Downhole Tool Mandrel

Name: Rod Mandrel Bar for Harsh Well Conditions - Frigate
Price: 249.00 USD
Availability: InStock

A Downhole Tool Mandrel must maintain mechanical stability under HPHT conditions without compromising its structural form. These mandrels are produced using high-yield strength alloy steels with controlled chemical composition and grain refinement for enhanced thermal and pressure endurance. Each Downhole Tool Mandrel undergoes calibrated heat treatment cycles—such as quench and tempering—to achieve the required hardness-to-toughness ratio and eliminate susceptibility to creep or low-cycle thermal fatigue.

Material Grade & Specification

AISI 4145H (or equivalent), API Spec 7-1, ASTM A182 F22 (for higher strength)

Dimensional Tolerances

±0.005 inches (±0.13 mm) for critical dimensions, ±0.002 inches (±0.05 mm) for threads

Surface Finish Requirement

Ra ≤ 1.6 µm (63 µin) for sealing surfaces, Ra ≤ 3.2 µm (125 µin) for non-critical areas

Heat Treatment Specification

Quenching and Tempering (QT) to 28-32 HRC (Hardness) for increased strength and durability

Concentricity Requirement

≤ 0.002 inches (0.05 mm) for critical concentricity of bore to OD for high performance

Product Description

Dimensional accuracy is critical when the Downhole Tool Mandrel interfaces with completion tools, setting mechanisms, or internal sleeves. Machining is performed with CNC systems calibrated for repeatable tolerance bands within ±0.0015″, ensuring axial alignment and stable engagement under pressure. Downhole Tool Mandrel thread geometries follow API, VAM, or customer-specific profiles with optimized flank contact to handle combined axial and torsional loads without galling.

Thread Type & Specification

API Spec 7-1, 2 3/8″ Reg API, 2 7/8″ IF (or per customer request), NPT (if applicable)

Hardness Requirement

28-32 HRC (after heat treatment)

Non-Destructive Testing (NDT) Requirement

Ultrasonic Testing (UT), Magnetic Particle Testing (MT), Dye Penetrant Testing (DPT) as per API standards

Tensile Strength Requirement

Minimum 120,000 psi (827 MPa) or per customer specifications for downhole performance

Certification Standard

API Spec 7-1, ISO 9001:2015, PED (Pressure Equipment Directive), ATEX (if required)

Technical Advantages

Repeated load cycling from setting tools, pressure pulsation, and fluid hammering can cause micro-crack propagation in any improperly designed Downhole Tool Mandrel. To mitigate this, mandrel profiles are optimized using finite element stress mapping, with stress-relief features such as blended shoulders and undercuts introduced in high-tension zones. Select Downhole Tool Mandrels undergo shot peening to induce surface-level compressive stress, thereby increasing fatigue strength.

Downhole Tool Mandrels must reliably maintain seal integrity under fluctuating wellbore pressures and thermal cycles. Concentricity, circularity, and surface profile are tightly controlled across seal zones to support long-term engagement with packers, sleeves, or internal sealing elements. Each sealing region of the Downhole Tool Mandrel is processed to an 8–16 µin Ra surface finish, and material hardness is matched to prevent seal extrusion or wear during pressure surges.

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Industry Applications

Packer Setting Assemblies

Used as structural support for mechanical or hydraulic packers, transmitting setting forces and maintaining axial alignment under high pressure.

Frac Sleeve Activation Tools

Forms the core body for tools that initiate or control frac sleeve opening using shifting profiles or hydraulic actuation chambers.

Wireline Tool Carriers

Serves as the base structure for wireline-deployed sensors, incorporating channels for electrical pass-through and shock-isolated electronics housing.

Shifting Tools for Sliding Sleeves

Provides mechanical engagement points and load transmission for tools shifting sliding sleeves in multizone completion or zonal isolation systems.

Bridge Plug and Cement Retainer Assemblies

Acts as the central mandrel for bridge plugs, enabling anchoring, sealing, and pressure containment during temporary or permanent wellbore isolation.

Downhole Safety Valve Components

Supports axial movement and sealing within subsurface safety valves, maintaining concentricity and integrity under high-pressure actuation cycles.

Corrosion Resistance in Sour and Multiphase Fluids

The Downhole Tool Mandrel is exposed to corrosive agents like H₂S, CO₂, and brine, requiring NACE-compliant alloys with verified sulfide stress cracking resistance. To prevent galvanic corrosion in mixed-material assemblies, mandrels are passivated or coated with Xylan, ceramic, or electroless nickel. For wireline or MWD use, CRA or low-magnetic materials are selected based on formation chemistry and magnetic sensitivity.

The Downhole Tool Mandrel is designed to transfer axial and torsional loads without inducing stress risers or deformation. Geometries are optimized to ensure linear stress flow and are validated for burst and collapse per ISO 10423 and API 5C3. For rotating tools, mandrels are dynamically balanced and held to strict straightness tolerances to prevent eccentric wear.

Having Doubts? Our FAQ

Check all our Frequently Asked Question

How does Frigate ensure thread integrity in Downhole Tool Mandrels used in high-torque operations?

Frigate uses CNC machining with controlled flank engagement and root radius to reduce stress concentration at the thread roots. All threads are validated using optical measurement systems to confirm pitch consistency and lead accuracy. Galling resistance is improved through surface treatments like phosphate coating or copper plating. For torque-critical applications, thread form geometry is customized to balance axial load transfer and seal integrity.

What process does Frigate follow to prevent seal failure in Downhole Tool Mandrels during HPHT operations?

Frigate machines seal surfaces to 8–16 µin Ra finish, minimizing leakage across elastomeric or metal-to-metal seals. Concentricity and axial runout are measured using calibrated metrology tools to ensure seal line alignment. Material hardness is matched to seal material to prevent extrusion and abrasion. In corrosive zones, seal areas can be overlaid with hard coatings to resist wear and chemical degradation.

How does Frigate validate material selection for sour service Downhole Tool Mandrels?

All mandrel materials are sourced to meet NACE MR0175 / ISO 15156 standards for hydrogen sulfide environments. Each heat lot undergoes hardness testing, sulfide stress cracking (SSC) resistance evaluation, and grain flow inspection. Metallurgical certification includes chemical analysis, mechanical property data, and microstructure imaging. Frigate also performs in-house corrosion simulation testing for specific downhole fluid conditions.

How does Frigate ensure fatigue life in mandrels exposed to pressure pulsing or dynamic shifting?

Mandrel designs are FEA-modeled to locate high-stress regions, which are then optimized with smooth transitions and balanced cross-sections. Critical zones are shot-peened to induce compressive surface stress and delay crack initiation. Fatigue-sensitive areas undergo polishing to remove machining marks that can act as crack starters. Frigate validates fatigue performance using load cycle simulation and comparative S-N curve analysis.

How does Frigate manage dimensional control for long-form Downhole Tool Mandrels?

Mandrels exceeding 1.5 meters are machined with live tooling and tailstock support to maintain straightness and dimensional consistency. Final inspection includes full-length CMM scanning for runout, taper, and bore concentricity. Thermal expansion coefficients are considered during machining to account for temperature variation in downhole conditions. Frigate applies ISO 2768-mK tolerances or tighter, based on functional requirements.

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