Sintering a Multi-lobed Helical Rotor

Abstract

The present disclosure relates to a method and system for manufacturing a multi-lobed helical rotor. The method for manufacturing a multi-lobed helical rotor may comprise mixing one or more powdered metals, compacting a mixture of one or more powdered metals to form a solid metal piece, sintering the solid metal piece, and polishing the solid metal piece. The system may comprise a positive displacement pump, which may comprise a casing, a multi-lobed helical rotor disposed in the casing, wherein the multi-lobed helical rotor comprise sintered powdered metals, an inlet to the casing, and an outlet leading from the casing.

What is claimed is: 
     
         1 . A method for manufacturing a multi-lobed helical rotor comprising:
 mixing one or more powdered metals;   compacting a mixture of the one or more powdered metals to form a solid metal piece;   sintering the solid metal piece; and   polishing the solid metal piece.   
     
     
         2 . The method of  claim 1 , further comprising choosing the one or more powdered metals as the base material for the multi-lobed helical rotor. 
     
     
         3 . The method of  claim 1 , further comprising choosing the one or more powdered metals and at least one additive as the base material for the multi-lobed helical rotor. 
     
     
         4 . The method of  claim 1 , wherein the step of mixing comprises combining the one or more powdered metals with at least one additive. 
     
     
         5 . The method of  claim 1 , wherein the step of compacting comprises adding the at least one powdered metal and at least one additive to a die. 
     
     
         6 . The method of  claim 5 , wherein the step of compacting comprises compacting the at least one powdered metal and at least one additive with a hydraulic ram. 
     
     
         7 . The method of  claim 6 , wherein the step of compacting the at least one powdered metal and the at least one additive with a hydraulic ram forms the multi-lobed helical rotor. 
     
     
         8 . The method of  claim 7 , wherein the step of sintering comprises placing the multi-lobed helical rotor in a furnace.
 The method of  claim 8 , wherein the furnace is a multi-belt furnace.   
     
     
         10 . The method of claim  9 , wherein the step of polishing is performed by an abrasive flow machine. 
     
     
         11 . The method of  claim 1 , wherein the step of compacting and the step of sintering are combined into a single step in which the compacting is performed at elevated temperatures. 
     
     
         12 . A system comprising:
 a positive displacement pump comprising:
 a casing; 
 a multi-lobed helical rotor disposed in the casing, wherein the multi-lobed helical rotor comprises sintered powdered metals; 
 an inlet to the casing; and 
 an outlet leading from the casing. 
   
     
     
         13 . The system of  claim 12 , wherein the sintered powdered metals were formed from powdered metals having a particle size of from about 0.5 microns to about 100 microns. 
     
     
         14 . The system of  claim 12 , wherein the multi-lobed helical rotor comprises 17-4 stainless steel. 
     
     
         15 . The system of  claim 12 , wherein the multi-lobed helical rotor further comprises at least one additive selected from the group consisting of plastic, carbon, copper, wax, and combinations thereof. 
     
     
         16 . The system of  claim 12 , wherein the system further comprises a second multi-lobed helical rotor disposed in the casing, wherein the second multi-lobed helical rotor comprises sintered powdered metal. 
     
     
         17 . The system of  claim 12 , wherein the system further comprises feed conduit coupled to the positive displacement pump, and a drill string coupled to the feed conduit, wherein the drill string is at least partially disposed in a wellbore. 
     
     
         18 . The system of  claim 17 , further comprising a derrick comprising a traveling block for raising and lowering the drill string. 
     
     
         19 . The system of  claim 17 , wherein the positive displacement pump is connected to a solids control system. 
     
     
         20 . The system of  claim 17 , wherein the solids control system is connected to a retention pit. Sintering a multi-lobed helical rotor