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US20060283603A1 - Expandable tubular - Google Patents

Expandable tubular Download PDF

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Publication number
US20060283603A1
US20060283603A1 US10/570,417 US57041706A US2006283603A1 US 20060283603 A1 US20060283603 A1 US 20060283603A1 US 57041706 A US57041706 A US 57041706A US 2006283603 A1 US2006283603 A1 US 2006283603A1
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US
United States
Prior art keywords
tubular
assembly
tubular member
predetermined portion
plastic deformation
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US10/570,417
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English (en)
Inventor
Mark Shuster
Kevin Waddell
Edwin Zwald
Vladimir Didyk
Malcolm Gray
Scott Costa
Grigory Greenberg
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Enventure Global Technology Inc
Original Assignee
Enventure Global Technology Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Enventure Global Technology Inc filed Critical Enventure Global Technology Inc
Priority to US10/570,417 priority Critical patent/US20060283603A1/en
Publication of US20060283603A1 publication Critical patent/US20060283603A1/en
Assigned to ENVENTURE GLOBAL TECHNOLOGY, L.L.C. reassignment ENVENTURE GLOBAL TECHNOLOGY, L.L.C. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: SHUSTER, MARK, ZWALD, EDWIN ARNOLD, JR., GRAY, MALCOLM, DIDYK, VLADIMIR, COSTA, SCOTT, WADDELL, KEVIN K., GRINBERG, GRIGORIY
Abandoned legal-status Critical Current

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B17/00—Drilling rods or pipes; Flexible drill strings; Kellies; Drill collars; Sucker rods; Cables; Casings; Tubings
    • E21B17/02—Couplings; joints
    • E21B17/04—Couplings; joints between rod or the like and bit or between rod and rod or the like
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B17/00—Drilling rods or pipes; Flexible drill strings; Kellies; Drill collars; Sucker rods; Cables; Casings; Tubings
    • E21B17/02—Couplings; joints
    • E21B17/04—Couplings; joints between rod or the like and bit or between rod and rod or the like
    • E21B17/042—Threaded
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B17/00—Drilling rods or pipes; Flexible drill strings; Kellies; Drill collars; Sucker rods; Cables; Casings; Tubings
    • E21B17/02—Couplings; joints
    • E21B17/08—Casing joints
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B29/00—Cutting or destroying pipes, packers, plugs or wire lines, located in boreholes or wells, e.g. cutting of damaged pipes, of windows; Deforming of pipes in boreholes or wells; Reconditioning of well casings while in the ground
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
    • E21B43/02—Subsoil filtering
    • E21B43/10—Setting of casings, screens, liners or the like in wells
    • E21B43/103—Setting of casings, screens, liners or the like in wells of expandable casings, screens, liners, or the like
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
    • E21B43/02—Subsoil filtering
    • E21B43/10—Setting of casings, screens, liners or the like in wells
    • E21B43/103—Setting of casings, screens, liners or the like in wells of expandable casings, screens, liners, or the like
    • E21B43/105—Expanding tools specially adapted therefor
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
    • E21B43/02—Subsoil filtering
    • E21B43/10—Setting of casings, screens, liners or the like in wells
    • E21B43/103—Setting of casings, screens, liners or the like in wells of expandable casings, screens, liners, or the like
    • E21B43/106—Couplings or joints therefor

Definitions

  • This invention relates generally to oil and gas exploration, and in particular to forming and repairing wellbore casings to facilitate oil and gas exploration.
  • a method of forming a tubular liner within a preexisting structure includes positioning a tubular assembly within the preexisting structure; and radially expanding and plastically deforming the tubular assembly within the preexisting structure, wherein, prior to the radial expansion and plastic deformation of the tubular assembly, a predetermined portion of the tubular assembly has a lower yield point than another portion of the tubular assembly.
  • an expandable tubular member that includes a steel alloy including: 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and 0.02% Cr.
  • an expandable tubular member that includes a steel alloy including: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr.
  • an expandable tubular member that includes a steel alloy including: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16% Cu, 0.05% Ni, and 0.05% Cr.
  • an expandable tubular member that includes a steel alloy including: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S, 0.45% Si, 9.1% Ni, and 18.7% Cr.
  • an expandable tubular member wherein the yield point of the expandable tubular member is at most about 46.9 ksi prior to a radial expansion and plastic deformation; and wherein the yield point of the expandable tubular member is at least about 65.9 ksi after the radial expansion and plastic deformation.
  • an expandable tubular member wherein a yield point of the expandable tubular member after a radial expansion and plastic deformation is at least about 40% greater than the yield point of the expandable tubular member prior to the radial expansion and plastic deformation.
  • an expandable tubular member wherein the anisotropy of the expandable tubular member, prior to the radial expansion and plastic deformation, is at least about 1.48.
  • an expandable tubular member wherein the yield point of the expandable tubular member is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the expandable tubular member is at least about 74.4 ksi after the radial expansion and plastic deformation.
  • an expandable tubular member wherein the yield point of the expandable tubular member after a radial expansion and plastic deformation is at least about 28% greater than the yield point of the expandable tubular member prior to the radial expansion and plastic deformation.
  • an expandable tubular member wherein the anisotropy of the expandable tubular member, prior to the radial expansion and plastic deformation, is at least about 1.04.
  • an expandable tubular member wherein the anisotropy of the expandable tubular member, prior to the radial expansion and plastic deformation, is at least about 1.92.
  • an expandable tubular member wherein the anisotropy of the expandable tubular member, prior to the radial expansion and plastic deformation, is at least about 1.34.
  • an expandable tubular member wherein the anisotropy of the expandable tubular member, prior to the radial expansion and plastic deformation, ranges from about 1.04 to about 1.92.
  • an expandable tubular member wherein the yield point of the expandable tubular member, prior to the radial expansion and plastic deformation, ranges from about 47.6 ksi to about 61.7 ksi.
  • an expandable tubular member wherein the expandability coefficient of the expandable tubular member, prior to the radial expansion and plastic deformation, is greater than 0.12.
  • an expandable tubular member is provided, wherein the expandability coefficient of the expandable tubular member is greater than the expandability coefficient of another portion of the expandable tubular member.
  • an expandable tubular member wherein the tubular member has a higher ductility and a lower yield point prior to a radial expansion and plastic deformation than after the radial expansion and plastic deformation.
  • a method of radially expanding and plastically deforming a tubular assembly including a first tubular member coupled to a second tubular member includes radially expanding and plastically deforming the tubular assembly within a preexisting structure; and using less power to radially expand each unit length of the first tubular member than to radially expand each unit length of the second tubular member.
  • a system for radially expanding and plastically deforming a tubular assembly including a first tubular member coupled to a second tubular member includes means for radially expanding the tubular assembly within a preexisting structure; and means for using less power to radially expand each unit length of the first tubular member than required to radially expand each unit length of the second tubular member.
  • a method of manufacturing a tubular member includes processing a tubular member until the tubular member is characterized by one or more intermediate characteristics; positioning the tubular member within a preexisting structure; and processing the tubular member within the preexisting structure until the tubular member is characterized one or more final characteristics.
  • an apparatus that includes an expandable tubular assembly; and an expansion device coupled to the expandable tubular assembly; wherein a predetermined portion of the expandable tubular assembly has a lower yield point than another portion of the expandable tubular assembly.
  • an expandable tubular member wherein a yield point of the expandable tubular member after a radial expansion and plastic deformation is at least about 5.8% greater than the yield point of the expandable tubular member prior to the radial expansion and plastic deformation.
  • a method of determining the expandability of a selected tubular member includes determining an anisotropy value for the selected tubular member, determining a strain hardening value for the selected tubular member; and multiplying the anisotropy value times the strain hardening value to generate an expandability value for the selected tubular member.
  • a method of radially expanding and plastically deforming tubular members includes selecting a tubular member; determining an anisotropy value for the selected tubular member; determining a strain hardening value for the selected tubular member; multiplying the anisotropy value times the strain hardening value to generate an expandability value for the selected tubular member; and if the anisotropy value is greater than 0.12, then radially expanding and plastically deforming the selected tubular member.
  • a radially expandable tubular member apparatus includes a first tubular member; a second tubular member engaged with the first tubular member forming a joint; and a sleeve overlapping and coupling the first and second tubular members at the joint; wherein, prior to a radial expansion and plastic deformation of the apparatus, a predetermined portion of the apparatus has a lower yield point than another portion of the apparatus.
  • a radially expandable tubular member apparatus includes: a first tubular member; a second tubular member engaged with the first tubular member forming a joint; a sleeve overlapping and coupling the first and second tubular members at the joint; the sleeve having opposite tapered ends and a flange engaged in a recess formed in an adjacent tubular member; and one of the tapered ends being a surface formed on the flange; wherein, prior to a radial expansion and plastic deformation of the apparatus, a predetermined portion of the apparatus has a lower yield point than another portion of the apparatus.
  • a method of joining radially expandable tubular members includes: providing a first tubular member; engaging a second tubular member with the first tubular member to form a joint; providing a sleeve; mounting the sleeve for overlapping and coupling the first and second tubular members at the joint; wherein the first tubular member, the second tubular member, and the sleeve define a tubular assembly; and radially expanding and plastically deforming the tubular assembly; wherein, prior to the radial expansion and plastic deformation, a predetermined portion of the tubular assembly has a lower yield point than another portion of the tubular assembly.
  • a method of joining radially expandable tubular members includes providing a first tubular member; engaging a second tubular member with the first tubular member to form a joint; providing a sleeve having opposite tapered ends and a flange, one of the tapered ends being a surface formed on the flange; mounting the sleeve for overlapping and coupling the first and second tubular members at the joint, wherein the flange is engaged in a recess formed in an adjacent one of the tubular members; wherein the first tubular member, the second tubular member, and the sleeve define a tubular assembly; and radially expanding and plastically deforming the tubular assembly; wherein, prior to the radial expansion and plastic deformation, a predetermined portion of the tubular assembly has a lower yield point than another portion of the tubular assembly.
  • an expandable tubular assembly includes a first tubular member; a second tubular member coupled to the first tubular member; a first threaded connection for coupling a portion of the first and second tubular members; a second threaded connection spaced apart from the first threaded connection for coupling another portion of the first and second tubular members; a tubular sleeve coupled to and receiving end portions of the first and second tubular members; and a sealing element positioned between the first and second spaced apart threaded connections for sealing an interface between the first and second tubular member; wherein the sealing element is positioned within an annulus defined between the first and second tubular members; and wherein, prior to a radial expansion and plastic deformation of the assembly, a predetermined portion of the assembly has a lower yield point than another portion of the apparatus.
  • a method of joining radially expandable tubular members includes: providing a first tubular member; providing a second tubular member; providing a sleeve; mounting the sleeve for overlapping and coupling the first and second tubular members; threadably coupling the first and second tubular members at a first location; threadably coupling the first and second tubular members at a second location spaced apart from the first location; sealing an interface between the first and second tubular members between the first and second locations using a compressible sealing element, wherein the first tubular member, second tubular member, sleeve, and the sealing element define a tubular assembly; and radially expanding and plastically deforming the tubular assembly; wherein, prior to the radial expansion and plastic deformation, a predetermined portion of the tubular assembly has a lower yield point than another portion of the tubular assembly.
  • an expandable tubular member wherein the carbon content of the tubular member is less than or equal to 0.12 percent; and wherein the carbon equivalent value for the tubular member is less than 0.21.
  • an expandable tubular member wherein the carbon content of the tubular member is greater than 0.12 percent; and wherein the carbon equivalent value for the tubular member is less than 0.36.
  • a method of selecting tubular members for radial expansion and plastic deformation includes selecting a tubular member from a collection of tubular member; determining a carbon content of the selected tubular member, determining a carbon equivalent value for the selected tubular member; and if the carbon content of the selected tubular member is less than or equal to 0.12 percent and the carbon equivalent value for the selected tubular member is less than 0.21, then determining that the selected tubular member is suitable for radial expansion and plastic deformation.
  • a method of selecting tubular members for radial expansion and plastic deformation includes selecting a tubular member from a collection of tubular member; determining a carbon content of the selected tubular member; determining a carbon equivalent value for the selected tubular member; and if the carbon content of the selected tubular member is greater than 0.12 percent and the carbon equivalent value for the selected tubular member is less than 0.36, then determining that the selected tubular member is suitable for radial expansion and plastic deformation.
  • an expandable tubular member that includes a tubular body; wherein a yield point of an inner tubular portion of the tubular body is less than a yield point of an outer tubular portion of the tubular body.
  • a method of manufacturing an expandable tubular member includes: providing a tubular member; heat treating the tubular member; and quenching the tubular member; wherein following the quenching, the tubular member comprises a microstructure comprising a hard phase structure and a soft phase structure.
  • an expandable tubular member includes a steel alloy comprising: 0.07% Carbon, 1.64% Manganese, 0.011% Phosphor, 0.001% Sulfur, 0.23% Silicon, 0.5% Nickel, 0.51% Chrome, 0.31% Molybdenum, 0.15% Copper, 0.021% Aluminum, 0.04% Vanadium, 0.03% Niobium, and 0.007% Titanium.
  • an expandable tubular member includes a collapse strength of approximately 70 ksi comprising: 0.07% Carbon, 1.64% Manganese, 0.011% Phosphor, 0.001% Sulfur, 0.23% Silicon, 0.5% Nickel, 0.51% Chrome, 0.31% Molybdenum, 0.15% Copper, 0.021% Aluminum, 0.04% Vanadium, 0.03% Niobium, and 0.007% Titanium, wherein, upon radial expansion and plastic deformation, the collapse strength increases to approximately 110 ksi.
  • an expandable tubular member that includes an outer surface and means for increasing the collapse strength of a tubular assembly when the expandable tubular member is radially expanded and plastically deformed against a preexisting structure, the means coupled to the outer surface.
  • a preexisting structure for accepting an expandable tubular member includes a passage defined by the structure, an inner surface on the passage and means for increasing the collapse strength of a tubular assembly when an expandable tubular member is radially expanded and plastically deformed against the preexisting structure, the means coupled to the inner surface.
  • an expandable tubular assembly includes a structure defining a passage therein, an expandable tubular member positioned in the passage and means for increasing the collapse strength of the assembly when the expandable tubular member is radially expanded and plastically deformed against the structure, the means positioned between the expandable tubular member and the structure.
  • a tubular assembly includes a structure defining a passage therein, an expandable tubular member positioned in the passage and an interstitial layer positioned between the structure and expandable tubular member, wherein the collapse strength of the assembly with the interstitial layer is at least 20% greater than the collapse strength without the interstitial layer.
  • a tubular assembly includes a structure defining a passage therein, an expandable tubular member positioned in the passage and an interstitial layer positioned between the structure and expandable tubular member, wherein the collapse strength of the assembly with the interstitial layer is at least 30% greater than the collapse strength without the interstitial layer.
  • a tubular assembly includes a structure defining a passage therein, an expandable tubular member positioned in the passage and an interstitial layer positioned between the structure and expandable tubular member, wherein the collapse strength of the assembly with the interstitial layer is at least 40% greater than the collapse strength without the interstitial layer.
  • a tubular assembly includes a structure defining a passage therein, an expandable tubular member positioned in the passage and an interstitial layer positioned between the structure and expandable tubular member, wherein the collapse strength of the assembly with the interstitial layer is at least 50% greater than the collapse strength without the interstitial layer.
  • an expandable tubular assembly includes an outer tubular member comprising a steel alloy and defining a passage, an inner tubular member comprising a steel alloy and positioned in the passage and an interstitial layer between the inner tubular member and the outer tubular member, the interstitial layer comprising an aluminum material lining an inner surface of the outer tubular member, whereby the collapse strength of the assembly with the interstitial layer is greater than the collapse strength of the assembly without the interstitial layer.
  • a method for increasing the collapse strength of a tubular assembly includes providing a preexisting structure defining a passage therein, providing an expandable tubular member, coating the expandable tubular member with an interstitial material, positioning the expandable tubular member in the passage defined by the preexisting structure and expanding the expandable tubular member such that the interstitial material engages the preexisting structure, whereby the collapse strength of the preexisting structure and expandable tubular member with the interstitial material is greater than the collapse strength of the preexisting structure and expandable tubular member without the interstitial material.
  • a method for increasing the collapse strength of a tubular assembly includes providing a preexisting structure defining a passage therein, providing an expandable tubular member, coating the preexisting structure with an interstitial material, positioning the expandable tubular member in the passage defined by the preexisting structure and expanding the expandable tubular member such that the interstitial material engages the expandable tubular member, whereby the collapse strength of the preexisting structure and expandable tubular member with the interstitial material is greater than the collapse strength of the preexisting structure and expandable tubular member without the interstitial material.
  • an expandable tubular member that includes an outer surface and an interstitial layer on the outer surface, wherein the interstitial layer comprises an aluminum material resulting in a required expansion operating pressure of approximately 3900 psi for the tubular member.
  • an expandable tubular assembly includes an outer surface and an interstitial layer on the outer surface, wherein the interstitial layer comprises an aluminum/zinc material resulting in a required expansion operating pressure of approximately 3700 psi for the tubular member.
  • an expandable tubular assembly includes an outer surface and an interstitial layer on the outer surface, wherein the interstitial layer comprises an plastic material resulting in a required expansion operating pressure of approximately 3600 psi for the tubular member.
  • an expandable tubular assembly includes a structure defining a passage therein, an expandable tubular member positioned in the passage and an interstitial layer positioned between the expandable tubular member and the structure, wherein the interstitial layer has a thickness of approximately 0.05 inches to 0.15 inches.
  • an expandable tubular assembly includes a structure defining a passage therein, an expandable tubular member positioned in the passage and an interstitial layer positioned between the expandable tubular member and the structure, wherein the interstitial layer has a thickness of approximately 0.07 inches to 0.13 inches.
  • an expandable tubular assembly includes a structure defining a passage therein, an expandable tubular member positioned in the passage and an interstitial layer positioned between the expandable tubular member and the structure, wherein the interstitial layer has a thickness of approximately 0.06 inches to 0.14 inches.
  • an expandable tubular assembly includes a structure defining a passage therein, an expandable tubular member positioned in the passage and an interstitial layer positioned between the expandable tubular member and the structure, wherein the interstitial layer has a thickness of approximately 1.6 mm to 2.5 mm between the structure and the expandable tubular member.
  • an expandable tubular assembly includes a structure defining a passage therein, an expandable tubular member positioned in the passage and an interstitial layer positioned between the expandable tubular member and the structure, wherein the interstitial layer has a thickness of approximately 2.6 mm to 3.1 mm between the structure and the expandable tubular member.
  • an expandable tubular assembly includes a structure defining a passage therein, an expandable tubular member positioned in the passage and an interstitial layer positioned between the expandable tubular member and the structure, wherein the interstitial layer has a thickness of approximately 1.9 mm to 2.5 mm between the structure and the expandable tubular member.
  • an expandable tubular assembly includes a structure defining a passage therein, an expandable tubular member positioned in the passage, an interstitial layer positioned between the expandable tubular member and the structure and a collapse strength greater than approximately 20000 psi.
  • an expandable tubular assembly includes a structure defining a passage therein, an expandable tubular member positioned in the passage, an interstitial layer positioned between the expandable tubular member and the structure and a collapse strength greater than approximately 14000 psi.
  • a method for determining the collapse resistance of a tubular assembly includes measuring the collapse resistance of a first tubular member, measuring the collapse resistance of a second tubular member, determining the value of a reinforcement factor for a reinforcement of the first and second tubular members and multiplying the reinforcement factor by the sum of the collapse resistance of the first tubular member and the collapse resistance of the second tubular member.
  • an expandable tubular assembly includes a structure defining a passage therein, an expandable tubular member positioned in the passage and means for modifying the residual stresses in at least one of the structure and the expandable tubular member when the expandable tubular member is radially expanded and plastically deformed against the structure, the means positioned between the expandable tubular member and the structure.
  • FIG. 1 is a fragmentary cross sectional view of an exemplary embodiment of an expandable tubular member positioned within a preexisting structure.
  • FIG. 2 is a fragmentary cross sectional view of the expandable tubular member of FIG. 1 after positioning an expansion device within the expandable tubular member.
