Downhole flame spray welding tool system and method

An apparatus for filling an opening in well casing from the inside of the well casing, said apparatus comprising:

• an oxygen supply;
• a fuel tank;
• a metal supply;
• and
• metal depositing means in communication with said oxygen supply, fuel tank and metal supply such that heat is generated by the mixture of oxygen and fuel, and heated metal is deposited in the opening and adhered to the well casing.

An apparatus for spraying metal into a desired area of a well casing from the inside of the well casing, said apparatus comprising:

• a steering sub adapted for connection to a tool string;
• a housing attached to said steering sub such that said steering sub provides movement of said housing with respect to the tool string;
• an oxygen tank in said housing, said oxygen tank having a quantity of pressurized oxygen therein;
• an inert gas supply;
• a fuel tank in said housing, said fuel tank having a quantity of fuel therein;
• a powder container in said housing, said powder container having a quantity of metal powder therein and being in communication with said inert gas tank such that said pressurized inert gas tends to push said metal powder out of said powder container;
• and
• a spray head connected to said housing and in communication with said oxygen tank, fuel tank and powder container such that fuel, oxygen, inert gas and metal powder are mixed in said spray head and discharged therefrom as a metallic flame spray whereby metal may be deposited at the desired area in the casing.

An apparatus for spraying metal into a desired area of a well casing from the inside of the well casing, said apparatus comprising:

• a steering sub adapted for connection to a tool string;
• a housing attached to said steering sub such that said steering sub provides movement of said housing with respect to the tool string;
• a gas tank in said housing, said gas tank having a quantity of pressurized nitrous oxide therein;
• a sparking device positioned in said gas tank such that application of electrical power to said sparking device applies heat to the nitrous oxide in said gas tank and thereby initiates a decomposition reaction so that the nitrous oxide is separated into oxygen and nitrogen components thereof;
• a fuel tank in said housing, said fuel tank having a quantity of fuel therein;
• a powder container in said housing, said powder container having a quantity of metal powder therein;
• and
• a spray head connected to said housing and in communication with said gas tank, fuel tank and powder container such that fuel, oxygen, nitrogen and metal powder are mixed in said spray head and discharged therefrom as a metallic flame spray whereby metal may be deposited at the desired area in the casing.