Sintered metal substitute for prepack screen aggregate

A well screen for separating unconsolidated material out of inflowing well fluid in water, oil, gas and recovery wells, characterized by a tubular, porous body of sintered powdered metal, said sintered body having a multiplicity of first pores resulting from its formation and additional, substantially larger pores therein.

A well screen for separating particulate material from formation fluid, comprising:

• tubular mandrel means having a bore defining a production flow passage, said mandrel means being intersected by at least one flow aperture connecting with said flow passage;
• and
• a permeable screen of sintered metal positioned along at least a portion of said mandrel means and covering said flow aperture, the sintered metal comprising compressed metal slivers having an uncompressed length in the range of about 50 microns to about 1,400 microns.

A method for making a well screen, comprising the steps of:

• forming a porous tubular body of sintered powdered metal;
• and
• increasing the pore size of the sintered body to increase the permeability of the body.