  • FIG. 3 is a fragmentary cross sectional view of the expandable tubular member of FIG. 2 after operating the expansion device within the expandable tubular member to radially expand and plastically deform a portion of the expandable tubular member.
  • FIG. 4 is a fragmentary cross sectional view of the expandable tubular member of FIG. 3 after operating the expansion device within the expandable tubular member to radially expand and plastically deform another portion of the expandable tubular member.
  • FIG. 5 is a graphical illustration of exemplary embodiments of the stress/strain curves for several portions of the expandable tubular member of FIGS. 1-4 .
  • FIG. 6 is a graphical illustration of the an exemplary embodiment of the yield strength vs. ductility curve for at least a portion of the expandable tubular member of FIGS. 1-4 .
  • FIG. 7 is a fragmentary cross sectional illustration of an embodiment of a series of overlapping expandable tubular members.
  • FIG. 8 is a fragmentary cross sectional view of an exemplary embodiment of an expandable tubular member positioned within a preexisting structure.
  • FIG. 9 is a fragmentary cross sectional view of the expandable tubular member of FIG. 8 after positioning an expansion device within the expandable tubular member.
  • FIG. 10 is a fragmentary cross sectional view of the expandable tubular member of
  • FIG. 9 after operating the expansion device within the expandable tubular member to radially expand and plastically deform a portion of the expandable tubular member.
  • FIG. 11 is a fragmentary cross sectional view of the expandable tubular member of FIG. 10 after operating the expansion device within the expandable tubular member to radially expand and plastically deform another portion of the expandable tubular member.
  • FIG. 12 is a graphical illustration of exemplary embodiments of the stress/strain curves for several portions of the expandable tubular member of FIGS. 8-11 .
  • FIG. 13 is a graphical illustration of an exemplary embodiment of the yield strength vs. ductility curve for at least a portion of the expandable tubular member of FIGS. 8-11 .
  • FIG. 14 is a fragmentary cross sectional view of an exemplary embodiment of an expandable tubular member positioned within a preexisting structure.
  • FIG. 15 is a fragmentary cross sectional view of the expandable tubular member of FIG. 14 after positioning an expansion device within the expandable tubular member.
  • FIG. 16 is a fragmentary cross sectional view of the expandable tubular member of FIG. 15 after operating the expansion device within the expandable tubular member to radially expand and plastically deform a portion of the expandable tubular member.
  • FIG. 17 is a fragmentary cross sectional view of the expandable tubular member of FIG. 16 after operating the expansion device within the expandable tubular member to radially expand and plastically deform another portion of the expandable tubular member.
  • FIG. 18 is a flow chart illustration of an exemplary embodiment of a method of processing an expandable tubular member.
  • FIG. 19 is a graphical illustration of the an exemplary embodiment of the yield strength vs. ductility curve for at least a portion of the expandable tubular member during the operation of the method of FIG. 18 .
  • FIG. 20 is a graphical illustration of stress/strain curves for an exemplary embodiment of an expandable tubular member.
  • FIG. 21 is a graphical illustration of stress/strain curves for an exemplary embodiment of an expandable tubular member.
  • FIG. 22 is a fragmentary cross-sectional view illustrating an embodiment of the radial expansion and plastic deformation of a portion of a first tubular member having an internally threaded connection at an end portion, an embodiment of a tubular sleeve supported by the end portion of the first tubular member, and a second tubular member having an externally threaded portion coupled to the internally threaded portion of the first tubular member and engaged by a flange of the sleeve.
  • the sleeve includes the flange at one end for increasing axial compression loading.
  • FIG. 23 is a fragmentary cross-sectional view illustrating an embodiment of the radial expansion and plastic deformation of a portion of a first tubular member having an internally threaded connection at an end portion, a second tubular member having an externally threaded portion coupled to the internally threaded portion of the first tubular member, and an embodiment of a tubular sleeve supported by the end portion of both tubular members.
  • the sleeve includes flanges at opposite ends for increasing axial tension loading.
  • FIG. 24 is a fragmentary cross-sectional illustration of the radial expansion and plastic deformation of a portion of a first tubular member having an internally threaded connection at an end portion, a second tubular member having an externally threaded portion coupled to the internally threaded portion of the first tubular member, and an embodiment of a tubular sleeve supported by the end portion of both tubular members.
  • the sleeve includes flanges at opposite ends for increasing axial compression/tension loading.
  • FIG. 25 is a fragmentary cross-sectional illustration of the radial expansion and plastic deformation of a portion of a first tubular member having an internally threaded connection at an end portion, a second tubular member having an externally threaded portion coupled to the internally threaded portion of the first tubular member, and an embodiment of a tubular sleeve supported by the end portion of both tubular members.
  • the sleeve includes flanges at opposite ends having sacrificial material thereon.
  • FIG. 26 is a fragmentary cross-sectional illustration of the radial expansion and plastic deformation of a portion of a first tubular member having an internally threaded connection at an end portion, a second tubular member having an externally threaded portion coupled to the internally threaded portion of the first tubular member, and an embodiment of a tubular sleeve supported by the end portion of both tubular members.
  • the sleeve includes a thin walled cylinder of sacrificial material.
  • FIG. 27 is a fragmentary cross-sectional illustration of the radial expansion and plastic deformation of a portion of a first tubular member having an internally threaded connection at an end portion, a second tubular member having an externally threaded portion coupled to the internally threaded portion of the first tubular member, and an embodiment of a tubular sleeve supported by the end portion of both tubular members.
  • the sleeve includes a variable thickness along the length thereof.
  • FIG. 28 is a fragmentary cross-sectional illustration of the radial expansion and plastic deformation of a portion of a first tubular member having an internally threaded connection at an end portion, a second tubular member having an externally threaded portion coupled to the internally threaded portion of the first tubular member, and an embodiment of a tubular sleeve supported by the end portion of both tubular members.
  • the sleeve includes a member coiled onto grooves formed in the sleeve for varying the sleeve thickness.
  • FIG. 29 is a fragmentary cross-sectional illustration of an exemplary embodiment of an expandable connection.
  • FIGS. 30 a - 30 c are fragmentary cross-sectional illustrations of exemplary embodiments of expandable connections.
  • FIG. 31 is a fragmentary cross-sectional illustration of an exemplary embodiment of an expandable connection.
  • FIGS. 32 a and 32 b are fragmentary cross-sectional illustrations of the formation of an exemplary embodiment of an expandable connection.
  • FIG. 33 is a fragmentary cross-sectional illustration of an exemplary embodiment of an expandable connection.
  • FIGS. 34 a , 34 b and 34 c are fragmentary cross-sectional illustrations of an exemplary embodiment of an expandable connection.
  • FIG. 35 a is a fragmentary cross-sectional illustration of an exemplary embodiment of an expandable tubular member.
  • FIG. 35 b is a graphical illustration of an exemplary embodiment of the variation in the yield point for the expandable tubular member of FIG. 35 a.
  • FIG. 36 a is a flow chart illustration of an exemplary embodiment of a method for processing a tubular member.
  • FIG. 36 b is an illustration of the microstructure of an exemplary embodiment of a tubular member prior to thermal processing.
  • FIG. 36 c is an illustration of the microstructure of an exemplary embodiment of a tubular member after thermal processing.
  • FIG. 37 a is a flow chart illustration of an exemplary embodiment of a method for processing a tubular member.
  • FIG. 37 b is an illustration of the microstructure of an exemplary embodiment of a tubular member prior to thermal processing.
  • FIG. 37 c is an illustration of the microstructure of an exemplary embodiment of a tubular member after thermal processing.
  • FIG. 38 a is a flow chart illustration of an exemplary embodiment of a method for processing a tubular member.
  • FIG. 38 b is an illustration of the microstructure of an exemplary embodiment of a tubular member prior to thermal processing.
  • FIG. 38 c is an illustration of the microstructure of an exemplary embodiment of a tubular member after thermal processing.
  • FIG. 39 is a schematic view illustrating an exemplary embodiment of a method for increasing the collapse strength of a tubular assembly.
  • FIG. 40 is a perspective view illustrating an exemplary embodiment of an expandable tubular member used in the method of FIG. 39 .
  • FIG. 41 a is a perspective view illustrating an exemplary embodiment of the expandable tubular member of FIG. 40 coated with a layer of material according to the method of FIG. 39 .
  • FIG. 41 b is a cross sectional view taken along line 41 b in FIG. 41 a illustrating an exemplary embodiment of the expandable tubular member of FIG. 40 coated with a layer of material according to the method of FIG. 39 .
  • FIG. 41 c is a perspective view illustrating an exemplary embodiment of the expandable tubular member and layer of FIG. 41 a where the coating layer is plastic according to the method of FIG. 39 .
  • FIG. 41 d is a perspective view illustrating an exemplary embodiment of the expandable tubular member and layer of FIG. 41 a where the coating layer is aluminum according to the method of FIG. 39 .
  • FIG. 42 is a perspective view illustrating an exemplary embodiment of the expandable tubular member and layer of FIG. 41 a positioned within a preexisting structure according to the method of FIG. 39 .
  • FIG. 43 is a perspective view illustrating an exemplary embodiment of the expandable tubular member and layer within the preexisting structure of FIG. 42 with the expandable tubular member being expanded according to the method of FIG. 39 .
  • FIG. 44 is a perspective view illustrating an exemplary embodiment of the expandable tubular member and layer within the preexisting structure of FIG. 42 with the expandable tubular member expanded according to the method of FIG. 39 .
  • FIG. 45 is a schematic view illustrating an exemplary embodiment of a method for increasing the collapse strength of a tubular assembly.
  • FIG. 46 is a perspective view illustrating an exemplary embodiment of a preexisting structure used in the method of FIG. 45 .
  • FIG. 47 a is a perspective view illustrating an exemplary embodiment of the preexisting structure of FIG. 46 being coated with a layer of material according to the method of FIG. 45 .
  • FIG. 47 b is a cross sectional view taken along line 47 b in FIG. 47 a illustrating an exemplary embodiment of the preexisting structure of FIG. 46 coated with a layer of material according to the method of FIG. 45 .
  • FIG. 48 is a perspective view illustrating an exemplary embodiment of an expandable tubular member positioned within the preexisting structure and layer of material of FIG. 47 a according to the method of FIG. 45 .
  • FIG. 49 is a perspective view illustrating an exemplary embodiment of the expandable tubular member within the preexisting structure and layer of FIG. 48 with the expandable tubular member being expanded according to the method of FIG. 45 .
  • FIG. 50 is a perspective view illustrating an exemplary embodiment of the expandable tubular member within the preexisting structure and layer of FIG. 48 with the expandable tubular member expanded according to the method of FIG. 45 .
  • FIG. 51 a is a perspective view illustrating an exemplary embodiment of the expandable tubular member of FIG. 40 coated with multiple layers of material according to the method of FIG. 39 .
  • FIG. 51 b is a perspective view illustrating an exemplary embodiment of the preexisting structure of FIG. 46 coated with multiple layers of material according to the method of FIG. 39 .
  • FIG. 52 a is a perspective view illustrating an exemplary embodiment of the expandable tubular member of FIG. 40 coated by winding a wire around its circumference according to the method of FIG. 39 .
  • FIG. 52 b is a perspective view illustrating an exemplary embodiment of the expandable tubular member of FIG. 40 coated by winding wire around its circumference according to the method of FIG. 39 .
  • FIG. 52 c is a cross sectional view taken along line 52 c of FIG. 52 b illustrating an exemplary embodiment of the expandable tubular member of FIG. 40 coated by winding wire around its circumference according to the method of FIG. 39 .
  • FIG. 53 is a chart view illustrating an exemplary experimental embodiment of the energy required to expand a plurality of tubular assemblies produced by the methods of FIG. 39 and FIG. 45 .
  • FIG. 54 a is a cross sectional view illustrating an exemplary experimental embodiment of a tubular assembly produced by the method of FIG. 39 .
  • FIG. 54 b is a cross sectional view illustrating an exemplary experimental embodiment of a tubular assembly produced by the method of FIG. 39 .
  • FIG. 54 c is a chart view illustrating an exemplary experimental embodiment of the thickness of the interstitial layer for a plurality of tubular assemblies produced by the method of FIG. 39 .
  • FIG. 55 a is a chart view illustrating an exemplary experimental embodiment of the thickness of the interstitial layer for a plurality of tubular assemblies produced by the method of FIG. 39 .
  • FIG. 55 b is a chart view illustrating an exemplary experimental embodiment of the thickness of the interstitial layer for a plurality of tubular assemblies produced by the method of FIG. 39 .
  • FIG. 56 is a cross sectional view illustrating an exemplary experimental embodiment of a tubular assembly produced by the method of FIG. 39 but omitting the coating with a layer of material.
  • FIG. 56 a is a close up cross sectional view illustrating an exemplary experimental embodiment of a tubular assembly produced by the method of FIG. 39 but omitting the coating with a layer of material.
  • FIG. 57 a is a graphical view illustrating an exemplary experimental embodiment of the collapse strength for a tubular assembly produced by the method of FIG. 39 but omitting the coating with a layer of material.
  • FIG. 57 b is a graphical view illustrating an exemplary experimental embodiment of the thickness of the air gap for a tubular assembly produced by the method of FIG. 39 but omitting the coating with a layer of material.
  • FIG. 58 is a graphical view illustrating an exemplary experimental embodiment of the thickness of the air gap and the collapse strength for a tubular assembly produced by the method of FIG. 39 but omitting the coating with a layer of material.
  • FIG. 59 is a graphical view illustrating an exemplary experimental embodiment of the thickness of the interstitial layer and the collapse strength for a tubular assembly produced by the method of FIG. 39 .
  • FIG. 60 a is a graphical view illustrating an exemplary experimental embodiment of the thickness of the air gap for a tubular assembly produced by the method of FIG. 39 but omitting the coating with a layer of material.
  • FIG. 60 b is a graphical view illustrating an exemplary experimental embodiment of the thickness of the interstitial layer for a tubular assembly produced by the method of FIG. 39 .
  • FIG. 60 c is a graphical view illustrating an exemplary experimental embodiment of the thickness of the interstitial layer for a tubular assembly produced by the method of FIG. 39 .
  • FIG. 61 a is a graphical view illustrating an exemplary experimental embodiment of the wall thickness of an expandable tubular member for a tubular assembly produced by the method of FIG. 39 but omitting the coating with a layer of material.
  • FIG. 61 b is a graphical view illustrating an exemplary experimental embodiment of the wall thickness of an expandable tubular member for a tubular assembly produced by the method of FIG. 39 .
  • FIG. 61 c is a graphical view illustrating an exemplary experimental embodiment of the wall thickness of an expandable tubular member for a tubular assembly produced by the method of FIG. 39 .
  • FIG. 62 a is a graphical view illustrating an exemplary experimental embodiment of the wall thickness of a preexisting structure for a tubular assembly produced by the method of FIG. 39 but omitting the coating with a layer of material.
  • FIG. 62 b is a graphical view illustrating an exemplary experimental embodiment of the wall thickness of a preexisting structure for a tubular assembly produced by the method of FIG. 39 .
  • FIG. 62 c is a graphical view illustrating an exemplary experimental embodiment of the wall thickness of a preexisting structure for a tubular assembly produced by the method of FIG. 39 .
  • FIG. 63 is a graphical view illustrating an exemplary experimental embodiment of the collapse strength for a tubular assembly produced by the method of FIG. 39 .
  • an exemplary embodiment of an expandable tubular assembly 10 includes a first expandable tubular member 12 coupled to a second expandable tubular member 14 .
  • the ends of the first and second expandable tubular members, 12 and 14 are coupled using, for example, a conventional mechanical coupling, a welded connection, a brazed connection, a threaded connection, and/or an interference fit connection.
  • the first expandable tubular member 12 has a plastic yield point YP 1
  • the second expandable tubular member 14 has a plastic yield point YP 2 .
  • the expandable tubular assembly 10 is positioned within a preexisting structure such as, for example, a wellbore 16 that traverses a subterranean formation 18 .
  • an expansion device 20 may then be positioned within the second expandable tubular member 14 .
  • the expansion device 20 may include, for example, one or more of the following conventional expansion devices: a) an expansion cone; b) a rotary expansion device; c) a hydroforming expansion device; d) an impulsive force expansion device; d) any one of the expansion devices commercially available from, or disclosed in any of the published patent applications or issued patents, of Weatherford International, Baker Hughes, Halliburton Energy Services, Shell Oil Co., Schlumberger, and/or Enventure Global Technology L.L.C.
  • the expansion device 20 is positioned within the second expandable tubular member 14 before, during, or after the placement of the expandable tubular assembly 10 within the preexisting structure 16 .
  • the expansion device 20 may then be operated to radially expand and plastically deform at least a portion of the second expandable tubular member 14 to form a bell-shaped section.
  • the expansion device 20 may then be operated to radially expand and plastically deform the remaining portion of the second expandable tubular member 14 and at least a portion of the first expandable tubular member 12 .
  • At least a portion of at least a portion of at least one of the first and second expandable tubular members, 12 and 14 are radially expanded into intimate contact with the interior surface of the preexisting structure 16 .
  • the plastic yield point YP 1 is greater than the plastic yield point YP 2 .
  • the amount of power and/or energy required to radially expand the second expandable tubular member 14 is less than the amount of power and/or energy required to radially expand the first expandable tubular member 12 .
  • the first expandable tubular member 12 and/or the second expandable tubular member 14 have a ductility D PE and a yield strength YS PE prior to radial expansion and plastic deformation, and a ductility D AE and a yield strength YS AE after radial expansion and plastic deformation.
  • D PE is greater than D AE
  • YS AE is greater than YS PE .
  • the amount of power and/or energy required to radially expand each unit length of the first and/or second expandable tubular members, 12 and 14 is reduced. Furthermore, because the YS AE is greater than YS PE , the collapse strength of the first expandable tubular member 12 and/or the second expandable tubular member 14 is increased after the radial expansion and plastic deformation process.
  • At least a portion of the second expandable tubular member 14 has an inside diameter that is greater than at least the inside diameter of the first expandable tubular member 12 . In this manner a bell-shaped section is formed using at least a portion of the second expandable tubular member 14 .
  • Another expandable tubular assembly 22 that includes a first expandable tubular member 24 and a second expandable tubular member 26 may then be positioned in overlapping relation to the first expandable tubular assembly 10 and radially expanded and plastically deformed using the methods described above with reference to FIGS. 1-4 .
  • At least a portion of the second expandable tubular member 26 has an inside diameter that is greater than at least the inside diameter of the first expandable tubular member 24 .
  • a bell-shaped section is formed using at least a portion of the second expandable tubular member 26 .
  • a mono-diameter tubular assembly is formed that defines an internal passage 28 having a substantially constant cross-sectional area and/or inside diameter.
  • an exemplary embodiment of an expandable tubular assembly 100 includes a first expandable tubular member 102 coupled to a tubular coupling 104 .
  • the tubular coupling 104 is coupled to a tubular coupling 106 .
  • the tubular coupling 106 is coupled to a second expandable tubular member 108 .
  • the tubular couplings, 104 and 106 provide a tubular coupling assembly for coupling the first and second expandable tubular members, 102 and 108 , together that may include, for example, a conventional mechanical coupling, a welded connection, a brazed connection, a threaded connection, and/or an interference fit connection.
  • the first and second expandable tubular members 12 have a plastic yield point YP 1
  • the tubular couplings, 104 and 106 have a plastic yield point YP 2
  • the expandable tubular assembly 100 is positioned within a preexisting structure such as, for example, a wellbore 110 that traverses a subterranean formation 112 .
  • an expansion device 114 may then be positioned within the second expandable tubular member 108 .
  • the expansion device 114 may include, for example, one or more of the following conventional expansion devices: a) an expansion cone; b) a rotary expansion device; c) a hydroforming expansion device; d) an impulsive force expansion device; d) any one of the expansion devices commercially available from, or disclosed in any of the published patent applications or issued patents, of Weatherford International, Baker Hughes, Halliburton Energy Services, Shell Oil Co., Schlumberger, and/or Enventure Global Technology L.L.C.
