composites with their microstructural characteristics.

Stacking faults in deformed α-silicon nitride single crystals

1993 ◽  
Vol 51 ◽  
pp. 916-917
Author(s):  
H. Suematsu ◽  
J. J. Petrovic ◽  
T. E. Mitchell
Keyword(s):  
High Temperature ◽  
Silicon Nitride ◽  
Single Crystals ◽  
Stacking Faults ◽  
High Strength ◽  
Secondary Phase ◽  
High Resolution Electron Microscopy ◽  
Diffusional Creep ◽  
Dislocation Slip ◽  
High Temperature Strength

Silicon nitride(Si3N4) is well known for its high toughness and strength. This is the reason why it is selected for ceramic turbo charger rotors in automobile engines. However, the high strength of most sintered Si3N4 products drops above 1200°C because sintering aids like Y2O3 and MgO are required which form glassy phases with low melting points on the grain boundaries. This secondary phase degrades the high temperature characteristics of Si3N4. In order to overcome this deficiency, much work has been reported which aims at crystallizing or removing the glassy phase. If this aim could be successful, resulting in an increase in high temperature strength, other processes would determine the high temperature performance of Si3N4, such as diffusional creep and dislocation slip. Line and planar defects in Si3N4 play an important role in such the processes particularly in slip, however, available knowledge about them is limited. In the present work, stacking faults in deformed Si3N4 single crystals are investigated using high resolution electron microscopy(HREM).

The Effect of Bond Phase Additive and Sintering Temperature on the Properties of Mullite Bonded Porous SiC Ceramics

2020 ◽  
Vol 978 ◽  
pp. 454-462
Author(s):  
Dulal Das ◽  
Nijhuma Kayal
Keyword(s):  
High Temperature ◽  
Structural Properties ◽  
Sintering Temperature ◽  
High Strength ◽  
Secondary Phases ◽  
Reaction Bonding ◽  
Sintering Additives ◽  
Sic Ceramics ◽  
Porous Sic ◽  
Very High

Currently, porous SiC ceramics have been a focus of interesting research in the field of porous materials due to their excellent structural properties, high strength, high hardness, and superb mechanical and chemical stabilities even at high temperatures and hostile atmospheres. Porous SiC ceramics have been considered as suitable candidate materials for catalyst supports [1-2], hot gas or molten metal filters [3], high temperature membrane reactors [4], thermal insulating materials [5], gas sensors [6] etc. Porous SiC ceramics are fabricated by various methods including partial sintering [7], carbothermal reduction [8-9], replication or pyrolysis of polymeric sponge [10-12], reaction bonding [13] etc. In all these methods SiC needs to be sintered which requires a very high temperature due to the strong covalent nature of the Si-C bond, selective sintering additives, expensive atmosphere, costly and delicate instrumentation. Processing of porous SiC ceramics at low temperature using a simple technique thus becomes necessary. Bonding of SiC can be done at low temperatures by use of different oxide and non-oxide secondary phases. They include silica, mullite, cordierite, silicon nitride, etc. Various sintering additives are used for the formation of variety of secondary oxide bond phases for formations for porous SiC [14-19] Choice of mullite as a bond for SiC has many advantages. Mullite possesses a high melting point (Tm= 1850°C) and a low oxygen diffusion coefficient (5.6 x 10-14 m2/sec at 50°C). It has a matching thermal expansion coefficient with SiC (CTEmullite= 5.3 ×10-6/K; CTESiC = 4.7 ×10-6/K at RT-1000 °C) and a high strength that can be retained up to a very high temperature. Different sources of aluminum, such as Al2O3, Al, AlN, and Al (OH)3 powders were used for the formation of mullite bonded porous SiC ceramics (MBSC) [20-21]. However, the mullitization temperature of 1550o C is still necessary. In this work, mullite bonded porous SiC ceramics were fabricated by an in situ reaction-bonding process; the mixture of clay and CaCO3 were chosen as sintering additives to lower the mullitization reaction between Al2O3 and oxidation-derived SiO2. The effect amount of alumina, sintering temperature and other sintering aids on material property such as porosity/pore size distribution mechanical and micro structural properties of porous oxide bonded SiC ceramics were studied.

ELEKTRON ZW3

Alloy Digest ◽  
1955 ◽  
Vol 4 (9) ◽  
Keyword(s):  
Compressive Strength ◽  
Corrosion Resistance ◽  
High Temperature ◽  
Magnesium Alloy ◽  
Physical Properties ◽  
Surface Treatment ◽  
Stress Corrosion Cracking ◽  
High Strength ◽  
Temperature Performance ◽  
Wrought Magnesium Alloy

Abstract ELEKTRON ZW3 is a high strength wrought magnesium alloy. It shows improved hot formability; it is free from stress-corrosion cracking in service and is readily weldable by the argonarc and heliarc machine processes and by the manual method for simple joints. This datasheet provides information on composition, physical properties, hardness, elasticity, tensile properties, and compressive strength as well as fatigue. It also includes information on low and high temperature performance, and corrosion resistance as well as forming, machining, joining, and surface treatment. Filing Code: Mg-19. Producer or source: Magnesium Elektron Inc..

High temperature strength of silicon nitride ceramics with ytterbium silicon oxynitride

1997 ◽  
Vol 12 (1) ◽  
pp. 203-209 ◽  
Author(s):  
Toshiyuki Nishimura ◽  
Mamoru Mitomo ◽  
Hisayuki Suematsu
Keyword(s):  
High Temperature ◽  
Silicon Nitride ◽  
Bending Strength ◽  
High Strength ◽  
Secondary Phase ◽  
Silicon Oxynitride ◽  
High Temperature Strength ◽  
High Melting Point ◽  
Powder Mixtures ◽  
Nitride Ceramics

Silicon nitride ceramics with ytterbium silicon oxynitride (Yb4Si2O7N2) as secondary phase were fabricated by hot-pressing the powder mixtures, including 50.0 to 97.0 mol% of silicon nitride with a mixture of Yb2O3 and SiO2 (Yb2O3/SiO2 = 4). Sinterability of the materials with Yb2O3 was higher than that with Y2O3 in the same composition of raw powder mixtures. High density materials were obtained under the condition of 50.0 to 89.1 mol% of silicon nitride in raw powder mixtures. Mechanical properties of silicon nitride containing 97.6 mol% of Si3N4 and 2.4 mol% of Yb4Si2O7N2 were measured. Fracture toughness measured by the indentation technique was 5.9 MPam1/2. Bending strength at room temperature and at 1500 °C was 977 MPa and 484 MPa, respectively. The silicon nitride grains consisted of highly elongated rod-like grains and thin needle-like grains. The Yb4Si2O7N2 grains were crystallized at multigrain junctions and bonded close to Si3N4 grains. High strength at high temperature is supposed to be based on the presence of crystalline Yb4Si2O7N2 having a high melting point.

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