Method and device for the formation of borehole casing by application of material layers by means of kinetic sputtering

Abstract

A formation of a borehole casing by application of material layers is achieved by means of kinetic sputtering. Specifically, the formation is achieved by additive kinetic sputtering of metallic, non-metallic and composite materials using acceleration and heating of material powder particles and subsequent plastic deformation of deformable powder fraction upon the impact onto the surface. The accelerated and heated particles of material in the form of powder impinge onto the surface of a borehole wall and/or on a mould and/or onto the surface of a previous layer of the casing in such manner that they form the layered composite casing on the inside wall of the borehole and/or on the mould, particularly in a liquid medium.

What is claimed is: 
     
         1 . A formation of a borehole casing by application of material layers by means of kinetic sputtering, namely by additive kinetic sputtering of metallic, non-metallic and composite materials using acceleration and heating of materials in form of powder particles and subsequent plastic deformation of deformable powder fraction upon the impact onto a surface, wherein the accelerated and heated particles of materials in the form of powder impinge onto a surface of a borehole wall and/or on a mould or onto a surface of the previous layer of the casing in such manner that they are deposited on the surface and form a layered composite casing on an inside wall of the borehole and/or on the mould, particularly in a liquid medium. 
     
     
         2 . The formation of the borehole casing according to the  claim 1 , wherein a carrier layer of the casing is formed on the borehole wall and/or on the mould in such manner that the material is deposited onto the borehole wall and/or on the mould in layers, wherein these layers have the same or different material composition and the carrier layer preferably forms a composite at the level of microstructure and/or macrostructure, and additional layers of casing can be deposited onto the carrier layer. 
     
     
         3 . The formation of the borehole casing according to  claim 1 , wherein the layers of casing are deposited simultaneously along the whole circumference of the borehole, while the deposited surface may vary from roundness and have surface irregularities. 
     
     
         4 . The formation of the borehole casing according to  claim 1 , wherein the acceleration and heating of the particles to be deposited onto the borehole wall and/or the mould, or onto the previous casing layer is achieved by mixing them with a carrier gas having necessary thermal and kinetic energy, and the accelerated and heated mixture of material particles and the carrier gas is deposited onto the borehole wall and/or on the mould, or onto the previous casing layer from a place situated in close proximity of the borehole wall. 
     
     
         5 . The formation of the borehole casing according to  claim 1 , wherein several layers of the casing are deposited simultaneously in several stages onto the borehole wall and/or onto the previously deposited layers of casing in such manner that a next layer is deposited onto the previous layer with such shift, which allows to deposit and superimpose the deposited layers onto each another. 
     
     
         6 . The formation of the borehole casing according to  claim 1 , wherein additives strengthening and reinforcing the wall of the formed casing and/or foaming additives, such as agents initiating a formation of porous structure of the casing wall, including but not limited to titanium hydride, are added into the deposited material. 
     
     
         7 . The formation of the borehole casing according to  claim 1 , wherein the surface of the borehole wall or of the previous layer of the casing is treated prior to the application of the layers in such manner that the mixture of the carrier gas mixed with the particles of material is not capable of applying (deposition) of the material, as the particles of the material do not contain a binder or the kinetic energy is lower than critical speed of plastic deformation of particles and of application of the material particles, and in such case the treated surface is mechanically cleaned, roughened and otherwise treated, and surface treatment preferable for application of further layer is achieved. 
     
     
         8 . The formation of the borehole casing according to  claim 1 , wherein the deposited layers of the casing or the borehole wall are preheated in order to increase adhesion of a subsequent layer, efficiency of application process onto the wall surface or previous layer before further applying, wherein layers being deposited are further heated—thermally treated—in order to improve their mechanical properties and/or in order to activate foaming additives. 
     
     
         9 . The formation of the borehole casing according to  claim 1 , wherein at least one deposited layer or part of the layer slidably separates adjacent layers of the casing or the deposited layers of the casing from the mould due to different properties of the materials being deposited and reduce the shear stress in such layer, which thereby forms a sliding interface preferably forming a sliding insert for movement of a forming mandrel for piping distribution system formed in the walls of the casing. 
     
     
         10 . The formation of the borehole casing according to  claim 1  wherein at least one layer of the casing is formed from a metallic matrix filled with a material that can be obtained by separation of material disintegrated in the drilling process and/or the formed layers are thermally treated by heat flows in at least one heat treatment mode in which the formed layers are exposed to gradual thermal effect in order to achieve preferable metallurgical changes depending on the type of the material. 
     