  • the expansion device 114 is positioned within the second expandable tubular member 108 before, during, or after the placement of the expandable tubular assembly 100 within the preexisting structure 110 .
  • the expansion device 114 may then be operated to radially expand and plastically deform at least a portion of the second expandable tubular member 108 to form a bell-shaped section.
  • the expansion device 114 may then be operated to radially expand and plastically deform the remaining portion of the second expandable tubular member 108 , the tubular couplings, 104 and 106 , and at least a portion of the first expandable tubular member 102 .
  • At least a portion of at least a portion of at least one of the first and second expandable tubular members, 102 and 108 are radially expanded into intimate contact with the interior surface of the preexisting structure 110 .
  • the plastic yield point YP 1 is less than the plastic yield point YP 2 .
  • the amount of power and/or energy required to radially expand each unit length of the first and second expandable tubular members, 102 and 108 is less than the amount of power and/or energy required to radially expand each unit length of the tubular couplings, 104 and 106 .
  • the first expandable tubular member 12 and/or the second expandable tubular member 14 have a ductility D PE and a yield strength YS PE prior to radial expansion and plastic deformation, and a ductility D AE and a yield strength YS AE after radial expansion and plastic deformation.
  • D PE is greater than D AE
  • YS AE is greater than YS PE .
  • the amount of power and/or energy required to radially expand each unit length of the first and/or second expandable tubular members, 12 and 14 is reduced. Furthermore, because the YS AE is greater than YS PE , the collapse strength of the first expandable tubular member 12 and/or the second expandable tubular member 14 is increased after the radial expansion and plastic deformation process.
  • an exemplary embodiment of an expandable tubular assembly 200 includes a first expandable tubular member 202 coupled to a second expandable tubular member 204 that defines radial openings 204 a , 204 b , 204 c , and 204 d .
  • the ends of the first and second expandable tubular members, 202 and 204 are coupled using, for example, a conventional mechanical coupling, a welded connection, a brazed connection, a threaded connection, and/or an interference fit connection.
  • one or more of the radial openings, 204 a , 204 b , 204 c , and 204 d have circular, oval, square, and/or irregular cross sections and/or include portions that extend to and interrupt either end of the second expandable tubular member 204 .
  • the expandable tubular assembly 200 is positioned within a preexisting structure such as, for example, a wellbore 206 that traverses a subterranean formation 208 .
  • an expansion device 210 may then be positioned within the second expandable tubular member 204 .
  • the expansion device 210 may include, for example, one or more of the following conventional expansion devices: a) an expansion cone; b) a rotary expansion device; c) a hydroforming expansion device; d) an impulsive force expansion device; d) any one of the expansion devices commercially available from, or disclosed in any of the published patent applications or issued patents, of Weatherford International, Baker Hughes, Halliburton Energy Services, Shell Oil Co., Schlumberger, and/or Enventure Global Technology L.L.C.
  • the expansion device 210 is positioned within the second expandable tubular member 204 before, during, or after the placement of the expandable tubular assembly 200 within the preexisting structure 206 .
  • the expansion device 210 may then be operated to radially expand and plastically deform at least a portion of the second expandable tubular member 204 to form a bell-shaped section.
  • the expansion device 20 may then be operated to radially expand and plastically deform the remaining portion of the second expandable tubular member 204 and at least a portion of the first expandable tubular member 202 .
  • WT f final wall thickness of the expandable tubular member following the radial expansion and plastic deformation of the expandable tubular member
  • WT i initial wall thickness of the expandable tubular member prior to the radial expansion and plastic deformation of the expandable tubular member
  • D f final inside diameter of the expandable tubular member following the radial expansion and plastic deformation of the expandable tubular member
  • D i initial inside diameter of the expandable tubular member prior to the radial expansion and plastic deformation of the expandable tubular member.
  • the anisotropy ratio AR for the first and/or second expandable tubular members, 204 and 204 is greater than 1.
  • the second expandable tubular member 204 had an anisotropy ratio AR greater than 1, and the radial expansion and plastic deformation of the second expandable tubular member did not result in any of the openings, 204 a , 204 b , 204 c , and 204 d , splitting or otherwise fracturing the remaining portions of the second expandable tubular member. This was an unexpected result.
  • one or more of the expandable tubular members, 12 , 14 , 24 , 26 , 102 , 104 , 106 , 108 , 202 and/or 204 are processed using a method 300 in which a tubular member in an initial state is thermo-mechanically processed in step 302 .
  • the thermo-mechanical processing 302 includes one or more heat treating and/or mechanical forming processes.
  • the tubular member is transformed to an intermediate state.
  • the tubular member is then further thermo-mechanically processed in step 304 .
  • the thermo-mechanical processing 304 includes one or more heat treating and/or mechanical forming processes.
  • the tubular member is transformed to a final state.
  • the tubular member has a ductility D PE and a yield strength YS PE prior to the final thermo-mechanical processing in step 304 , and a ductility D AE and a yield strength YS AE after final thermo-mechanical processing.
  • D PE is greater than D AE
  • YS AE is greater than YS PE .
  • the amount of energy and/or power required to transform the tubular member, using mechanical forming processes, during the final thermo-mechanical processing in step 304 is reduced.
  • the YS AE is greater than YS PE , the collapse strength of the tubular member is increased after the final thermo-mechanical processing in step 304 .
  • one or more of the expandable tubular members, 12 , 14 , 24 , 26 , 102 , 104 , 106 , 108 , 202 and/or 204 have the following characteristics: Characteristic Value Tensile Strength 60 to 120 ksi Yield Strength 50 to 100 ksi Y/T Ratio Maximum of 50/85% Elongation During Radial Expansion and Minimum of 35% Plastic Deformation Width Reduction During Radial Expansion Minimum of 40% and Plastic Deformation Wall Thickness Reduction During Radial Minimum of 30% Expansion and Plastic Deformation Anisotropy Minimum of 1.5 Minimum Absorbed Energy at ⁇ 4 F.
  • the anisotropy coefficient for one or more of the expandable tubular members, 12 , 14 , 24 , 26 , 102 , 104 , 106 , 108 , 202 and/or 204 is greater than 1.
  • the strain hardening exponent for one or more of the expandable tubular members, 12 , 14 , 24 , 26 , 102 , 104 , 106 , 108 , 202 and/or 204 is greater than 0.12.
  • the expandability coefficient for one or more of the expandable tubular members, 12 , 14 , 24 , 26 , 102 , 104 , 106 , 108 , 202 and/or 204 is greater than 0.12.
  • a tubular member having a higher expandability coefficient requires less power and/or energy to radially expand and plastically deform each unit length than a tubular member having a lower expandability coefficient. In an exemplary embodiment, a tubular member having a higher expandability coefficient requires less power and/or energy per unit length to radially expand and plastically deform than a tubular member having a lower expandability coefficient.
  • one or more of the expandable tubular members, 12 , 14 , 24 , 26 , 102 , 104 , 106 , 108 , 202 and/or 204 are steel alloys having one of the following compositions: Steel Element and Percentage By Weight Alloy C Mn P S Si Cu Ni Cr A 0.065 1.44 0.01 0.002 0.24 0.01 0.01 0.02 B 0.18 1.28 0.017 0.004 0.29 0.01 0.01 0.03 C 0.08 0.82 0.006 0.003 0.30 0.16 0.05 0.05 D 0.02 1.31 0.02 0.001 0.45 — 9.1 18.7
  • a sample of an expandable tubular member composed of Alloy A exhibited a yield point before radial expansion and plastic deformation YP BE , a yield point after radial expansion and plastic deformation of about 16% YP AE16% , and a yield point after radial expansion and plastic deformation of about 24% YP AE24% .
  • YP AE24 %>YP AE16 %>YP BE .
  • the ductility of the sample of the expandable tubular member composed of Alloy A also exhibited a higher ductility prior to radial expansion and plastic deformation than after radial expansion and plastic deformation.
  • a sample of an expandable tubular member composed of Alloy A exhibited the following tensile characteristics before and after radial expansion and plastic deformation: Width Wall Yield Elon- Reduc- Thickness Point Yield gation tion Reduction Anisot- ksi Ratio % % % ropy Before 46.9 0.69 53 ⁇ 52 55 0.93 Radial Expansion and Plastic Deformation After 16% 65.9 0.83 17 42 51 0.78 Radial Expansion After 24% 68.5 0.83 5 44 54 0.76 Radial Expansion % 40% for Increase 16% radial expansion 46% for 24% radial expansion
  • a sample of an expandable tubular member composed of Alloy B exhibited a yield point before radial expansion and plastic deformation YP BE , a yield point after radial expansion and plastic deformation of about 16% YP AE16% , and a yield point after radial expansion and plastic deformation of about 24% YP AE24% .
  • YP AE24 %>YP AE16 %>YP BE .
  • the ductility of the sample of the expandable tubular member composed of Alloy B also exhibited a higher ductility prior to radial expansion and plastic deformation than after radial expansion and plastic deformation.
  • a sample of an expandable tubular member composed of Alloy B exhibited the following tensile characteristics before and after radial expansion and plastic deformation: Width Wall Yield Elon- Reduc- Thickness Point Yield gation tion Reduction Anisot- ksi Ratio % % % ropy Before 57.8 0.71 44 43 46 0.93 Radial Expansion and Plastic Deformation After 16% 74.4 0.84 16 38 42 0.87 Radial Expansion After 24% 79.8 0.86 20 36 42 0.81 Radial Expansion % 28.7% Increase increase for 16% radial expansion 38% increase for 24% radial expansion
  • samples of expandable tubulars composed of Alloys A, B, C, and D exhibited the following tensile characteristics prior to radial expansion and plastic deformation: Expand- Absorbed ability Steel Yield Yield Elon- Anisot- Energy Coef- Alloy ksi Ratio gation % ropy ft-lb ficient A 47.6 0.71 44 1.48 145 B 57.8 0.71 44 1.04 62.2 C 61.7 0.80 39 1.92 268 D 48 0.55 56 1.34 —
  • one or more of the expandable tubular members, 12 , 14 , 24 , 26 , 102 , 104 , 106 , 108 , 202 and/or 204 have a strain hardening exponent greater than 0.12, and a yield ratio is less than 0.85.
  • Mn manganese percentage by weight
  • V vanadium percentage by weight
  • g. Nb niobium percentage by weight
  • Ni nickel percentage by weight
  • the carbon equivalent value C e for tubular members having a carbon content less than or equal to 0.12% (by weight), for one or more of the expandable tubular members, 12 , 14 , 24 , 26 , 102 , 104 , 106 , 108 , 202 and/or 204 is less than 0.21.
  • Si silicon percentage by weight
  • Ni nickel percentage by weight
  • V vanadium percentage by weight
  • the carbon equivalent value C e for tubular members having greater than 0.12% carbon content (by weight), for one or more of the expandable tubular members, 12 , 14 , 24 , 26 , 102 , 104 , 106 , 108 , 202 and/or 204 is less than 0.36.
  • a first tubular member 2210 includes an internally threaded connection 2212 at an end portion 2214 .
  • a first end of a tubular sleeve 2216 that includes an internal flange 2218 having a tapered portion 2220 , and a second end that includes a tapered portion 2222 is then mounted upon and receives the end portion 2214 of the first tubular member 2210 .
  • the end portion 2214 of the first tubular member 2210 abuts one side of the internal flange 2218 of the tubular sleeve 2216 , and the internal diameter of the internal flange 2218 of the tubular sleeve 2216 is substantially equal to or greater than the maximum internal diameter of the internally threaded connection 2212 of the end portion 2214 of the first tubular member 2210 .
  • An externally threaded connection 2224 of an end portion 2226 of a second tubular member 2228 having an annular recess 2230 is then positioned within the tubular sleeve 2216 and threadably coupled to the internally threaded connection 2212 of the end portion 2214 of the first tubular member 2210 .
  • the internal flange 2218 of the tubular sleeve 2216 mates with and is received within the annular recess 2230 of the end portion 2226 of the second tubular member 2228 .
  • the tubular sleeve 2216 is coupled to and surrounds the external surfaces of the first and second tubular members, 2210 and 2228 .
  • the internally threaded connection 2212 of the end portion 2214 of the first tubular member 2210 is a box connection
  • the externally threaded connection 2224 of the end portion 2226 of the second tubular member 2228 is a pin connection.
  • the internal diameter of the tubular sleeve 2216 is at least approximately 0.020′′ greater than the outside diameters of the first and second tubular members, 2210 and 2228 . In this manner, during the threaded coupling of the first and second tubular members, 2210 and 2228 , fluidic materials within the first and second tubular members may be vented from the tubular members.
  • first and second tubular members, 2210 and 2228 , and the tubular sleeve 2216 may be positioned within another structure 2232 such as, for example, a cased or uncased wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating a conventional expansion device 2234 within and/or through the interiors of the first and second tubular members.
  • the tapered portions, 2220 and 2222 , of the tubular sleeve 2216 facilitate the insertion and movement of the first and second tubular members within and through the structure 2232 , and the movement of the expansion device 2234 through the interiors of the first and second tubular members, 2210 and 2228 , may be, for example, from top to bottom or from bottom to top.
  • the tubular sleeve 2216 is also radially expanded and plastically deformed. As a result, the tubular sleeve 2216 may be maintained in circumferential tension and the end portions, 2214 and 2226 , of the first and second tubular members, 2210 and 2228 , may be maintained in circumferential compression.
  • Sleeve 2216 increases the axial compression loading of the connection between tubular members 2210 and 2228 before and after expansion by the expansion device 2234 .
  • Sleeve 2216 may, for example, be secured to tubular members 2210 and 2228 by a heat shrink fit.
  • first and second tubular members, 2210 and 2228 are radially expanded and plastically deformed using other conventional methods for radially expanding and plastically deforming tubular members such as, for example, internal pressurization, hydroforming, and/or roller expansion devices and/or any one or combination of the conventional commercially available expansion products and services available from Baker Hughes, Weatherford International, and/or Enventure Global Technology L.L.C.
  • tubular sleeve 2216 during (a) the coupling of the first tubular member 2210 to the second tubular member 2228 , (b) the placement of the first and second tubular members in the structure 2232 , and (c) the radial expansion and plastic deformation of the first and second tubular members provides a number of significant benefits.
  • the tubular sleeve 2216 protects the exterior surfaces of the end portions, 2214 and 2226 , of the first and second tubular members, 2210 and 2228 , during handling and insertion of the tubular members within the structure 2232 .
  • tubular sleeve 2216 provides an alignment guide that facilitates the insertion and threaded coupling of the second tubular member 2228 to the first tubular member 2210 . In this manner, misalignment that could result in damage to the threaded connections, 2212 and 2224 , of the first and second tubular members, 2210 and 2228 , may be avoided.
  • the tubular sleeve 2216 provides an indication of to what degree the first and second tubular members are threadably coupled. For example, if the tubular sleeve 2216 can be easily rotated, that would indicate that the first and second tubular members, 2210 and 2228 , are not fully threadably coupled and in intimate contact with the internal flange 2218 of the tubular sleeve. Furthermore, the tubular sleeve 2216 may prevent crack propagation during the radial expansion and plastic deformation of the first and second tubular members, 2210 and 2228 .
  • the tubular sleeve 2216 may provide a fluid tight metal-to-metal seal between interior surface of the tubular sleeve 2216 and the exterior surfaces of the end portions, 2214 and 2226 , of the first and second tubular members.
  • tubular sleeve 2216 may be maintained in circumferential tension and the end portions, 2214 and 2226 , of the first and second tubular members, 2210 and 2228 , may be maintained in circumferential compression, axial loads and/or torque loads may be transmitted through the tubular sleeve.
  • one or more portions of the first and second tubular members, 2210 and 2228 , and the tubular sleeve 2216 have one or more of the material properties of one or more of the tubular members 12 , 14 , 24 , 26 , 102 , 104 , 106 , 108 , 202 and/or 204 .
  • a first tubular member 210 includes an internally threaded connection 2312 at an end portion 2314 .
  • a first end of a tubular sleeve 2316 includes an internal flange 2318 and a tapered portion 2320 .
  • a second end of the sleeve 2316 includes an internal flange 2321 and a tapered portion 2322 .
  • An externally threaded connection 2324 of an end portion 2326 of a second tubular member 2328 having an annular recess 2330 is then positioned within the tubular sleeve 2316 and threadably coupled to the internally threaded connection 2312 of the end portion 2314 of the first tubular member 2310 .
  • the internal flange 2318 of the sleeve 2316 mates with and is received within the annular recess 2330 .
  • the first tubular member 2310 includes a recess 2331 .
  • the internal flange 2321 mates with and is received within the annular recess 2331 .
  • the sleeve 2316 is coupled to and surrounds the external surfaces of the first and second tubular members 2310 and 2328 .
  • the internally threaded connection 2312 of the end portion 2314 of the first tubular member 2310 is a box connection
  • the externally threaded connection 2324 of the end portion 2326 of the second tubular member 2328 is a pin connection.
  • the internal diameter of the tubular sleeve 2316 is at least approximately 0.020′′ greater than the outside diameters of the first and second tubular members 2310 and 2328 . In this manner, during the threaded coupling of the first and second tubular members 2310 and 2328 , fluidic materials within the first and second tubular members may be vented from the tubular members.
  • the first and second tubular members 2310 and 2328 , and the tubular sleeve 2316 may then be positioned within another structure 2332 such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device 2334 through and/or within the interiors of the first and second tubular members.
  • the tapered portions 2320 and 2322 , of the tubular sleeve 2316 facilitates the insertion and movement of the first and second tubular members within and through the structure 2332 , and the displacement of the expansion device 2334 through the interiors of the first and second tubular members 2310 and 2328 , may be from top to bottom or from bottom to top.
  • the tubular sleeve 2316 is also radially expanded and plastically deformed.
  • the tubular sleeve 2316 may be maintained in circumferential tension and the end portions 2314 and 2326 , of the first and second tubular members 2310 and 2328 , may be maintained in circumferential compression.
  • Sleeve 2316 increases the axial tension loading of the connection between tubular members 2310 and 2328 before and after expansion by the expansion device 2334 .
  • Sleeve 2316 may be secured to tubular members 2310 and 2328 by a heat shrink fit.
  • one or more portions of the first and second tubular members, 2310 and 2328 , and the tubular sleeve 2316 have one or more of the material properties of one or more of the tubular members 12 , 14 , 24 , 26 , 102 , 104 , 106 , 108 , 202 and/or 204 .
  • a first tubular member 2410 includes an internally threaded connection 2412 at an end portion 2414 .
  • a first end of a tubular sleeve 2416 includes an internal flange 2418 and a tapered portion 2420 .
  • a second end of the sleeve 2416 includes an internal flange 2421 and a tapered portion 2422 .
  • An externally threaded connection 2424 of an end portion 2426 of a second tubular member 2428 having an annular recess 2430 is then positioned within the tubular sleeve 2416 and threadably coupled to the internally threaded connection 2412 of the end portion 2414 of the first tubular member 2410 .
  • the internal flange 2418 of the sleeve 2416 mates with and is received within the annular recess 2430 .
  • the first tubular member 2410 includes a recess 2431 .
  • the internal flange 2421 mates with and is received within the annular recess 2431 .
  • the sleeve 2416 is coupled to and surrounds the external surfaces of the first and second tubular members 2410 and 2428 .
  • the internally threaded connection 2412 of the end portion 2414 of the first tubular member 2410 is a box connection
  • the externally threaded connection 2424 of the end portion 2426 of the second tubular member 2428 is a pin connection.
  • the internal diameter of the tubular sleeve 2416 is at least approximately 0.020′′ greater than the outside diameters of the first and second tubular members 2410 and 2428 . In this manner, during the threaded coupling of the first and second tubular members 2410 and 2428 , fluidic materials within the first and second tubular members may be vented from the tubular members.
  • first and second tubular members 2410 and 2428 , and the tubular sleeve 2416 may then be positioned within another structure 2432 such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device 2434 through and/or within the interiors of the first and second tubular members.
  • the tapered portions 2420 and 2422 , of the tubular sleeve 2416 facilitate the insertion and movement of the first and second tubular members within and through the structure 2432 , and the displacement of the expansion device 2434 through the interiors of the first and second tubular members, 2410 and 2428 , may be from top to bottom or from bottom to top.
