US 11,697,181 B2
Fusible metal clay, structures formed therefrom, and associated methods
David W. Teale, Spring, TX (US); Michael T. Smalley, Katy, TX (US); Richard S. Green, Cypress, TX (US); and William R. Howie, Katy, TX (US)
Assigned to Weatherford Technology Holdings, LLC, Houston, TX (US)
Filed by Weatherford Technology Holdings, LLC, Houston, TX (US)
Filed on Jan. 27, 2020, as Appl. No. 16/773,766.
Prior Publication US 2021/0229225 A1, Jul. 29, 2021
Int. Cl. B23P 15/34 (2006.01); B23K 35/02 (2006.01); B23K 35/30 (2006.01); B23K 35/36 (2006.01); B23K 35/22 (2006.01); B23K 11/30 (2006.01); B23K 103/00 (2006.01); B23K 101/34 (2006.01); B23K 101/20 (2006.01); B23K 103/12 (2006.01)
CPC B23P 15/34 (2013.01) [B23K 11/30 (2013.01); B23K 35/0211 (2013.01); B23K 35/228 (2013.01); B23K 35/302 (2013.01); B23K 35/3601 (2013.01); B23K 2101/20 (2018.08); B23K 2101/35 (2018.08); B23K 2103/12 (2018.08); B23K 2103/30 (2018.08); B23K 2103/50 (2018.08)] 20 Claims
OG exemplary drawing
 
1. A method of overlaying a downhole tool for engagement downhole, the method comprising:
molding a clay in a wet state into a structure, the clay in the wet state being a workable combination comprising a first grain, a second grain, and a binder, the first grain comprising a metal alloy having a first hardness and a first melting point, the second grain comprising a second material, the second material having a second hardness greater than the first hardness of the metal alloy and having a second melting point higher than of the first melting point of the metal alloy, the binder binding the first and second grains into the workable combination and having a combustion temperature at least not greater than the first melting point; and
affixing the structure to the downhole tool by:
positioning the structure in a fusible state adjacent the downhole tool;
applying a heat treatment to the structure at least up to the first melting point;
fusing the structure together with the applied heat treatment; and
forming a metallurgical bond between the structure with the downhole tool with the applied heat treatment.