     
         11 . The formation of the borehole casing according to  claim 1 , wherein a carrier gas stream flows from nozzles along circle circumference at such speed, at which accelerated material particles achieve the level of kinetic energy necessary to plastic deformation, and thus to their application. 
     
     
         12 . The formation of the borehole casing according to  claim 1 , wherein at the site of application, a liquid of a working medium is locally displaced by a stream of carrier gas with particles or by a stream of protective gas. 
     
     
         13 . The formation of the borehole casing according to  claim 1 , wherein in a liquid medium is a stream of carrier gas with particles surrounded by a protective stream, which forms a protective shell between a liquid of a working medium and the carrier gas with particles and maintains integrity of the stream of the carrier gas with particles, and separates it from the liquid medium. 
     
     
         14 . The formation of the borehole casing according to  claim 1 , wherein a protective stream removes a liquid of a working medium from the surface being deposited, which is dehumidified and preheated prior to the application of the material. 
     
     
         15 . The formation of the borehole casing according to  claim 1 , wherein a stream of carrier gas is being compressed by a protective stream, which separates the stream of carrier gas with material particles from walls of an outlet nozzle and protects the outlet from direct contact with the material particles passing through the outlet, thereby forming a hydrodynamic nozzle. 
     
     
         16 . The formation of the borehole casing according to  claim 1 , wherein carrier gases are preferably accelerated during flowing by an electric arc and thermal plasma, wherein increase in pressure by heating and expansion of the carrier gases occur at a contact of the carrier gases with the electric arc. 
     
     
         17 . A device for formation of the borehole casing by application of material layers to the borehole walls by process of additive application of powders according to  claim 1 , wherein the device includes at least one stage containing a carrier gas generation and acceleration chamber ( 3 ) and a material designated to be deposited and carrier gas mixing chamber ( 4 ) and further contains separation, control and regulatory mechanisms; and wherein the carrier gas generation and acceleration chamber ( 3 ) is connected to a media inlet ( 2 ) for forming carrier and protective gas and the material and carrier gas mixing chamber ( 4 ) is connected to an inlet ( 1 ) for powders and additives being deposited and the particles of powder material ( 8 ) designated for application onto borehole walls ( 9 ) are supplied and dosed via this inlet ( 1 ) into the carrier gas, wherein the material and carrier gas mixing chamber ( 4 ) is preferably connected to an outlet of the accelerated carrier gases in the carrier gas generation and acceleration chamber ( 3 ) and whereby in such arrangement the material and carrier gas mixing chamber ( 4 ) contains an outflow nozzle ( 5 ) for exhaust of the mixture of the carrier gas and the material ( 8 ) being deposited out of the material and carrier gas mixing chamber ( 4 ) and this outlet nozzle ( 5 ) can be placed in a close proximity of the borehole wall ( 9 ) for forming material layers ( 10 ) onto the borehole casing ( 12 ). 
     
     
         18 . The device for formation of the borehole casing according to  claim 17 , wherein the carrier gas generation and acceleration chamber ( 3 ) and the material and carrier gas mixing chamber ( 4 ) form a single chamber ( 3 , 4 ) and the individual parts of the chamber ( 3 , 4 ) succeed one another, wherein preferably the carrier gas generation and acceleration chamber ( 3 ) contains a module for increasing pressure based on the principle of heating and expansion of gas by thermal plasma of the electric arc. 
     
     
         19 . The device for formation of the borehole casing according to  claim 17 , wherein the device includes several stages arranged in series with a space gap so as to be able to work in parallel. 
     
     
         20 . The device for formation of the borehole casing according to  claim 17 , wherein the outflow nozzle ( 5 ) has an annular shape with outlets in radial direction along its circumference. 
     
     
         21 . The device for formation of the borehole casing according to  claim 17 , wherein the outlet nozzle ( 5 ) has the shape of a slot and preferably it is surrounded in circumferential parts by hydrodynamic jets ( 11 ), the function of which is to protect the outlet nozzle ( 5 ). 
     
     
         22 . The device for formation of the borehole casing according to  claim 17 , further comprising regulatory mechanisms which include in particular temperature control and regulation mechanisms, carrier gas acceleration control and regulation mechanisms, and control and regulation mechanisms for dosing the powder into the carrier gas.