  • the tubular sleeve 2416 is also radially expanded and plastically deformed.
  • the tubular sleeve 2416 may be maintained in circumferential tension and the end portions, 2414 and 2426 , of the first and second tubular members, 2410 and 2428 , may be maintained in circumferential compression.
  • the sleeve 2416 increases the axial compression and tension loading of the connection between tubular members 2410 and 2428 before and after expansion by expansion device 2424 .
  • Sleeve 2416 may be secured to tubular members 2410 and 2428 by a heat shrink fit.
  • one or more portions of the firsthand second tubular members, 2410 and 2428 , and the tubular sleeve 2416 have one or more of the material properties of one or more of the tubular members 12 , 14 , 24 , 26 , 102 , 104 , 106 , 108 , 202 and/or 204 .
  • a first tubular member 2510 includes an internally threaded connection 2512 at an end portion 2514 .
  • a first end of a tubular sleeve 2516 includes an internal flange 2518 and a relief 2520 .
  • a second end of the sleeve 2516 includes an internal flange 2521 and a relief 2522 .
  • An externally threaded connection 2524 of an end portion 2526 of a second tubular member 2528 having an annular recess 2530 is then positioned within the tubular sleeve 2516 and threadably coupled to the internally threaded connection 2512 of the end portion 2514 of the first tubular member 2510 .
  • the internal flange 2518 of the sleeve 2516 mates with and is received within the annular recess 2530 .
  • the first tubular member 2510 includes a recess 2531 .
  • the internal flange 2521 mates with and is received within the annular recess 2531 .
  • the sleeve 2516 is coupled to and surrounds the external surfaces of the first and second tubular members 2510 and 2528 .
  • the internally threaded connection 2512 of the end portion 2514 of the first tubular member 2510 is a box connection
  • the externally threaded connection 2524 of the end portion 2526 of the second tubular member 2528 is a pin connection.
  • the internal diameter of the tubular sleeve 2516 is at least approximately 0.020′′ greater than the outside diameters of the first and second tubular members 2510 and 2528 . In this manner, during the threaded coupling of the first and second tubular members 2510 and 2528 , fluidic materials within the first and second tubular members may be vented from the tubular members.
  • the first and second tubular members 2510 and 2528 , and the tubular sleeve 2516 may then be positioned within another structure 2532 such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device 2534 through and/or within the interiors of the first and second tubular members.
  • the reliefs 2520 and 2522 are each filled with a sacrificial material 2540 including a tapered surface 2542 and 2544 , respectively.
  • the material 2540 may be a metal or a synthetic, and is provided to facilitate the insertion and movement of the first and second tubular members 2510 and 2528 , through the structure 2532 .
  • the displacement of the expansion device 2534 through the interiors of the first and second tubular members 2510 and 2528 may, for example, be from top to bottom or from bottom to top.
  • the tubular sleeve 2516 is also radially expanded and plastically deformed.
  • the tubular sleeve 2516 may be maintained in circumferential tension and the end portions 2514 and 2526 , of the first and second tubular members, 2510 and 2528 , may be maintained in circumferential compression.
  • sacrificial material 2540 provided on sleeve 2516 , avoids stress risers on the sleeve 2516 and the tubular member 2510 .
  • the tapered surfaces 2542 and 2544 are intended to wear or even become damaged, thus incurring such wear or damage which would otherwise be borne by sleeve 2516 .
  • Sleeve 2516 may be secured to tubular members 2510 and 2528 by a heat shrink fit.
  • one or more portions of the first and second tubular members, 2510 and 2528 , and the tubular sleeve 2516 have one or more of the material properties of one or more of the tubular members 12 , 14 , 24 , 26 , 102 , 104 , 106 , 108 , 202 and/or 204 .
  • a first tubular member 2610 includes an internally threaded connection 2612 at an end portion 2614 .
  • a first end of a tubular sleeve 2616 includes an internal flange 2618 and a tapered portion 2620 .
  • a second end of the sleeve 2616 includes an internal flange 2621 and a tapered portion 2622 .
  • An externally threaded connection 2624 of an end portion 2626 of a second tubular member 2628 having an annular recess 2630 is then positioned within the tubular sleeve 2616 and threadably coupled to the internally threaded connection 2612 of the end portion 2614 of the first tubular member 2610 .
  • the internal flange 2618 of the sleeve 2616 mates with and is received within the annular recess 2630 .
  • the first tubular member 2610 includes a recess 2631 .
  • the internal flange 2621 mates with and is received within the annular recess 2631 .
  • the sleeve 2616 is coupled to and surrounds the external surfaces of the first and second tubular members 2610 and 2628 .
  • the internally threaded connection 2612 of the end portion 2614 of the first tubular member 2610 is a box connection
  • the externally threaded connection 2624 of the end portion 2626 of the second tubular member 2628 is a pin connection.
  • the internal diameter of the tubular sleeve 2616 is at least approximately 0.020′′ greater than the outside diameters of the first and second tubular members 2610 and 2628 . In this manner, during the threaded coupling of the first and second tubular members 2610 and 2628 , fluidic materials within the first and second tubular members may be vented from the tubular members.
  • first and second tubular members 2610 and 2628 , and the tubular sleeve 2616 may then be positioned within another structure 2632 such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device 2634 through and/or within the interiors of the first and second tubular members.
  • the tapered portions 2620 and 2622 , of the tubular sleeve 2616 facilitates the insertion and movement of the first and second tubular members within and through the structure 2632 , and the displacement of the expansion device 2634 through the interiors of the first and second tubular members 2610 and 2628 , may, for example, be from top to bottom or from bottom to top.
  • the tubular sleeve 2616 is also radially expanded and plastically deformed.
  • the tubular sleeve 2616 may be maintained in circumferential tension and the end portions 2614 and 2626 , of the first and second tubular members 2610 and 2628 , may be maintained in circumferential compression.
  • Sleeve 2616 is covered by a thin walled cylinder of sacrificial material 2640 . Spaces 2623 and 2624 , adjacent tapered portions 2620 and 2622 , respectively, are also filled with an excess of the sacrificial material 2640 .
  • the material may be a metal or a synthetic, and is provided to facilitate the insertion and movement of the first and second tubular members 2610 and 2628 , through the structure 2632 .
  • sacrificial material 2640 provided on sleeve 2616 , avoids stress risers on the sleeve 2616 and the tubular member 2610 .
  • the excess of the sacrificial material 2640 adjacent tapered portions 2620 and 2622 are intended to wear or even become damaged, thus incurring such wear or damage which would otherwise be borne by sleeve 2616 .
  • Sleeve 2616 may be secured to tubular members 2610 and 2628 by a heat shrink fit.
  • one or more portions of the first and second tubular members, 2610 and 2628 , and the tubular sleeve 2616 have one or more of the material properties of one or more of the tubular members 12 , 14 , 24 , 26 , 102 , 104 , 106 , 108 , 202 and/or 204 .
  • a first tubular member 2710 includes an internally threaded connection 2712 at an end portion 2714 .
  • a first end of a tubular sleeve 2716 includes an internal flange 2718 and a tapered portion 2720 .
  • a second end of the sleeve 2716 includes an internal flange 2721 and a tapered portion 2722 .
  • An externally threaded connection 2724 of an end portion 2726 of a second tubular member 2728 having an annular recess 2730 is then positioned within the tubular sleeve 2716 and threadably coupled to the internally threaded connection 2712 of the end portion 2714 of the first tubular member 2710 .
  • the internal flange 2718 of the sleeve 2716 mates with and is received within the annular recess 2730 .
  • the first tubular member 2710 includes a recess 2731 .
  • the internal flange 2721 mates with and is received within the annular recess 2731 .
  • the sleeve 2716 is coupled to and surrounds the external surfaces of the first and second tubular members 2710 and 2728 .
  • the internally threaded connection 2712 of the end portion 2714 of the first tubular member 2710 is a box connection
  • the externally threaded connection 2724 of the end portion 2726 of the second tubular member 2728 is a pin connection.
  • the internal diameter of the tubular sleeve 2716 is at least approximately 0.020′′ greater than the outside diameters of the first and second tubular members 2710 and 2728 . In this manner, during the threaded coupling of the first and second tubular members 2710 and 2728 , fluidic materials within the first and second tubular members may be vented from the tubular members.
  • first and second tubular members 2710 and 2728 , and the tubular sleeve 2716 may then be positioned within another structure 2732 such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device 2734 through and/or within the interiors of the first and second tubular members.
  • the tapered portions 2720 and 2722 , of the tubular sleeve 2716 facilitates the insertion and movement of the first and second tubular members within and through the structure 2732 , and the displacement of the expansion device 2734 through the interiors of the first and second tubular members 2710 and 2728 , may be from top to bottom or from bottom to top.
  • the tubular sleeve 2716 is also radially expanded and plastically deformed.
  • the tubular sleeve 2716 may be maintained in circumferential tension and the end portions 2714 and 2726 , of the first and second tubular members 2710 and 2728 , may be maintained in circumferential compression.
  • Sleeve 2716 has a variable thickness due to one or more reduced thickness portions 2790 and/or increased thickness portions 2792 .
  • Varying the thickness of sleeve 2716 provides the ability to control or induce stresses at selected positions along the length of sleeve 2716 and the end portions 2724 and 2726 .
  • Sleeve 2716 may be secured to tubular members 2710 and 2728 by a heat shrink fit.
  • one or more portions of the first and second tubular members, 2710 and 2728 , and the tubular sleeve 2716 have one or more of the material properties of one or more of the tubular members 12 , 14 , 24 , 26 , 102 , 104 , 106 , 108 , 202 and/or 204 .
  • the same result described above with reference to FIG. 27 may be achieved by adding a member 2740 which may be coiled onto the grooves 2739 formed in sleeve 2716 , thus varying the thickness along the length of sleeve 2716 .
  • a first tubular member 2910 includes an internally threaded connection 2912 and an internal annular recess 2914 at an end portion 2916 .
  • a first end of a tubular sleeve 2918 includes an internal flange 2920 , and a second end of the sleeve 2916 mates with and receives the end portion 2916 of the first tubular member 2910 .
  • An externally threaded connection 2922 of an end portion 2924 of a second tubular member 2926 having an annular recess 2928 is then positioned within the tubular sleeve 2918 and threadably coupled to the internally threaded connection 2912 of the end portion 2916 of the first tubular member 2910 .
  • the internal flange 2920 of the sleeve 2918 mates with and is received within the annular recess 2928 .
  • a sealing element 2930 is received within the internal annular recess 2914 of the end portion 2916 of the first tubular member 2910 .
  • the internally threaded connection 2912 of the end portion 2916 of the first tubular member 2910 is a box connection
  • the externally threaded connection 2922 of the end portion 2924 of the second tubular member 2926 is a pin connection.
  • the internal diameter of the tubular sleeve 2918 is at least approximately 0.020′′ greater than the outside diameters of the first tubular member 2910 . In this manner, during the threaded coupling of the first and second tubular members 2910 and 2926 , fluidic materials within the first and second tubular members may be vented from the tubular members.
  • the first and second tubular members 2910 and 2926 , and the tubular sleeve 2918 may be positioned within another structure such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device through and/or within the interiors of the first and second tubular members.
  • the tubular sleeve 2918 is also radially expanded and plastically deformed.
  • the tubular sleeve 2918 may be maintained in circumferential tension and the end portions 2916 and 2924 , of the first and second tubular members 2910 and 2926 , respectively, may be maintained in circumferential compression.
  • the sealing element 2930 seals the interface between the first and second tubular members.
  • a metal to metal seal is formed between at least one of: the first and second tubular members 2910 and 2926 , the first tubular member and the tubular sleeve 2918 , and/or the second tubular member and the tubular sleeve.
  • the metal to metal seal is both fluid tight and gas tight.
  • one or more portions of the first and second tubular members, 2910 and 2926 , the tubular sleeve 2918 , and the sealing element 2930 have one or more of the material properties of one or more of the tubular members 12 , 14 , 24 , 26 , 102 , 104 , 106 , 108 , 202 and/or 204 .
  • a first tubular member 3010 includes internally threaded connections 3012 a and 3012 b , spaced apart by a cylindrical internal surface 3014 , at an end portion 3016 .
  • Externally threaded connections 3018 a and 3018 b spaced apart by a cylindrical external surface 3020 , of an end portion 3022 of a second tubular member 3024 are threadably coupled to the internally threaded connections, 3012 a and 3012 b , respectively, of the end portion 3016 of the first tubular member 3010 .
  • a sealing element 3026 is received within an annulus defined between the internal cylindrical surface 3014 of the first tubular member 3010 and the external cylindrical surface 3020 of the second tubular member 3024 .
  • the internally threaded connections, 3012 a and 3012 b , of the end portion 3016 of the first tubular member 3010 are box connections, and the externally threaded connections, 3018 a and 3018 b , of the end portion 3022 of the second tubular member 3024 are pin connections.
  • the sealing element 3026 is an elastomeric and/or metallic sealing element.
  • the first and second tubular members 3010 and 3024 may be positioned within another structure such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device through and/or within the interiors of the first and second tubular members.
  • the sealing element 3026 seals the interface between the first and second tubular members.
  • a metal to metal seal is formed between at least one of the first and second tubular members 3010 and 3024 , the first tubular member and the sealing element 3026 , and/or the second tubular member and the sealing element.
  • the metal to metal seal is both fluid tight and gas tight.
  • the sealing element 3026 is omitted, and during and/or after the radial expansion and plastic deformation of the first and second tubular members 3010 and 3024 , a metal to metal seal is formed between the first and second tubular members.
  • one or more portions of the first and second tubular members, 3010 and 3024 , the sealing element 3026 have one or more of the material properties of one or more of the tubular members 12 , 14 , 24 , 26 , 102 , 104 , 106 , 108 , 202 and/or 204 .
  • a first tubular member 3030 includes internally threaded connections 3032 a and 3032 b , spaced apart by an undulating approximately cylindrical internal surface 3034 , at an end portion 3036 .
  • Externally threaded connections 3038 a and 3038 b spaced apart by a cylindrical external surface 3040 , of an end portion 3042 of a second tubular member 3044 are threadably coupled to the internally threaded connections, 3032 a and 3032 b , respectively, of the end portion 3036 of the first tubular member 3030 .
  • a sealing element 3046 is received within an annulus defined between the undulating approximately cylindrical internal surface 3034 of the first tubular member 3030 and the external cylindrical surface 3040 of the second tubular member 3044 .
  • the internally threaded connections, 3032 a and 3032 b , of the end portion 3036 of the first tubular member 3030 are box connections, and the externally threaded connections, 3038 a and 3038 b , of the end portion 3042 of the second tubular member 3044 are pin connections.
  • the sealing element 3046 is an elastomeric and/or metallic sealing element.
  • the first and second tubular members 3030 and 3044 may be positioned within another structure such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device through and/or within the interiors of the first and second tubular members.
  • the sealing element 3046 seals the interface between the first and second tubular members.
  • a metal to metal seal is formed between at least one of: the first and second tubular members 3030 and 3044 , the first tubular member and the sealing element 3046 , and/or the second tubular member and the sealing element.
  • the metal to metal seal is both fluid tight and gas tight.
  • the sealing element 3046 is omitted, and during and/or after the radial expansion and plastic deformation of the first and second tubular members 3030 and 3044 , a metal to metal seal is formed between the first and second tubular members.
  • one or more portions of the first and second tubular members, 3030 and 3044 , the sealing element 3046 have one or more of the material properties of one or more of the tubular members 12 , 14 , 24 , 26 , 102 , 104 , 106 , 108 , 202 and/or 204 .
  • a first tubular member 3050 includes internally threaded connections 3052 a and 3052 b , spaced apart by a cylindrical internal surface 3054 including one or more square grooves 3056 , at an end portion 3058 .
  • Externally threaded connections 3060 a and 3060 b spaced apart by a cylindrical external surface 3062 including one or more square grooves 3064 , of an end portion 3066 of a second tubular member 3068 are threadably coupled to the internally threaded connections, 3052 a and 3052 b , respectively, of the end portion 3058 of the first tubular member 3050 .
  • a sealing element 3070 is received within an annulus defined between the cylindrical internal surface 3054 of the first tubular member 3050 and the external cylindrical surface 3062 of the second tubular member 3068 .
  • the internally threaded connections, 3052 a and 3052 b , of the end portion 3058 of the first tubular member 3050 are box connections, and the externally threaded connections, 3060 a and 3060 b , of the end portion 3066 of the second tubular member 3068 are pin connections.
  • the sealing element 3070 is an elastomeric and/or metallic sealing element.
  • the first and second tubular members 3050 and 3068 may be positioned within another structure such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device through and/or within the interiors of the first and second tubular members.
  • the sealing element 3070 seals the interface between the first and second tubular members.
  • a metal to metal seal is formed between at least one of: the first and second tubular members, the first tubular member and the sealing element 3070 , and/or the second tubular member and the sealing element.
  • the metal to metal seal is both fluid tight and gas tight.
  • the sealing element 3070 is omitted, and during and/or after the radial expansion and plastic deformation of the first and second tubular members 950 and 968 , a metal to metal seal is formed between the first and second tubular members.
  • one or more portions of the first and second tubular members, 3050 and 3068 , the sealing element 3070 have one or more of the material properties of one or more of the tubular members 12 , 14 , 24 , 26 , 102 , 104 , 106 , 108 , 202 and/or 204 .
  • a first tubular member 3110 includes internally threaded connections, 3112 a and 3112 b , spaced apart by a non-threaded internal surface 3114 , at an end portion 3116 .
  • Externally threaded connections, 3118 a and 3118 b , spaced apart by a non-threaded external surface 3120 , of an end portion 3122 of a second tubular member 3124 are threadably coupled to the internally threaded connections, 3112 a and 3112 b , respectively, of the end portion 3122 of the first tubular member 3124 .
  • First, second, and/or third tubular sleeves, 3126 , 3128 , and 3130 are coupled the external surface of the first tubular member 3110 in opposing relation to the threaded connection formed by the internal and external threads, 3112 a and 3118 a , the interface between the non-threaded surfaces, 3114 and 3120 , and the threaded connection formed by the internal and external threads, 3112 b and 3118 b , respectively.
  • the internally threaded connections, 3112 a and 3112 b , of the end portion 3116 of the first tubular member 3110 are box connections, and the externally threaded connections, 3118 a and 3118 b , of the end portion 3122 of the second tubular member 3124 are pin connections.
  • the first and second tubular members 3110 and 3124 , and the tubular sleeves 3126 , 3128 , and/or 3130 may then be positioned within another structure 3132 such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device 3134 through and/or within the interiors of the first and second tubular members.
  • the tubular sleeves 3126 , 3128 and/or 3130 are also radially expanded and plastically deformed.
  • the tubular sleeves 3126 , 3128 , and/or 3130 are maintained in circumferential tension and the end portions 3116 and 3122 , of the first and second tubular members 3110 and 3124 , may be maintained in circumferential compression.
  • the sleeves 3126 , 3128 , and/or 3130 may, for example, be secured to the first tubular member 3110 by a heat shrink fit.
  • one or more portions of the first and second tubular members, 3110 and 3124 , and the sleeves, 3126 , 3128 , and 3130 have one or more of the material properties of one or more of the tubular members 12 , 14 , 24 , 26 , 102 , 104 , 106 , 108 , 202 and/or 204 .
  • a first tubular member 3210 includes an internally threaded connection 3212 at an end portion 3214 .
  • An externally threaded connection 3216 of an end portion 3218 of a second tubular member 3220 are threadably coupled to the internally threaded connection 3212 of the end portion 3214 of the first tubular member 3210 .
  • the internally threaded connection 3212 of the end portion 3214 of the first tubular member 3210 is a box connection
  • the externally threaded connection 3216 of the end portion 3218 of the second tubular member 3220 is a pin connection.
