Article of manufacture having a sub-surface friction stir welded channel
AssigneeSmith International, Inc.
InventorRichard Davis
Life of this patent
Estimating the term…
Abstract
A method for routing an electrical conductor through a sub-surface channel in substantially any suitable metallic article of manufacture includes friction stir welding a cap in a groove formed in a surface of the article so as to form the sub-surface channel. An electrical conductor is then routed through the channel. The channel may further include a substantially tubular conduit formed therein with the electrical conductor being routed through the conduit. The friction stir weld zone formed during friction stir welding is generally harder and more wear resistant that the article body.
Claims24
A method for routing an electrical conductor through a sub-surface channel in a downhole tool, the method comprising:
- forming a bore in a body of the downhole tool;
- forming a groove in at least one exterior surface of the body, the bore being aligned with and connected to the groove;
- fitting a metallic cap into the groove, the cap being sized and shaped such that:
- (i) it creates a sub-surface channel in the groove and
- (ii) it engages the side walls of the groove to form first and second seams between the groove and the surface;
- friction stir welding at least a portion of the first and second seams so as to secure the cap to the surface:
- and
- drawing an electrical conductor through the bore and the sub-surface channel.
A method for routing an electrical conductor through a sub-surface channel formed in a downhole tool, the method comprising:
- gun drilling at least one bore in a downhole tool body;
- forming a groove in at least one exterior surface of the downhole tool body, the groove and the bore being connected with one another;
- deploying a substantially tubular conduit in the groove;
- fitting a metallic cap into the groove, the cap being sized and shaped such that it
- (i) creates a sub-surface channel in the groove and
- (ii) engages the side walls of the groove to form first and second seams between the groove and the tool body;
- friction stir welding at least a portion of the first and second seams so as to secure the cap to the tool body;
- and
- drawing an electrical conductor through the at least one bore and the conduit in the sub-surface channel.
A downhole tool, comprising:
- a metallic body having a bore formed at least partially therein and a groove formed in an exterior surface thereof, the bore being aligned with and connected to the groove;
- a metallic cap deployed in the groove, the cap being sized and shaped such that a sub-surface channel is formed in the groove internal to the cap, the metallic cap being joined to the outer surface of the body via at least one friction stir weld zone, the friction stir weld zone including a mechanical mixture of a portion of the metallic cap and a portion of the body;
- and
- an electrical conductor routed through the bore and the subsurface channel.
A downhole tool, comprising:
- a downhole tool body having a bore formed at least partially therein and a groove formed in an outer surface thereof, the bore being aligned with and connected to the groove and the tool body being configured for coupling with a drill string;
- a metallic cap deployed in the groove, the cap being sized and shaped such that a sub-surface channel is formed in the groove internal to the cap, the metallic cap being joined to the outer surface of the body via at least one friction stir weld zone, the friction stir weld zone including a mechanical mixture of a portion of the metallic cap and a portion of the tool body;
- a substantially tubular conduit deployed in the sub-surface channel radially between the cap and the tool body;
- and
- an electrical conductor routed through the bore and the conduit in the sub-surface channel.
Dependencies are inferred from the claim text.