  • a tubular sleeve 3222 including internal flanges 3224 and 3226 is positioned proximate and surrounding the end portion 3214 of the first tubular member 3210 . As illustrated in FIG. 32 b , the tubular sleeve 3222 is then forced into engagement with the external surface of the end portion 3214 of the first tubular member 3210 in a conventional manner. As a result, the end portions, 3214 and 3218 , of the first and second tubular members, 3210 and 3220 , are upset in an undulating fashion.
  • the first and second tubular members 3210 and 3220 , and the tubular sleeve 3222 may then be positioned within another structure such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device through and/or within the interiors of the first and second tubular members.
  • the tubular sleeve 3222 is also radially expanded and plastically deformed.
  • the tubular sleeve 3222 is maintained in circumferential tension and the end portions 3214 and 3218 , of the first and second tubular members 3210 and 3220 , may be maintained in circumferential compression.
  • one or more portions of the first and second tubular members, 3210 and 3220 , and the sleeve 3222 have one or more of the material properties of one or more of the tubular members 12 , 14 , 24 , 26 , 102 , 104 , 106 , 108 , 202 and/or 204 .
  • a first tubular member 3310 includes an internally threaded connection 3312 and an annular projection 3314 at an end portion 3316 .
  • the end portion 3316 of the first tubular member 3310 abuts one side of the internal flange 3320 of the tubular sleeve 3318 and the annular projection 3314 of the end portion of the first tubular member mates with and is received within the annular recess 3324 of the internal flange of the tubular sleeve, and the internal diameter of the internal flange 3320 of the tubular sleeve 3318 is substantially equal to or greater than the maximum internal diameter of the internally threaded connection 3312 of the end portion 3316 of the first tubular member 3310 .
  • An externally threaded connection 3326 of an end portion 3328 of a second tubular member 3330 having an annular recess 3332 is then positioned within the tubular sleeve 3318 and threadably coupled to the internally threaded connection 3312 of the end portion 3316 of the first tubular member 3310 .
  • the internal flange 3332 of the tubular sleeve 3318 mates with and is received within the annular recess 3332 of the end portion 3328 of the second tubular member 3330 .
  • the tubular sleeve 3318 is coupled to and surrounds the external surfaces of the first and second tubular members, 3310 and 3328 .
  • the internally threaded connection 3312 of the end portion 3316 of the first tubular member 3310 is a box connection
  • the externally threaded connection 3326 of the end portion 3328 of the second tubular member 3330 is a pin connection.
  • the internal diameter of the tubular sleeve 3318 is at least approximately 0.020′′ greater than the outside diameters of the first and second tubular members, 3310 and 3330 . In this manner, during the threaded coupling of the first and second tubular members, 3310 and 3330 , fluidic materials within the first and second tubular members may be vented from the tubular members.
  • first and second tubular members, 3310 and 3330 , and the tubular sleeve 3318 may be positioned within another structure 3334 such as, for example, a cased or uncased wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating a conventional expansion device 3336 within and/or through the interiors of the first and second tubular members.
  • another structure 3334 such as, for example, a cased or uncased wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating a conventional expansion device 3336 within and/or through the interiors of the first and second tubular members.
  • the tapered portions, 3322 and 3326 , of the tubular sleeve 3318 facilitate the insertion and movement of the first and second tubular members within and through the structure 3334 , and the movement of the expansion device 3336 through the interiors of the first and second tubular members, 3310 and 3330 , may, for example, be from top to bottom or from bottom to top.
  • the tubular sleeve 3318 is also radially expanded and plastically deformed. As a result, the tubular sleeve 3318 may be maintained in circumferential tension and the end portions, 3316 and 3328 , of the first and second tubular members, 3310 and 3330 , may be maintained in circumferential compression.
  • Sleeve 3316 increases the axial compression loading of the connection between tubular members 3310 and 3330 before and after expansion by the expansion device 3336 .
  • Sleeve 3316 may be secured to tubular members 3310 and 3330 , for example, by a heat shrink fit.
  • first and second tubular members, 3310 and 3330 are radially expanded and plastically deformed using other conventional methods for radially expanding and plastically deforming tubular members such as, for example, internal pressurization, hydroforming, and/or roller expansion devices and/or any one or combination of the conventional commercially available expansion products and services available from Baker Hughes, Weatherford International, and/or Enventure Global Technology L.L.C.
  • tubular sleeve 3318 during (a) the coupling of the first tubular member 3310 to the second tubular member 3330 , (b) the placement of the first and second tubular members in the structure 3334 , and (c) the radial expansion and plastic deformation of the first and second tubular members provides a number of significant benefits.
  • the tubular sleeve 3318 protects the exterior surfaces of the end portions, 3316 and 3328 , of the first and second tubular members, 3310 and 3330 , during handling and insertion of the tubular members within the structure 3334 .
  • tubular sleeve 3318 provides an alignment guide that facilitates the insertion and threaded coupling of the second tubular member 3330 to the first tubular member 3310 . In this manner, misalignment that could result in damage to the threaded connections, 3312 and 3326 , of the first and second tubular members, 3310 and 3330 , may be avoided.
  • the tubular sleeve 3318 provides an indication of to what degree the first and second tubular members are threadably coupled. For example, if the tubular sleeve 3318 can be easily rotated, that would indicate that the first and second tubular members, 3310 and 3330 , are not fully threadably coupled and in intimate contact with the internal flange 3320 of the tubular sleeve. Furthermore, the tubular sleeve 3318 may prevent crack propagation during the radial expansion and plastic deformation of the first and second tubular members, 3310 and 3330 .
  • the tubular sleeve 3318 may provide a fluid tight metal-to-metal seal between interior surface of the tubular sleeve 3318 and the exterior surfaces of the end portions, 3316 and 3328 , of the first and second tubular members.
  • tubular sleeve 3318 may be maintained in circumferential tension and the end portions, 3316 and 3328 , of the first and second tubular members, 3310 and 3330 , may be maintained in circumferential compression, axial loads and/or torque loads may be transmitted through the tubular sleeve.
  • one or more portions of the first and second tubular members, 3310 and 3330 , and the sleeve 3318 have one or more of the material properties of one or more of the tubular members 12 , 14 , 24 , 26 , 102 , 104 , 106 , 108 , 202 and/or 204 .
  • a first tubular member 3410 includes an internally threaded connection 1312 and one or more external grooves 3414 at an end portion 3416 .
  • the end portion 3416 of the first tubular member 3410 abuts one side of the internal flange 3420 of the tubular sleeve 3418 , and the internal diameter of the internal flange 3420 of the tubular sleeve 3416 is substantially equal to or greater than the maximum internal diameter of the internally threaded connection 3412 of the end portion 3416 of the first tubular member 3410 .
  • An externally threaded connection 3428 of an end portion 3430 of a second tubular member 3432 that includes one or more internal grooves 3434 is then positioned within the tubular sleeve 3418 and threadably coupled to the internally threaded connection 3412 of the end portion 3416 of the first tubular member 3410 .
  • the internal flange 3420 of the tubular sleeve 3418 mates with and is received within an annular recess 3436 defined in the end portion 3430 of the second tubular member 3432 .
  • the tubular sleeve 3418 is coupled to and surrounds the external surfaces of the first and second tubular members, 3410 and 3432 .
  • the first and second tubular members, 3410 and 3432 , and the tubular sleeve 3418 may be positioned within another structure such as, for example, a cased or uncased wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating a conventional expansion device within and/or through the interiors of the first and second tubular members.
  • the tapered portions, 3422 and 3424 , of the tubular sleeve 3418 facilitate the insertion and movement of the first and second tubular members within and through the structure, and the movement of the expansion device through the interiors of the first and second tubular members, 3410 and 3432 , may be from top to bottom or from bottom to top.
  • the tubular sleeve 3418 is also radially expanded and plastically deformed. As a result, the tubular sleeve 3418 may be maintained in circumferential tension and the end portions, 3416 and 3430 , of the first and second tubular members, 3410 and 3432 , may be maintained in circumferential compression.
  • Sleeve 3416 increases the axial compression loading of the connection between tubular members 3410 and 3432 before and after expansion by the expansion device.
  • the sleeve 3418 may be secured to tubular members 3410 and 3432 , for example, by a heat shrink fit.
  • the grooves 3414 and/or 3434 and/or the openings 3426 provide stress concentrations that in turn apply added stress forces to the mating threads of the threaded connections, 3412 and 3428 .
  • the mating threads of the threaded connections, 3412 and 3428 are maintained in metal to metal contact thereby providing a fluid and gas tight connection.
  • the orientations of the grooves 3414 and/or 3434 and the openings 3426 are orthogonal to one another.
  • the grooves 3414 and/or 3434 are helical grooves.
  • first and second tubular members, 3410 and 3432 are radially expanded and plastically deformed using other conventional methods for radially expanding and plastically deforming tubular members such as, for example, internal pressurization, hydroforming, and/or roller expansion devices and/or any one or combination of the conventional commercially available expansion products and services available from Baker Hughes, Weatherford International, and/or Enventure Global Technology L.L.C.
  • tubular sleeve 3418 during (a) the coupling of the first tubular member 3410 to the second tubular member 3432 , (b) the placement of the first and second tubular members in the structure, and (c) the radial expansion and plastic deformation of the first and second tubular members provides a number of significant benefits.
  • the tubular sleeve 3418 protects the exterior surfaces of the end portions, 3416 and 3430 , of the first and second tubular members, 3410 and 3432 , during handling and insertion of the tubular members within the structure.
  • tubular sleeve 3418 provides an alignment guide that facilitates the insertion and threaded coupling of the second tubular member 3432 to the first tubular member 3410 . In this manner, misalignment that could result in damage to the threaded connections, 3412 and 3428 , of the first and second tubular members, 3410 and 3432 , may be avoided.
  • the tubular sleeve 3416 provides an indication of to what degree the first and second tubular members are threadably coupled. For example, if the tubular sleeve 3418 can be easily rotated, that would indicate that the first and second tubular members, 3410 and 3432 , are not fully threadably coupled and in intimate contact with the internal flange 3420 of the tubular sleeve. Furthermore, the tubular sleeve 3418 may prevent crack propagation during the radial expansion and plastic deformation of the first and second tubular members, 3410 and 3432 .
  • the tubular sleeve 3418 may provide a fluid and gas fight metal-to-metal seal between interior surface of the tubular sleeve 3418 and the exterior surfaces of the end portions, 3416 and 3430 , of the first and second tubular members.
  • tubular sleeve 3418 may be maintained in circumferential tension and the end portions, 3416 and 3430 , of the first and second tubular members, 3410 and 3432 , may be maintained in circumferential compression, axial loads and/or torque loads may be transmitted through the tubular sleeve.
  • the first and second tubular members described above with reference to FIGS. 1 to 34 c are radially expanded and plastically deformed using the expansion device in a conventional manner and/or using one or more of the methods and apparatus disclosed in one or more of the following:
  • the present application is related to the following: (1) U.S. patent application Ser. No. 09/454,139, attorney docket no. 25791.03.02, filed on Dec. 3, 1999, (2) U.S. patent application Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000, (3) U.S. patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000, (4) U.S.
  • an exemplary embodiment of an expandable tubular member 3500 includes a first tubular region 3502 and a second tubular portion 3504 .
  • the material properties of the first and second tubular regions, 3502 and 3504 are different.
  • the yield points of the first and second tubular regions, 3502 and 3504 are different.
  • the yield point of the first tubular region 3502 is less than the yield point of the second tubular region 3504 .
  • one or more of the expandable tubular members, 12 , 14 , 24 , 26 , 102 , 104 , 106 , 108 , 202 and/or 204 incorporate the tubular member 3500 .
  • the yield point within the first and second tubular regions, 3502 a and 3502 b , of the expandable tubular member 3502 vary as a function of the radial position within the expandable tubular member.
  • the yield point increases as a function of the radial position within the expandable tubular member 3502 .
  • the relationship between the yield point and the radial position within the expandable tubular member 3502 is a linear relationship.
  • the relationship between the yield point and the radial position within the expandable tubular member 3502 is a non-linear relationship.
  • the yield point increases at different rates within the first and second tubular regions, 3502 a and 3502 b , as a function of the radial position within the expandable tubular member 3502 .
  • the functional relationship, and value, of the yield points within the first and second tubular regions, 3502 a and 3502 b , of the expandable tubular member 3502 are modified by the radial expansion and plastic deformation of the expandable tubular member.
  • one or more of the expandable tubular members, 12 , 14 , 24 , 26 , 102 , 104 , 106 , 108 , 202 , 204 and/or 3502 prior to a radial expansion and plastic deformation, include a microstructure that is a combination of a hard phase, such as martensite, a soft phase, such as ferrite, and a transitionary phase, such as retained austentite.
  • the hard phase provides high strength
  • the soft phase provides ductility
  • the transitionary phase transitions to a hard phase, such as martensite, during a radial expansion and plastic deformation.
  • the yield point of the tubular member increases as a result of the radial expansion and plastic deformation. Further, in this manner, the tubular member is ductile, prior to the radial expansion and plastic deformation, thereby facilitating the radial expansion and plastic deformation.
  • the composition of a dual-phase expandable tubular member includes (weight percentages): about 0.1% C, 1.2% Mn, and 0.3% Si.
  • one or more of the expandable tubular members, 12 , 14 , 24 , 26 , 102 , 104 , 106 , 108 , 202 , 204 and/or 3502 are processed in accordance with a method 3600 , in which, in step 3602 , an expandable tubular member 3602 a is provided that is a steel alloy having following material composition (by weight percentage): 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, 0.02% Cr, 0.05% V, 0.01% Mo, 0.01% Nb, and 0.01% Ti.
  • the expandable tubular member 3602 a provided in step 3602 has a yield strength of 45 ksi, and a tensile strength of 69 ksi.
  • the expandable tubular member 3602 a includes a microstructure that includes martensite, pearlite, and V, Ni, and/or Ti carbides.
  • the expandable tubular member 3602 a is then heated at a temperature of 790° C. for about 10 minutes in step 3604 .
  • the expandable tubular member 3602 a is then quenched in water in step 3606 .
  • the expandable tubular member 3602 a includes a microstructure that includes new ferrite, grain pearlite, martensite, and ferrite.
  • the expandable tubular member 3602 a has a yield strength of 67 ksi, and a tensile strength of 95 ksi.
  • the expandable tubular member 3602 a is then radially expanded and plastically deformed using one or more of the methods and apparatus described above.
  • the yield strength of the expandable tubular member is about 95 ksi.
  • one or more of the expandable tubular members, 12 , 14 , 24 , 26 , 102 , 104 , 106 , 108 , 202 , 204 and/or 3502 are processed in accordance with a method 3700 , in which, in step 3702 , an expandable tubular member 3702 a is provided that is a steel alloy having following material composition (by weight percentage): 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, 0.03% Cr, 0.04% V, 0.01% Mo, 0.03% Nb, and 0.01% Ti.
  • the expandable tubular member 3702 a provided in step 3702 has a yield strength of 60 ksi, and a tensile strength of 80 ksi.
  • the expandable tubular member 3702 a includes a microstructure that includes pearlite and pearlite striation.
  • the expandable tubular member 3702 a is then heated at a temperature of 790° C. for about 10 minutes in step 3704 .
  • the expandable tubular member 3702 a is then quenched in water in step 3706 .
  • the expandable tubular member 3702 a includes a microstructure that includes ferrite, martensite, and bainite.
  • the expandable tubular member 3702 a has a yield strength of 82 ksi, and a tensile strength of 130 ksi.
  • the expandable tubular member 3702 a is then radially expanded and plastically deformed using one or more of the methods and apparatus described above.
  • the yield strength of the expandable tubular member is about 130 ksi.
  • one or more of the expandable tubular members, 12 , 14 , 24 , 26 , 102 , 104 , 106 , 108 , 202 , 204 and/or 3502 are processed in accordance with a method 3800 , in which, in step 3802 , an expandable tubular member 3802 a is provided that is a steel alloy having following material composition (by weight percentage): 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.06% Cu, 0.05% Ni, 0.05% Cr, 0.03% V, 0.03% Mo, 0.01% Nb, and 0.01% Ti.
  • the expandable tubular member 3802 a provided in step 3802 has a yield strength of 56 ksi, and a tensile strength of 75 ksi.
  • the expandable tubular member 3802 a includes a microstructure that includes grain pearlite, widmanstatten martensite and carbides of V, Ni, and/or Ti.
  • the expandable tubular member 3802 a is then heated at a temperature of 790° C. for about 10 minutes in step 3804 .
  • the expandable tubular member 3802 a is then quenched in water in step 3806 .
  • the expandable tubular member 3802 a includes a microstructure that includes bainite, pearlite, and new ferrite. In an exemplary experimental embodiment, following the completion of step 3806 , the expandable tubular member 3802 a has a yield strength of 60 ksi, and a tensile strength of 97 ksi.
  • the expandable tubular member 3802 a is then radially expanded and plastically deformed using one or more of the methods and apparatus described above.
  • the yield strength of the expandable tubular member is about 97 ksi.
  • a method 3900 for increasing the collapse strength of a tubular assembly begins with step 3902 in which an expandable tubular member 3902 a is provided.
  • the expandable tubular member 3902 a includes an inner surface 3902 b having an inner diameter D 1 , an outer surface 3902 c having an outer diameter D 2 , and a wall thickness 3902 d .
  • expandable tubular member 3902 a may be, for example, the tubular member 12 , 14 , 24 , 26 , 102 , 108 , 202 , 204 , 2210 , 2228 , 2310 , 2328 , 2410 , 2428 , 2510 , 2528 , 2610 , 2628 , 2710 , 2728 , 2910 , 2926 , 3010 , 3024 , 3030 , 3044 , 3050 , 3068 , 3110 , 3124 , 3210 , 3220 , 3310 , 3330 , 3410 , 3432 , or 3500 .
  • the expandable tubular member 3902 a may be, for example, the tubular assembly 10 , 22 , 100 , or 200 .
  • the method 3900 continues at step 3904 in which the expandable tubular member 3902 a is coated with a layer 3904 a of material.
  • the layer 3904 a of material includes a plastic such as, for example, a PVC plastic 3904 aa as illustrated in FIG. 41 c , and/or a soft metal such as, for example, aluminum 3904 ab as illustrated in FIG. 41 d , an aluminum/zinc combination, or equivalent metals known in the art, and/or a composite material such as, for example, a carbon fiber material, and substantially covers the outer surface 3902 c of expandable tubular member 3902 a .
  • the layer 3904 a of material is applied using conventional methods such as, for example, spray coating, vapor deposition, adhering layers of material to the surface, or a variety of other methods known in the art.
  • the method 3900 continues at step 3906 in which the expandable tubular member 3902 a is positioned within a passage 3906 a defined by a preexisting structure 3906 b which includes an inner surface 3906 c , an outer surface 3906 d , and a wall thickness 3906 e .
  • the preexisting structure 3906 b may be, for example, the wellbores 16 , 110 , or 206 .
  • the preexisting structure 3906 b may be, for example, the tubular member 12 , 14 , 24 , 26 , 102 , 108 , 202 , 204 , 2210 , 2228 , 2310 , 2328 , 2410 , 2428 , 2510 , 2528 , 2610 , 2628 , 2710 , 2728 , 2910 , 2926 , 3010 , 3024 , 3030 , 3044 , 3050 , 3068 , 3110 , 3124 , 3210 , 3220 , 3310 , 3330 , 3410 , 3432 , or 3500 .
  • preexisting structure 3906 b may be, for example, the tubular assembly 10 , 22 , 100 , or 200 .
  • the cross sections of expandable tubular member 3902 a and preexisting structure 3906 b are substantially concentric when the expandable tubular member 3902 a is positioned in the passage 3906 a defined by preexisting structure 3906 b.
  • step 3908 the method continues at step 3908 in which the expandable tubular member 3902 a is radially expanded and plastically deformed.
  • a force F is applied radially towards the inner surface 3902 b of expandable tubular member 3902 a , the force F being sufficient to radially expand and plastically deform the expandable tubular member 3902 a and the accompanying layer 3904 a on its outer surface 3902 c .
  • the force F increases the inner diameter D 1 and the outer diameter D 2 of expandable tubular member 3902 a until the layer 3904 a engages the inner surface 3906 c of preexisting structure 3906 b and forms an interstitial layer between the expandable tubular member 3902 a and the preexisting structure 3906 b .
  • the expandable tubular member 3902 a is radially expanded and plastically deformed using one or more conventional commercially available devices and/or using one or more of the methods disclosed in the present application.
  • the layer 3904 a forms an interstitial layer filling some or all of the annulus between the expandable tubular member 3902 a and the preexisting structure 3906 b .
  • the interstitial layer formed from the layer 3904 a between the expandable tubular member 3902 a and the preexisting structure 3906 b results in the combination of expandable tubular member 3902 a , the layer 3904 a , and the preexisting structure 3906 b exhibiting a higher collapse strength than would be exhibited without the interstitial layer.
  • the radial expansion and plastic deformation of expandable tubular member 3902 a with layer 3904 a into engagement with preexisting structure 3906 b results in a modification of the residual stresses in one or both of the expandable tubular member 3902 a and the preexisting structure 3906 b .
  • the radial expansion and plastic deformation of expandable tubular member 3902 a with layer 3904 a into engagement with preexisting structure 3906 b places at least a portion of the wall thickness of preexisting structure 3906 b in circumferential tension.
  • a method 4000 for increasing the collapse strength of a tubular assembly begins with step 4002 in which a preexisting structure 4002 a is provided.
  • the preexisting structure 4002 a defines a substantially cylindrical passage 4002 b and includes an inner surface 4002 c .
  • the preexisting structure 4002 a may be, for example, the wellbores 16 , 110 , or 206 .
  • the preexisting structure 4002 a may be, for example, the tubular member 12 , 14 , 24 , 26 , 102 , 108 , 202 , 204 , 2210 , 2228 , 2310 , 2328 , 2410 , 2428 , 2510 , 2528 , 2610 , 2628 , 2710 , 2728 , 2910 , 2926 , 3010 , 3024 , 3030 , 3044 , 3050 , 3068 , 3110 , 3124 , 3210 , 3220 , 3310 , 3330 , 3410 , 3432 , or 3500 .
  • the preexisting structure 4002 a may be, for example, the tubular assembly 10 , 22 , 100 , or 200 .
  • the method 4000 continues at step 4004 in which the inner surface 4002 c in passage 4002 b of preexisting structure 4002 a is coated with a layer 4004 a of material.
  • the layer 3904 a of material includes a plastic, and/or a soft metal such as, for example, aluminum, aluminum and zinc, or equivalent metals known in the art, and/or a composite material such as, for example, carbon fiber, and substantially covers the inner surface 4002 c of preexisting structure 4002 a .
  • the layer 3904 a of material is applied using conventional methods such as, for example, spray coating, vapor deposition, adhering layers of material to the surface, or a variety of other methods known in the art.
  • step 4006 in which expandable tubular member 3902 a including inner surface 3902 b , outer surface 3902 c , and wall thickness 3902 d , is positioned within passage 4002 b defined by preexisting structure 4002 a .
  • the cross sections of expandable tubular member 3902 a and preexisting structure 4002 a are substantially concentric when the expandable tubular member 3902 a is positioned in the passage 4002 b defined by preexisting structure 4002 a.
  • the method 4000 continues at step 4008 in which the expandable tubular member 3902 a is radially expanded and plastically deformed.
  • a force F is applied radially towards the inner surface 3902 b of expandable tubular member 3902 a , the force F being sufficient to radially expand and plastically deform the expandable tubular member 3902 a .
  • the force F increases the inner diameter D 1 and the outer diameter D 2 of expandable tubular member 3902 a until the outer surface 3902 c of expandable tubular member 3902 a engages layer 4004 a on preexisting structure 4002 a and forms an interstitial layer between the expandable tubular member 3902 a and the preexisting structure 4002 a .
  • the expandable tubular member 3902 a is radially expanded and plastically deformed using one or more conventional commercially available devices and/or using one or more of the methods disclosed in the present application.
  • the layer 4004 a forms an interstitial layer filling some or all of the annulus between the expandable tubular member 3902 a and the preexisting structure 4002 a .
  • the interstitial layer formed from the layer 4004 a between the expandable tubular member 3902 a and the preexisting structure 4002 a results in the combination of the expandable tubular member 3902 a , the layer 3904 a , and the preexisting structure 4002 a exhibiting a higher collapse strength than would be exhibited without the interstitial layer.
  • the radial expansion and plastic deformation of expandable tubular member 3902 a into engagement with preexisting structure 4002 a with layer 4004 a results in a modification of the residual stresses in one or both of the expandable tubular member 3902 a and the preexisting structure 4002 a .
  • the radial expansion and plastic deformation of expandable tubular member 3902 a with layer 4004 a into engagement with preexisting structure 4002 a places at least a portion of the wall thickness of the preexisting structure 4002 a in circumferential tension.
  • step 3904 of method 3900 may include coating multiple layers of material such as, for example, layers 3904 a and 4100 , on tubular member 3902 a , illustrated in FIG. 40 .
  • the layers 3904 a and/or 4100 may be applied using conventional methods such as, for example, spray coating, vapor deposition, adhering layers of material to the surface, or a variety of other methods known in the art.
  • step 4004 of method 4000 may include coating multiple layers of material such as, for example, layers 4002 c and 4200 , on tubular member 4002 a .
  • the layers 4002 c and 4200 may be applied using conventional methods such as, for example, spray coating, vapor deposition, adhering layers of material to the surface, or a variety of other methods known in the art.
  • steps 3904 of method 3900 and step 4004 of method 4000 may include coating the expandable tubular member 3902 a with a layer 3904 a of varying thickness.
  • step 3904 of method 3900 may include coating the expandable tubular member 3902 a with a non uniform layer 3904 a which, for example, may include exposing portions of the outer surface 3902 c of expandable tubular member 3902 a .
  • step 4004 of method 4000 may include coating the preexisting structure 4002 a with a non uniform layer 4004 a which, for example, may include exposing portions of the inner surface 4002 c of preexisting structure 4002 a.
  • step 3904 of method 3900 may be accomplished by laying a material 4300 around an expandable tubular member 4302 , which may be the expandable tubular member 3902 a in FIG. 40 .
  • step 4004 of method 4000 may be accomplished by using the material 4300 to line the inner surface of the preexisting structure such as, for example, the inner surface 4002 c of preexisting structure 4002 a .
  • the material 4300 may be a plastic, and/or a metal such as, for example, aluminum, aluminum/zinc, or other equivalent metals known in the art, and/or a composite material such as, for example, carbon fiber.
  • the material 4300 may include a wire that is wound around the expandable tubular member 4302 or lined on the inner surface 4002 c of preexisting structure 4002 a .
  • the material 4300 may include a plurality of rings place around the expandable tubular member 4302 or lined on the inner surface 4002 c of preexisting structure 4002 a .
  • the material 4300 may be a plurality of discrete components placed on the expandable tubular member 4302 or lined on the inner surface 4002 c or preexisting structure 4002 a.
  • EXP 1 of method 3900 a plurality of tubular members 3902 a were provided, as per step 3902 of method 3900 , which had a 75 ⁇ 8 inch diameter.
  • Each tubular member 3902 a was coated, as per step 3904 of method 3900 , with a layer 3904 a .
  • the tubular member 3902 a was then radially expanded and plastically deformed and the energy necessary to radially expand and plastically deform it such as, for example, the operating pressure required to radially expand and plastically deform the tubular member 3902 a , was recorded.
  • the layer 3904 a was aluminum, requiring a maximum operating pressure of approximately 3900 psi to radially expand and plastically deform the tubular member 3902 a .
  • the layer 3904 a was aluminum/zinc, requiring a maximum operating pressure of approximately 3700 psi to radially expand and plastically deform the tubular member 3902 a .
  • the layer 3904 a was PVC plastic, requiring a maximum operating pressure of approximately 3600 psi to radially expand and plastically deform the tubular member 3902 a .
  • the layer 3904 a was omitted resulting in an air gap, and requiring a maximum operating pressure of approximately 3400 psi to radially expand and plastically deform the tubular member 3902 a.
  • a plurality of expandable tubular members 3902 a were provided, as per step 3902 of method 3900 .
  • Each tubular member 3902 a was coated, as per step 3904 of method 3900 , with a layer 3904 a .
  • Each tubular member 3902 a was then positioned within a preexisting structure 3906 b as per step 3906 of method 3900 .
  • Each tubular member 3902 a was then radially expanded and plastically deformed 13.3% and the thickness of layer 3904 a between the tubular member 3902 a and the preexisting structure 3906 b was measured.
  • the layer 3904 a was aluminum and had a thickness between approximately 0.05 inches and 0.15 inches.
  • the layer 3904 a was aluminum/zinc and had a thickness between approximately 0.07 inches and 0.13 inches.
  • the layer 3904 a was PVC plastic and had a thickness between approximately 0.06 inches and 0.14 inches.
  • the layer 3904 a was omitted which resulted in an air gap between the tubular member 3902 a and the preexisting structure 3906 b between approximately 0.02 and 0.04 inches.
  • a plurality of expandable tubular members 3902 a were provided, as per step 3902 of method 3900 .
  • Each tubular member 3902 a was coated, as per step 3904 of method 3900 , with a layer 3904 a .
  • Each tubular member 3902 a was then positioned within a preexisting structure 3906 b as per step 3906 of method 3900 .
  • Each tubular member 3902 a was then radially expanded and plastically deformed in a preexisting structure 3906 b and the thickness of layer 3904 a between the tubular member 3902 a and the preexisting structure 3906 b was measured.
  • the layer 3904 a was plastic with a thickness between approximately 1.6 mm and 2.5 mm.
  • the layer 3904 a was aluminum with a thickness between approximately 2.6 mm and 3.1 mm.
  • the layer 3904 a was aluminum/zinc with a thickness between approximately 1.9 mm and 2.5 mm.
  • the layer 3904 a was omitted, resulting in an air gap between the tubular member 3902 a and the preexisting structure 3906 b between approximately 1.1 mm and 1.7 mm.
  • 55 b illustrates the distribution of the gap thickness between the tubular member and the preexisting structure for EXP 3A , EXP 3B , EXP 3C , and EXP 3D , illustrating that combinations with an layer between the tubular member 3902 a and the preexisting structure 3906 b exhibit a more uniform gap distribution.
  • a plurality of expandable tubular members 3902 a were provided, as per step 3902 of method 3900 .
  • Each tubular member 3902 a was coated, as per step 3904 of method 3900 , with a layer 3904 a .
  • Each tubular member 3902 a was then positioned within a preexisting structure 3906 b as per step 3906 of method 3900 .
  • Each tubular member 3902 a was then radially expanded and plastically deformed in a preexisting structure 3906 b , and conventional collapse testing was performed on the tubular assembly comprised of the tubular member 3902 a , layer 3904 a and preexisting structure 3906 b combination.
  • the preexisting structure 3906 b was composed of a P-110 Grade pipe with an inner diameter of approximately 95 ⁇ 8 inches.
  • the expandable tubular member 3902 a was composed of an LSX-80 Grade pipe with an inner diameter of approximately 75 ⁇ 8 inches.
  • the tubular member assemblies exhibited the following collapse strengths: Collapse Layer Strength EXP 4 3904a (psi) Remarks EXP 4A plastic 14230 This was an unexpected result.
  • EXP 4B aluminum/zinc 20500 This was an unexpected result.
  • EXP 4C air 14190 This was an unexpected result.
  • EXP 4D aluminum 20730 This was an unexpected result.
  • EXP 4A , EXP 4B , EXP 4C , and EXP 4D illustrate that using a soft metal such as, for example aluminum and or aluminum/zinc, as layer 3904 a in method 3900 increases the collapse strength of the tubular assembly comprising the expandable tubular member 3902 a , layer 3904 a , and preexisting structure 3906 b by approximately 50% when compared to using a layer 3904 a of plastic or omitting the layer 3904 a . This was an unexpected result.
  • a soft metal such as, for example aluminum and or aluminum/zinc
  • an expandable tubular member 3902 a was provided, as per step 3902 of method 3900 .
  • the coating of step 3904 with a layer 3904 a was omitted.
  • the tubular member 3902 a was then positioned within a preexisting structure 3906 b as per step 3906 of method 3900 .
  • the tubular member 3902 a was then radially expanded and plastically deformed in a preexisting structure 3906 b , resulting in an air gap between the tubular member 3902 a and the preexisting structure.
  • P ci is the collapse resistance of an inner casing such as, for example, the tubular member 12 , 14 , 24 , 26 , 102 , 108 , 202 , 204 , 2210 , 2228 , 2310 , 2328 , 2410 , 2428 , 2510 , 2528 , 2610 , 2628 , 2710 , 2728 , 2910 , 2926 , 3010 , 3024 , 3030 , 3044 , 3050 , 3068 , 3110 , 3124 , 3210 , 3220 , 3310 , 3330 , 3410 , 3432 , 3500 , or 3902 a , or the tubular assembly 10 , 22 , 100 , or 200 .
  • K is a reinforcement factor provided by a coating such as, for example, the coating 3904 a or 4004 a . In an exemplary embodiment, the reinforcement factor K increases as the strength of the material used for the coating increases.
  • EXP 6 of method 3900 as illustrated in FIGS. 58 a , 58 b , a computer simulation was run for an expandable tubular member 3902 a provided, as per step 3902 of method 3900 , positioned within a preexisting structure 3906 b , as per step 3906 of method 3900 , and radially expanded and plastically deformed in the preexisting structure 3906 b .
  • the coating of step 3904 with a layer 3904 a was omitted.
  • the radial expansion and plastic deformation of expandable tubular member 3902 a resulted in an air gap distribution between the expanded tubular member 3902 a and the preexisting structure 3906 b , illustrated in FIG. 58 b .
  • the tubular member 3902 a was a LSX-80 Grade pipe with a 75 ⁇ 8 inch inner diameter and the preexisting structure 3906 b was a P110 Grade pipe with a 95 ⁇ 8 inch inner diameter.
  • the tubular member 3902 a was radially expanded and plastically deformed 13.3% from its original diameter. After expansion, the maximum air gap was approximately 2 mm.
  • the expandable tubular member 3902 a and preexisting structure 3906 b combination exhibited a collapse strength of approximately 13200 psi. This was an unexpected result.
  • EXP 7 of method 3900 as illustrated in FIGS. 58 , a computer simulation was run for an expandable tubular members 3902 a provided, as per step 3902 of method 3900 , positioned within a preexisting structure 3906 b , as per step 3906 of method 3900 , and radially expanded and plastically deformed in the preexisting structure 3906 b .
  • the coating of step 3904 with a layer 3904 a was omitted.
  • the radial expansion and plastic deformation of expandable tubular member 3902 a resulted in an air gap distribution between the expanded tubular member 3902 a and the preexisting structure 3906 b , illustrated.
  • the tubular member 3902 a was a LSX-80 Grade pipe with a 75 ⁇ 8 inch inner diameter and the preexisting structure 3906 b was a P110 Grade pipe with a 95 ⁇ 8 inch inner diameter.
  • the tubular member 3902 a was radially expanded and plastically deformed 14.9% from its original diameter. After expansion, the maximum air gap was approximately 1.55 mm.
  • the expandable tubular member 3902 a and preexisting structure 3906 b combination exhibited a collapse strength of approximately 13050 psi. This was an unexpected result.
  • EXP 8 of method 3900 as illustrated in FIG. 59 , a computer simulation was run for an expandable tubular member 3902 a provided, as per step 3902 of method 3900 , coated with a layer 3904 a of soft metal, as per step 3904 of method 3900 , positioned within a preexisting structure 3906 b as per step 3906 of method 3900 , and radially expanded and plastically deformed in a preexisting structure 3906 b .
  • the tubular member 3902 a was a LSX-80 Grade pipe with a 75 ⁇ 8 inch inner diameter and the preexisting structure 3906 b was a P110 Grade pipe with a 95 ⁇ 8 inch inner diameter.
  • the soft metal distribution between the tubular member 3902 a and the preexisting structure 3906 b included aluminum. In an exemplary embodiment, the soft metal distribution between the tubular member 3902 a and the preexisting structure 3906 b included aluminum and zinc.
  • the tubular member 3906 was radially expanded and plastically deformed 13.3% from its original diameter. After expansion, the soft metal layer 3904 a included a maximum thickness of approximately 2 mm.
  • the expandable tubular member 3902 a , preexisting structure 3906 b , and soft metal layer 3904 a combination exhibited a collapse strength of greater than 20000 psi. This was an unexpected result.
  • an expandable tubular member 3902 a was provided, as per step 3902 of method 3900 .
  • the expandable tubular member 3902 a was then positioned within a preexisting structure 3906 b , as per step 3906 of method 3900 .
  • the coating of step 3904 with a layer 3904 a was omitted.
  • the expandable tubular member 3902 a was then radially expanded and plastically deformed in the preexisting structure 3906 b , resulting in an air gap distribution between the expandable tubular member 3902 a and the preexisting structure 3906 b , which was then measured.
  • a minimum air gap of approximately 1.2 mm and a maximum air gap of approximately 3.7 mm were exhibited.
  • an expandable tubular member 3902 a was provided, as per step 3902 of method 3900 .
  • the expandable tubular member 3902 a was then coated with a layer 3904 a of soft metal, as per step 3904 of method 3900 .
  • the expandable tubular member 3902 a was then positioned within a preexisting structure 3906 b , as per step 3906 of method 3900 .
  • the expandable tubular member 3902 a was then radially expanded and plastically deformed in the preexisting structure 3906 b and the soft metal layer 3904 a between the expandable tubular member 3902 a and the preexisting structure 3906 b was measured.
  • a minimum soft metal layer 3904 a thickness of approximately 3.2 mm and a maximum soft metal layer 3904 a thickness 5202 b of approximately 3.7 mm were exhibited.
  • an expandable tubular member 3902 a was provided, as per step 3902 of method 3900 .
  • the expandable tubular member 3902 a was then coated with a layer 3904 a of plastic, as per step 3904 of method 3900 .
  • the expandable tubular member 3902 a was then positioned within a preexisting structure 3906 b , as per step 3906 of method 3900 .
  • the expandable tubular member 3902 a was then radially expanded and plastically deformed in the preexisting structure 3906 b and the plastic layer 3904 a between the expandable tubular member 3902 a and the preexisting structure 3906 b was measured.
  • a minimum plastic layer 3904 a thickness 5204 a of approximately 1.7 mm and a maximum plastic layer 3904 a thickness 5204 b of approximately 2.5 mm were exhibited.
  • an expandable tubular member 3902 a was provided, as per step 3902 of method 3900 .
  • the expandable tubular member 3902 a was then positioned within a preexisting structure 3906 b , as per step 3906 of method 3900 .
  • the coating of step 3904 with a layer 3904 a was omitted.
  • the expandable tubular member 3902 a was then radially expanded and plastically deformed in the preexisting structure, resulting in an air gap between the expandable tubular member 3902 a and the preexisting structure 3906 b .
  • the wall thickness of the expandable tubular member 3902 a was then measured. A minimum wall thickness for the expandable tubular member 3902 a of approximately 8.6 mm and a maximum wall for the expandable tubular member 3902 a of approximately 9.5 mm were exhibited.
  • an expandable tubular member 3902 a was provided, as per step 3902 of method 3900 .
  • the expandable tubular member 3902 a was then coated with a layer 3904 a of plastic, as per step 3904 of method 3900 .
  • the expandable tubular member 3902 a was then positioned within a preexisting structure 3906 b , as per step 3906 of method 3900 .
  • the expandable tubular member 3902 a was then radially expanded and plastically deformed in the preexisting structure 3906 b .
  • the wall thickness of the expandable tubular member 3902 a was then measured. A minimum wall thickness for the expandable tubular member 3902 a of approximately 9.1 mm and a maximum wall thickness for the expandable tubular member 3902 a of approximately 9.6 mm were exhibited.
  • an expandable tubular member 3902 a was provided, as per step 3902 of method 3900 .
  • the expandable tubular member 3902 a was then coated with a layer 3904 a of soft metal, as per step 3904 of method 3900 .
  • the expandable tubular member 3902 a was then positioned within a preexisting structure 3906 b , as per step 3906 of method 3900 .
  • the expandable tubular member 3902 a was then radially expanded and plastically deformed in the preexisting structure 3906 b .
  • the wall thickness of the expandable tubular member 3902 a was then measured. A minimum wall thickness for the expandable tubular member 3902 a of approximately 9.3 mm and a maximum wall thickness for the expandable tubular member 3902 a of approximately 9.6 mm were exhibited.
  • an expandable tubular member 3902 a was provided, as per step 3902 of method 3900 .
  • the expandable tubular member 3902 a was then positioned within a preexisting structure 3906 b , as per step 3906 of method 3900 .
  • the coating of step 3904 with a layer 3904 a was omitted.
  • the expandable tubular member 3902 a was then radially expanded and plastically deformed in the preexisting structure, resulting in an air gap between the expandable tubular member 3902 a and the preexisting structure 3906 b .
  • the wall thickness of the preexisting structure 3906 b was then measured. A minimum wall thickness for the preexisting structure 3906 b of approximately 13.5 mm and a maximum wall thickness for the preexisting structure 3906 b of approximately 14.6 mm were exhibited.
  • an expandable tubular member 3902 a was provided, as per step 3902 of method 3900 .
  • the expandable tubular member 3902 a was then coated with a layer 3904 a of soft metal, as per step 3904 of method 3900 .
  • the expandable tubular member 3902 a was then positioned within a preexisting structure 3906 b , as per step 3906 of method 3900 .
  • the expandable tubular member 3902 a was then radially expanded and plastically deformed in the preexisting structure 3906 b .
  • the wall thickness of the preexisting structure 3906 b was then measured. A minimum wall thickness for the preexisting structure 3906 b of approximately 13.5 mm and a maximum wall thickness for the preexisting structure 3906 b of approximately 14.3 mm were exhibited.
  • an expandable tubular member 3902 a was provided, as per step 3902 of method 3900 .
  • the expandable tubular member 3902 a was then coated with a layer 3904 a of plastic, as per step 3904 of method 3900 .
  • the expandable tubular member 3902 a was then positioned within a preexisting structure 3906 b , as per step 3906 of method 3900 .
  • the expandable tubular member 3902 a was then radially expanded and plastically deformed in the preexisting structure 3906 b .
  • the wall thickness of the preexisting structure 3906 b was then measured. A minimum wall thickness for the preexisting structure 3906 b of approximately 13.5 mm and a maximum wall thickness for the preexisting structure 3906 b of approximately 14.6 mm were exhibited.
  • an expandable tubular member 3902 a was provided, as per step 3902 of method 3900 .
  • the expandable tubular member 3902 a was then coated with a layer 3904 a , as per step 3904 of method 3900 .
  • the expandable tubular member 3902 a was then positioned within a preexisting structure 3906 b , as per step 3906 of method 3900 .
  • the expandable tubular member 3902 a was then radially expanded and plastically deformed in the preexisting structure 3906 b .
  • the expandable tubular member 3902 a was radially expanded and plastically deformed 13.3% from its original inner diameter against the preexisting structure 3906 b .
  • the expandable tubular member 3902 a was an LSX-80 Grade pipe with a 75 ⁇ 8 inch inner diameter and the preexisting structure 3906 b was a P110 Grade pipe with a 95 ⁇ 8 inch inner diameter.
  • the collapse strength of the expandable tubular member 3902 a with layer 3904 a and preexisting structure 3906 b was measured at approximately 6300 psi. This was an unexpected result.
  • an expandable tubular member 3902 a was provided, as per step 3902 of method 3900 .
  • the expandable tubular member 3902 a was then coated with a layer 3904 a , as per step 3904 of method 3900 .
  • the expandable tubular member 3902 a was then positioned within a preexisting structure 3906 b , as per step 3906 of method 3900 .
  • the expandable tubular member 3902 a was then radially expanded and plastically deformed in the preexisting structure 3906 b , an expandable tubular member 3902 a was provided, as per step 3902 of method 3900 .
  • the expandable tubular member 3902 a was then coated with a layer 3904 a , as per step 3904 of method 3900 .
  • the expandable tubular member 3902 a was then positioned within a preexisting structure 3906 b , as per step 3906 of method 3900 .
  • the expandable tubular member 3902 a was then radially expanded and plastically deformed in the preexisting structure 3906 b , expanding the preexisting structure 3096 b by approximately 1 mm.
  • an expandable tubular member which had a collapse strength of approximately 70 ksi and included, by weight percent, 0.07% Carbon, 1.64% Manganese, 0.011% Phosphor, 0.001% Sulfur, 0.23% Silicon, 0.5% Nickel, 0.51% Chrome, 0.31% Molybdenum, 0.15% Copper, 0.021% Aluminum, 0.04% Vanadium, 0.03% Niobium, and 0.007% Titanium.
  • the collapse strength of the expandable tubular member increased to approximately 110 ksi.
  • teachings of the present disclosure are combined with one or more of the teachings disclosed in FR 2 841 626, filed on Jun. 28, 2002, and published on Jan. 2, 2004, the disclosure of which is incorporated herein by reference.
  • a method of forming a tubular liner within a preexisting structure includes positioning a tubular assembly within the preexisting structure; and radially expanding and plastically deforming the tubular assembly within the preexisting structure, wherein, prior to the radial expansion and plastic deformation of the tubular assembly, a predetermined portion of the tubular assembly has a lower yield point than another portion of the tubular assembly.
  • the predetermined portion of the tubular assembly has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
  • the predetermined portion of the tubular assembly has a higher ductility prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the tubular assembly has a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the tubular assembly has a larger inside diameter after the radial expansion and plastic deformation than other portions of the tubular assembly.
  • the method further includes positioning another tubular assembly within the preexisting structure in overlapping relation to the tubular assembly; and radially expanding and plastically deforming the other tubular assembly within the preexisting structure, wherein, prior to the radial expansion and plastic deformation of the tubular assembly, a predetermined portion of the other tubular assembly has a lower yield point than another portion of the other tubular assembly.
  • the inside diameter of the radially expanded and plastically deformed other portion of the tubular assembly is equal to the inside diameter of the radially expanded and plastically deformed other portion of the other tubular assembly.
  • the predetermined portion of the tubular assembly includes an end portion of the tubular assembly.
  • the predetermined portion of the tubular assembly includes a plurality of predetermined portions of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly includes a plurality of spaced apart predetermined portions of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly includes an end portion of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly includes a plurality of other portions of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly includes a plurality of spaced apart other portions of the tubular assembly. In an exemplary embodiment, the tubular assembly includes a plurality of tubular members coupled to one another by corresponding tubular couplings.
  • the tubular couplings include the predetermined portions of the tubular assembly; and wherein the tubular members comprise the other portion of the tubular assembly.
  • one or more of the tubular couplings include the predetermined portions of the tubular assembly.
  • one or more of the tubular members include the predetermined portions of the tubular assembly.
  • the predetermined portion of the tubular assembly defines one or more openings.
  • one or more of the openings include slots.
  • the anisotropy for the predetermined portion of the tubular assembly is greater than 1. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1.
  • the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1; and the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12. In an exemplary embodiment, the predetermined portion of the tubular assembly is a first steel alloy including: 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and 0.02% Cr.
  • the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and the yield point of the predetermined portion of the tubular assembly is at least about 65.9 ksi after the radial expansion and plastic deformation.
  • the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation.
  • the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation is about 1.48.
  • the predetermined portion of the tubular assembly includes a second steel alloy including: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr.
  • the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and the yield point of the predetermined portion of the tubular assembly is at least about 74.4 ksi after the radial expansion and plastic deformation.
  • the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 28% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation.
  • the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation is about 1.04.
  • the predetermined portion of the tubular assembly includes a third steel alloy including: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16% Cu, 0.05% Ni, and 0.05% Cr.
  • the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation is about 1.92.
  • the predetermined portion of the tubular assembly includes a fourth steel alloy including 0.02% C, 1.31% Mn, 0.02% P, 0.001% S, 0.45% Si, 9.1% Ni, and 18.7% Cr.
  • the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation is about 1.34.
  • the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 65.9 ksi after the radial expansion and plastic deformation.
  • the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation.
  • the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation is at least about 1.48.
  • the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and the yield point of the predetermined portion of the tubular assembly is at least about 74.4 ksi after the radial expansion and plastic deformation.
  • the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 28% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation.
  • the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation is at least about 1.04.
  • the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation is at least about 1.92. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.34. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, ranges from about 1.04 to about 1.92. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, ranges from about 47.6 ksi to about 61.7 ksi.
  • the expandability coefficient of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is greater than 0.12. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the tubular assembly is greater than the expandability coefficient of the other portion of the tubular assembly.
  • the tubular assembly includes a wellbore casing, a pipeline, or a structural support.
  • the carbon content of the predetermined portion of the tubular assembly is less than or equal to 0.12 percent; and wherein the carbon equivalent value for the predetermined portion of the tubular assembly is less than 0.21.
  • the carbon content of the predetermined portion of the tubular assembly is greater than 0.12 percent; and wherein the carbon equivalent value for the predetermined portion of the tubular assembly is less than 0.36.
  • a yield point of an inner tubular portion of at least a portion of the tubular assembly is less than a yield point of an outer tubular portion of the portion of the tubular assembly.
  • yield point of the inner tubular portion of the tubular body varies as a function of the radial position within the tubular body.
  • the yield point of the inner tubular portion of the tubular body varies in an linear fashion as a function of the radial position within the tubular body.
  • the yield point of the inner tubular portion of the tubular body varies in an non-linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the outer tubular portion of the tubular body varies as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the outer tubular portion of the tubular body varies in an linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the outer tubular portion of the tubular body varies in an non-linear fashion as a function of the radial position within the tubular body.
  • the yield point of the inner tubular portion of the tubular body varies as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies as a function of the radial position within the tubular body.
  • the yield point of the inner tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body.
  • the yield point of the inner tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body.
  • the yield point of the inner tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body.
  • the yield point of the inner tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body.
  • the rate of change of the yield point of the inner tubular portion of the tubular body is different than the rate of change of the yield point of the outer tubular portion of the tubular body.
  • the rate of change of the yield point of the inner tubular portion of the tubular body is different than the rate of change of the yield point of the outer tubular portion of the tubular body.
  • the tubular assembly prior to the radial expansion and plastic deformation, at least a portion of the tubular assembly comprises a microstructure comprising a hard phase structure and a soft phase structure. In an exemplary embodiment, prior to the radial expansion and plastic deformation, at least a portion of the tubular assembly comprises a microstructure comprising a transitional phase structure.
  • the hard phase structure comprises martensite.
  • the soft phase structure comprises ferrite.
  • the transitional phase structure comprises retained austentite.
  • the hard phase structure comprises martensite; wherein the soft phase structure comprises ferrite; and wherein the transitional phase structure comprises retained austentite.
  • the portion of the tubular assembly comprising a microstructure comprising a hard phase structure and a soft phase structure comprises, by weight percentage, about 0.1% C, about 1.2% Mn, and about 0.3% Si.
  • An expandable tubular member has been described that includes a steel alloy including: 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and 0.02% Cr.
  • a yield point of the tubular member is at most about 46.9 ksi prior to a radial expansion and plastic deformation; and a yield point of the tubular member is at least about 65.9 ksi after the radial expansion and plastic deformation.
  • the yield point of the tubular member after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the tubular member prior to the radial expansion and plastic deformation.
  • the anisotropy of the tubular member, prior to a radial expansion and plastic deformation is about 1.48.
  • the tubular member includes a wellbore casing, a pipeline, or a structural support.
  • An expandable tubular member has been described that includes a steel alloy including: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr.
  • a yield point of the tubular member is at most about 57.8 ksi prior to a radial expansion and plastic deformation; and the yield point of the tubular member is at least about 74.4 ksi after the radial expansion and plastic deformation.
  • a yield point of the of the tubular member after a radial expansion and plastic deformation is at least about 28% greater than the yield point of the tubular member prior to the radial expansion and plastic deformation.
  • the anisotropy of the tubular member, prior to a radial expansion and plastic deformation is about 1.04.
  • the tubular member includes a wellbore casing, a pipeline, or a structural support.
  • An expandable tubular member has been described that includes a steel alloy including: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16% Cu, 0.05% Ni, and 0.05% Cr.
  • the anisotropy of the tubular member, prior to a radial expansion and plastic deformation is about 1.92.
  • the tubular member includes a wellbore casing, a pipeline, or a structural support.
  • An expandable tubular member has been described that includes a steel alloy including: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S, 0.45% Si, 9.1% Ni, and 18.7% Cr.
  • the anisotropy of the tubular member, prior to a radial expansion and plastic deformation is about 1.34.
  • the tubular member includes a wellbore casing, a pipeline, or a structural support.
  • the tubular member includes a wellbore casing, a pipeline, or a structural support.
  • the tubular member includes a wellbore casing, a pipeline, or a structural support.
  • the tubular member includes a wellbore casing, a pipeline, or a structural support.
  • the tubular member includes a wellbore casing, a pipeline, or a structural support.
  • the tubular member includes a wellbore casing, a pipeline, or a structural support.
  • the tubular member includes a wellbore casing, a pipeline, or a structural support.
  • the tubular member includes a wellbore casing, a pipeline, or a structural support.
  • the tubular member includes a wellbore casing, a pipeline, or a structural support.
  • the tubular member includes a wellbore casing, a pipeline, or a structural support.
  • the tubular member includes a wellbore casing, a pipeline, or a structural support.
  • the tubular member includes a wellbore casing, a pipeline, or a structural support.
  • the tubular member includes a wellbore casing, a pipeline, or a structural support.
  • the tubular member has a higher ductility and a lower yield point prior to a radial expansion and plastic deformation than after the radial expansion and plastic deformation.
  • the tubular member includes a wellbore casing, a pipeline, or a structural support.
  • a method of radially expanding and plastically deforming a tubular assembly including a first tubular member coupled to a second tubular member has been described that includes radially expanding and plastically deforming the tubular assembly within a preexisting structure; and using less power to radially expand each unit length of the first tubular member than to radially expand each unit length of the second tubular member.
  • the tubular member includes a wellbore casing, a pipeline, or a structural support.
  • a system for radially expanding and plastically deforming a tubular assembly including a first tubular member coupled to a second tubular member includes means for radially expanding the tubular assembly within a preexisting structure; and means for using less power to radially expand each unit length of the first tubular member than required to radially expand each unit length of the second tubular member.
  • the tubular member includes a wellbore casing, a pipeline, or a structural support.
  • a method of manufacturing a tubular member includes processing a tubular member until the tubular member is characterized by one or more intermediate characteristics; positioning the tubular member within a preexisting structure; and processing the tubular member within the preexisting structure until the tubular member is characterized one or more final characteristics.
  • the tubular member includes a wellbore casing, a pipeline, or a structural support.
  • the preexisting structure includes a wellbore that traverses a subterranean formation.
  • the characteristics are selected from a group consisting of yield point and ductility.
  • processing the tubular member within the preexisting structure until the tubular member is characterized one or more final characteristics includes: radially expanding and plastically deforming the tubular member within the preexisting structure.
  • An apparatus has been described that includes an expandable tubular assembly; and an expansion device coupled to the expandable tubular assembly; wherein a predetermined portion of the expandable tubular assembly has a lower yield point than another portion of the expandable tubular assembly.
  • the expansion device includes a rotary expansion device, an axially displaceable expansion device, a reciprocating expansion device, a hydroforming expansion device, and/or an impulsive force expansion device.
  • the predetermined portion of the tubular assembly has a higher ductility and a lower yield point than another portion of the expandable tubular assembly.
  • the predetermined portion of the tubular assembly has a higher ductility than another portion of the expandable tubular assembly.
  • the predetermined portion of the tubular assembly has a lower yield point than another portion of the expandable tubular assembly.
  • the predetermined portion of the tubular assembly includes an end portion of the tubular assembly.
  • the predetermined portion of the tubular assembly includes a plurality of predetermined portions of the tubular assembly.
  • the predetermined portion of the tubular assembly includes a plurality of spaced apart predetermined portions of the tubular assembly.
  • the other portion of the tubular assembly includes an end portion of the tubular assembly.
  • the other portion of the tubular assembly includes a plurality of other portions of the tubular assembly.
  • the other portion of the tubular assembly includes a plurality of spaced apart other portions of the tubular assembly.
  • the tubular assembly includes a plurality of tubular members coupled to one another by corresponding tubular couplings.
  • the tubular couplings comprise the predetermined portions of the tubular assembly; and wherein the tubular members comprise the other portion of the tubular assembly.
  • one or more of the tubular couplings comprise the predetermined portions of the tubular assembly.
  • one or more of the tubular members comprise the predetermined portions of the tubular assembly.
  • the predetermined portion of the tubular assembly defines one or more openings.
  • one or more of the openings comprise slots.
  • the anisotropy for the predetermined portion of the tubular assembly is greater than 1. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1. In an exemplary embodiment, the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1; and wherein the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12.
  • the predetermined portion of the tubular assembly includes a first steel alloy including: 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and 0.02% Cr.
  • the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi.
  • the anisotropy of the predetermined portion of the tubular assembly is about 1.48.
  • the predetermined portion of the tubular assembly includes a second steel alloy including: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr.
  • the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi.
  • the anisotropy of the predetermined portion of the tubular assembly is about 1.04.
  • the predetermined portion of the tubular assembly includes a third steel alloy including: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16% Cu, 0.05% Ni, and 0.05% Cr.
  • the anisotropy of the predetermined portion of the tubular assembly is about 1.92.
  • the predetermined portion of the tubular assembly includes a fourth steel alloy including: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S, 0.45% Si, 9.1% Ni, and 18.7% Cr.
  • the anisotropy of the predetermined portion of the tubular assembly is at least about 1.34.
  • the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi.
  • the anisotropy of the predetermined portion of the tubular assembly is at least about 1.48.
  • the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi.
  • the anisotropy of the predetermined portion of the tubular assembly is at least about 1.04. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly is at least about 1.92. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly is at least about 1.34. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly ranges from about 1.04 to about 1.92. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly ranges from about 47.6 ksi to about 61.7 ksi. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the tubular assembly is greater than 0.12.
  • the expandability coefficient of the predetermined portion of the tubular assembly is greater than the expandability coefficient of the other portion of the tubular assembly.
  • the tubular assembly includes a wellbore casing, a pipeline, or a structural support.
  • the carbon content of the predetermined portion of the tubular assembly is less than or equal to 0.12 percent; and wherein the carbon equivalent value for the predetermined portion of the tubular assembly is less than 0.21.
  • the carbon content of the predetermined portion of the tubular assembly is greater than 0.12 percent; and wherein the carbon equivalent value for the predetermined portion of the tubular assembly is less than 0.36.
  • a yield point of an inner tubular portion of at least a portion of the tubular assembly is less than a yield point of an outer tubular portion of the portion of the tubular assembly.
  • the yield point of the inner tubular portion of the tubular body varies as a function of the radial position within the tubular body.
  • the yield point of the inner tubular portion of the tubular body varies in an linear fashion as a function of the radial position within the tubular body.
  • the yield point of the inner tubular portion of the tubular body varies in an non-linear fashion as a function of the radial position within the tubular body.
  • the yield point of the outer tubular portion of the tubular body varies as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the outer tubular portion of the tubular body varies in an linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the outer tubular portion of the tubular body varies in an non-linear fashion as a function of the radial position within the tubular body.
  • the yield point of the inner tubular portion of the tubular body varies as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies as a function of the radial position within the tubular body.
  • the yield point of the inner tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body.
  • the yield point of the inner tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body.
  • the yield point of the inner tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body.
  • the yield point of the inner tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body.
  • the rate of change of the yield point of the inner tubular portion of the tubular body is different than the rate of change of the yield point of the outer tubular portion of the tubular body.
  • the rate of change of the yield point of the inner tubular portion of the tubular body is different than the rate of change of the yield point of the outer tubular portion of the tubular body.
  • At least a portion of the tubular assembly comprises a microstructure comprising a hard phase structure and a soft phase structure.
  • at least a portion of the tubular assembly prior to the radial expansion and plastic deformation, at least a portion of the tubular assembly comprises a microstructure comprising a transitional phase structure.
  • the hard phase structure comprises martensite.
  • the soft phase structure comprises ferrite.
  • the transitional phase structure comprises retained austentite.
  • the hard phase structure comprises martensite, wherein the soft phase structure comprises ferrite; and wherein the transitional phase structure comprises retained austentite.
  • the portion of the tubular assembly comprising a microstructure comprising a hard phase structure and a soft phase structure comprises, by weight percentage, about 0.1% C, about 1.2% Mn, and about 0.3% Si.
  • at least a portion of the tubular assembly comprises a microstructure comprising a hard phase structure and a soft phase structure.
  • the portion of the tubular assembly comprises, by weight percentage, 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, 0.02% Cr, 0.05% V, 0.01% Mo, 0.01% Nb, and 0.01% Ti.
  • the portion of the tubular assembly comprises, by weight percentage, 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, 0.03% Cr, 0.04% V, 0.01% Mo, 0.03% Nb, and 0.01% Ti.
  • the portion of the tubular assembly comprises, by weight percentage, 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.06% Cu, 0.05% Ni, 0.05% Cr, 0.03% V, 0.03% Mo, 0.01% Nb, and 0.01% Ti.
  • the portion of the tubular assembly comprises a microstructure comprising one or more of the following: martensite, pearlite, vanadium carbide, nickel carbide, or titanium carbide.
  • the portion of the tubular assembly comprises a microstructure comprising one or more of the following: pearlite or pearlite striation.
  • the portion of the tubular assembly comprises a microstructure comprising one or more of the following: grain pearlite, widmanstatten martensite, vanadium carbide, nickel carbide, or titanium carbide.
  • the portion of the tubular assembly comprises a microstructure comprising one or more of the following: ferrite, grain pearlite, or martensite.
  • the portion of the tubular assembly comprises a microstructure comprising one or more of the following: ferrite, martensite, or bainite. In an exemplary embodiment, the portion of the tubular assembly comprises a microstructure comprising one or more of the following: bainite, pearlite, or ferrite. In an exemplary embodiment, the portion of the tubular assembly comprises a yield strength of about 67 ksi and a tensile strength of about 95 ksi. In an exemplary embodiment, the portion of the tubular assembly comprises a yield strength of about 82 ksi and a tensile strength of about 130 ksi. In an exemplary embodiment, the portion of the tubular assembly comprises a yield strength of about 60 ksi and a tensile strength of about 97 ksi.
  • the tubular member includes a wellbore casing, a pipeline, or a structural support.
  • a method of determining the expandability of a selected tubular member includes determining an anisotropy value for the selected tubular member, determining a strain hardening value for the selected tubular member; and multiplying the anisotropy value times the strain hardening value to generate an expandability value for the selected tubular member.
  • an anisotropy value greater than 0.12 indicates that the tubular member is suitable for radial expansion and plastic deformation.
  • the tubular member includes a wellbore casing, a pipeline, or a structural support.
  • a method of radially expanding and plastically deforming tubular members includes selecting a tubular member; determining an anisotropy value for the selected tubular member; determining a strain hardening value for the selected tubular member; multiplying the anisotropy value times the strain hardening value to generate an expandability value for the selected tubular member; and if the anisotropy value is greater than 0.12, then radially expanding and plastically deforming the selected tubular member.
  • the tubular member includes a wellbore casing, a pipeline, or a structural support.
  • radially expanding and plastically deforming the selected tubular member includes: inserting the selected tubular member into a preexisting structure; and then radially expanding and plastically deforming the selected tubular member.
  • the preexisting structure includes a wellbore that traverses a subterranean formation.
  • a radially expandable multiple tubular member apparatus includes a first tubular member; a second tubular member engaged with the first tubular member forming a joint; a sleeve overlapping and coupling the first and second tubular members at the joint; the sleeve having opposite tapered ends and a flange engaged in a recess formed in an adjacent tubular member; and one of the tapered ends being a surface formed on the flange.
  • the recess includes a tapered wall in mating engagement with the tapered end formed on the flange.
  • the sleeve includes a flange at each tapered end and each tapered end is formed on a respective flange.
  • each tubular member includes a recess.
  • each flange is engaged in a respective one of the recesses.
  • each recess includes a tapered wall in mating engagement with the tapered end formed on a respective one of the flanges.
  • a method of joining radially expandable multiple tubular members includes providing a first tubular member; engaging a second tubular member with the first tubular member to form a joint; providing a sleeve having opposite tapered ends and a flange, one of the tapered ends being a surface formed on the flange; and mounting the sleeve for overlapping and coupling the first and second tubular members at the joint, wherein the flange is engaged in a recess formed in an adjacent one of the tubular members.
  • the method further includes providing a tapered wall in the recess for mating engagement with the tapered end formed on the flange.
  • the method further includes providing a flange at each tapered end wherein each tapered end is formed on a respective flange. In an exemplary embodiment, the method further includes providing a recess in each tubular member. In an exemplary embodiment, the method further includes engaging each flange in a respective one of the recesses. In an exemplary embodiment, the method further includes providing a tapered wall in each recess for mating engagement with the tapered end formed on a respective one of the flanges.
  • a radially expandable multiple tubular member apparatus includes a first tubular member; a second tubular member engaged with the first tubular member forming a joint; and a sleeve overlapping and coupling the first and second tubular members at the joint; wherein at least a portion of the sleeve is comprised of a frangible material.
  • a radially expandable multiple tubular member apparatus includes a first tubular member; a second tubular member engaged with the first tubular member forming a joint; and a sleeve overlapping and coupling the first and second tubular members at the joint; wherein the wall thickness of the sleeve is variable.
  • a method of joining radially expandable multiple tubular members includes providing a first tubular member; engaging a second tubular member with the first tubular member to form a joint; providing a sleeve comprising a frangible material; and mounting the sleeve for overlapping and coupling the first and second tubular members at the joint.
  • a method of joining radially expandable multiple tubular members includes providing a first tubular member; engaging a second tubular member with the first tubular member to form a joint; providing a sleeve comprising a variable wall thickness; and mounting the sleeve for overlapping and coupling the first and second tubular members at the joint.
  • An expandable tubular assembly has been described that includes a first tubular member; a second tubular member coupled to the first tubular member; and means for increasing the axial compression loading capacity of the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members.
  • An expandable tubular assembly has been described that includes a first tubular member; a second tubular member coupled to the first tubular member; and means for increasing the axial tension loading capacity of the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members.
  • An expandable tubular assembly has been described that includes a first tubular member; a second tubular member coupled to the first tubular member; and means for increasing the axial compression and tension loading capacity of the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members.
  • An expandable tubular assembly has been described that includes a first tubular member; a second tubular member coupled to the first tubular member; and means for avoiding stress risers in the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members.
  • An expandable tubular assembly has been described that includes a first tubular member; a second tubular member coupled to the first tubular member; and means for inducing stresses at selected portions of the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members.
  • the sleeve is circumferentially tensioned; and wherein the first and second tubular members are circumferentially compressed.
  • the method further includes maintaining the sleeve in circumferential tension; and maintaining the first and second tubular members in circumferential compression before, during, and/or after the radial expansion and plastic deformation of the first and second tubular members.
  • An expandable tubular assembly has been described that includes a first tubular member, a second tubular member coupled to the first tubular member, a first threaded connection for coupling a portion of the first and second tubular members, a second threaded connection spaced apart from the first threaded connection for coupling another portion of the first and second tubular members, a tubular sleeve coupled to and receiving end portions of the first and second tubular members, and a sealing element positioned between the first and second spaced apart threaded connections for sealing an interface between the first and second tubular member, wherein the sealing element is positioned within an annulus defined between the first and second tubular members.
  • the annulus is at least partially defined by an irregular surface.
  • the annulus is at least partially defined by a toothed surface.
  • the sealing element comprises an elastomeric material.
  • the sealing element comprises a metallic material.
  • the sealing element comprises an elastomeric and a metallic material.
  • a method of joining radially expandable multiple tubular members includes providing a first tubular member, providing a second tubular member, providing a sleeve, mounting the sleeve for overlapping and coupling the first and second tubular members, threadably coupling the first and second tubular members at a first location, threadably coupling the first and second tubular members at a second location spaced apart from the first location, and sealing an interface between the first and second tubular members between the first and second locations using a compressible sealing element.
  • the sealing element includes an irregular surface.
  • the sealing element includes a toothed surface.
  • the sealing element comprises an elastomeric material.
  • the sealing element comprises a metallic material.
  • the sealing element comprises an elastomeric and a metallic material.
  • An expandable tubular assembly has been described that includes a first tubular member, a second tubular member coupled to the first tubular member, a first threaded connection for coupling a portion of the first and second tubular members, a second threaded connection spaced apart from the first threaded connection for coupling another portion of the first and second tubular members, and a plurality of spaced apart tubular sleeves coupled to and receiving end portions of the first and second tubular members.
  • at least one of the tubular sleeves is positioned in opposing relation to the first threaded connection; and wherein at least one of the tubular sleeves is positioned in opposing relation to the second threaded connection.
  • at least one of the tubular sleeves is not positioned in opposing relation to the first and second threaded connections.
  • a method of joining radially expandable multiple tubular members includes providing a first tubular member, providing a second tubular member, threadably coupling the first and second tubular members at a first location, threadably coupling the first and second tubular members at a second location spaced apart from the first location, providing a plurality of sleeves, and mounting the sleeves at spaced apart locations for overlapping and coupling the first and second tubular members.
  • at least one of the tubular sleeves is positioned in opposing relation to the first threaded coupling; and wherein at least one of the tubular sleeves is positioned in opposing relation to the second threaded coupling.
  • at least one of the tubular sleeves is not positioned in opposing relation to the first and second threaded couplings.
  • An expandable tubular assembly has been described that includes a first tubular member, a second tubular member coupled to the first tubular member, and a plurality of spaced apart tubular sleeves coupled to and receiving end portions of the first and second tubular members.
  • a method of joining radially expandable multiple tubular members includes providing a first tubular member, providing a second tubular member, providing a plurality of sleeves, coupling the first and second tubular members, and mounting the sleeves at spaced apart locations for overlapping and coupling the first and second tubular members.
  • An expandable tubular assembly has been described that includes a first tubular member, a second tubular member coupled to the first tubular member, a threaded connection for coupling a portion of the first and second tubular members, and a tubular sleeves coupled to and receiving end portions of the first and second tubular members, wherein at least a portion of the threaded connection is upset.
  • at least a portion of tubular sleeve penetrates the first tubular member.
  • a method of joining radially expandable multiple tubular members includes providing a first tubular member, providing a second tubular member, threadably coupling the first and second tubular members, and upsetting the threaded coupling.
  • the first tubular member further comprises an annular extension extending therefrom, and the flange of the sleeve defines an annular recess for receiving and mating with the annular extension of the first tubular member.
  • the first tubular member further comprises an annular extension extending therefrom; and the flange of the sleeve defines an annular recess for receiving and mating with the annular extension of the first tubular member.
  • a radially expandable multiple tubular member apparatus includes a first tubular member, a second tubular member engaged with the first tubular member forming a joint, a sleeve overlapping and coupling the first and second tubular members at the joint, and one or more stress concentrators for concentrating stresses in the joint.
  • one or more of the stress concentrators comprises one or more external grooves defined in the first tubular member.
  • one or more of the stress concentrators comprises one or more internal grooves defined in the second tubular member.
  • one or more of the stress concentrators comprises one or more openings defined in the sleeve.
  • one or more of the stress concentrators comprises one or more external grooves defined in the first tubular member; and one or more of the stress concentrators comprises one or more internal grooves defined in the second tubular member. In an exemplary embodiment, one or more of the stress concentrators comprises one or more external grooves defined in the first tubular member; and one or more of the stress concentrators comprises one or more openings defined in the sleeve. In an exemplary embodiment, one or more of the stress concentrators comprises one or more internal grooves defined in the second tubular member; and one or more of the stress concentrators comprises one or more openings defined in the sleeve.
  • one or more of the stress concentrators comprises one or more external grooves defined in the first tubular member; wherein one or more of the stress concentrators comprises one or more internal grooves defined in the second tubular member; and wherein one or more of the stress concentrators comprises one or more openings defined in the sleeve.
  • a method of joining radially expandable multiple tubular members includes providing a first tubular member, engaging a second tubular member with the first tubular member to form a joint, providing a sleeve having opposite tapered ends and a flange, one of the tapered ends being a surface formed on the flange, and concentrating stresses within the joint.
  • concentrating stresses within the joint comprises using the first tubular member to concentrate stresses within the joint.
  • concentrating stresses within the joint comprises using the second tubular member to concentrate stresses within the joint.
  • concentrating stresses within the joint comprises using the sleeve to concentrate stresses within the joint.
  • concentrating stresses within the joint comprises using the first tubular member and the second tubular member to concentrate stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the first tubular member and the sleeve to concentrate stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the second tubular member and the sleeve to concentrate stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the first tubular member, the second tubular member, and the sleeve to concentrate stresses within the joint.
  • a system for radially expanding and plastically deforming a first tubular member coupled to a second tubular member by a mechanical connection includes means for radially expanding the first and second tubular members, and means for maintaining portions of the first and second tubular member in circumferential compression following the radial expansion and plastic deformation of the first and second tubular members.
  • a system for radially expanding and plastically deforming a first tubular member coupled to a second tubular member by a mechanical connection includes means for radially expanding the first and second tubular members; and means for concentrating stresses within the mechanical connection during the radial expansion and plastic deformation of the first and second tubular members.
  • a system for radially expanding and plastically deforming a first tubular member coupled to a second tubular member by a mechanical connection includes means for radially expanding the first and second tubular members; means for maintaining portions of the first and second tubular member in circumferential compression following the radial expansion and plastic deformation of the first and second tubular members; and means for concentrating stresses within the mechanical connection during the radial expansion and plastic deformation of the first and second tubular members.
  • a radially expandable tubular member apparatus has been described that includes a first tubular member; a second tubular member engaged with the first tubular member forming a joint; and a sleeve overlapping and coupling the first and second tubular members at the joint; wherein, prior to a radial expansion and plastic deformation of the apparatus, a predetermined portion of the apparatus has a lower yield point than another portion of the apparatus.
  • the carbon content of the predetermined portion of the apparatus is less than or equal to 0.12 percent; and wherein the carbon equivalent value for the predetermined portion of the apparatus is less than 0.21.
  • the carbon content of the predetermined portion of the apparatus is greater than 0.12 percent; and wherein the carbon equivalent value for the predetermined portion of the apparatus is less than 0.36.
  • the apparatus further includes means for maintaining portions of the first and second tubular member in circumferential compression following the radial expansion and plastic deformation of the first and second tubular members.
  • the apparatus further includes means for concentrating stresses within the mechanical connection during the radial expansion and plastic deformation of the first and second tubular members.
  • the apparatus further includes means for maintaining portions of the first and second tubular member in circumferential compression following the radial expansion and plastic deformation of the first and second tubular members; and means for concentrating stresses within the mechanical connection during the radial expansion and plastic deformation of the first and second tubular members.
  • the apparatus further includes one or more stress concentrators for concentrating stresses in the joint.
  • one or more of the stress concentrators comprises one or more external grooves defined in the first tubular member.
  • one or more of the stress concentrators comprises one or more internal grooves defined in the second tubular member.
  • one or more of the stress concentrators comprises one or more openings defined in the sleeve.
  • one or more of the stress concentrators comprises one or more external grooves defined in the first tubular member, and wherein one or more of the stress concentrators comprises one or more internal grooves defined in the second tubular member. In an exemplary embodiment, one or more of the stress concentrators comprises one or more external grooves defined in the first tubular member; and wherein one or more of the stress concentrators comprises one or more openings defined in the sleeve. In an exemplary embodiment, one or more of the stress concentrators comprises one or more internal grooves defined in the second tubular member; and wherein one or more of the stress concentrators comprises one or more openings defined in the sleeve.
  • one or more of the stress concentrators comprises one or more external grooves defined in the first tubular member; wherein one or more of the stress concentrators comprises one or more internal grooves defined in the second tubular member; and wherein one or more of the stress concentrators comprises one or more openings defined in the sleeve.
  • the first tubular member further comprises an annular extension extending therefrom; and wherein the flange of the sleeve defines an annular recess for receiving and mating with the annular extension of the first tubular member.
  • the apparatus further includes a threaded connection for coupling a portion of the first and second tubular members; wherein at least a portion of the threaded connection is upset.
  • the apparatus further includes means for increasing the axial compression loading capacity of the joint between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members. In an exemplary embodiment, the apparatus further includes means for increasing the axial tension loading capacity of the joint between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members. In an exemplary embodiment, the apparatus further includes means for increasing the axial compression and tension loading capacity of the joint between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members.
  • the apparatus further includes means for avoiding stress risers in the joint between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members. In an exemplary embodiment, the apparatus further includes means for inducing stresses at selected portions of the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members. In an exemplary embodiment, the sleeve is circumferentially tensioned; and wherein the first and second tubular members are circumferentially compressed.
  • the means for increasing the axial compression loading capacity of the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members is circumferentially tensioned; and wherein the first and second tubular members are circumferentially compressed.
  • the means for increasing the axial tension loading capacity of the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members is circumferentially tensioned; and wherein the first and second tubular members are circumferentially compressed.
  • the means for increasing the axial compression and tension loading capacity of the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members is circumferentially tensioned; and wherein the first and second tubular members are circumferentially compressed.
  • the means for avoiding stress risers in the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members is circumferentially tensioned; and wherein the first and second tubular members are circumferentially compressed.
  • the means for inducing stresses at selected portions of the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members is circumferentially tensioned; and wherein the first and second tubular members are circumferentially compressed.
  • at least a portion of the sleeve is comprised of a frangible material.
  • the wall thickness of the sleeve is variable.
  • the predetermined portion of the apparatus has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
  • the predetermined portion of the apparatus has a higher ductility prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the apparatus has a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the apparatus has a larger inside diameter after the radial expansion and plastic deformation than other portions of the tubular assembly. In an exemplary embodiment, the sleeve is circumferentially tensioned; and wherein the first and second tubular members are circumferentially compressed.
  • the sleeve is circumferentially tensioned; and wherein the first and second tubular members are circumferentially compressed.
  • the apparatus further includes positioning another apparatus within the preexisting structure in overlapping relation to the apparatus; and radially expanding and plastically deforming the other apparatus within the preexisting structure; wherein, prior to the radial expansion and plastic deformation of the apparatus, a predetermined portion of the other apparatus has a lower yield point than another portion of the other apparatus.
  • the inside diameter of the radially expanded and plastically deformed other portion of the apparatus is equal to the inside diameter of the radially expanded and plastically deformed other portion of the other apparatus.
  • the predetermined portion of the apparatus comprises an end portion of the apparatus. In an exemplary embodiment, the predetermined portion of the apparatus comprises a plurality of predetermined portions of the apparatus. In an exemplary embodiment, the predetermined portion of the apparatus comprises a plurality of spaced apart predetermined portions of the apparatus. In an exemplary embodiment, the other portion of the apparatus comprises an end portion of the apparatus. In an exemplary embodiment, the other portion of the apparatus comprises a plurality of other portions of the apparatus. In an exemplary embodiment, the other portion of the apparatus comprises a plurality of spaced apart other portions of the apparatus. In an exemplary embodiment, the apparatus comprises a plurality of tubular members coupled to one another by corresponding tubular couplings.
  • the tubular couplings comprise the predetermined portions of the apparatus; and wherein the tubular members comprise the other portion of the apparatus.
  • one or more of the tubular couplings comprise the predetermined portions of the apparatus.
  • one or more of the tubular members comprise the predetermined portions of the apparatus.
  • the predetermined portion of the apparatus defines one or more openings.
  • one or more of the openings comprise slots.
  • the anisotropy for the predetermined portion of the apparatus is greater than 1. In an exemplary embodiment, the anisotropy for the predetermined portion of the apparatus is greater than 1.
  • the strain hardening exponent for the predetermined portion of the apparatus is greater than 0.12. In an exemplary embodiment, the anisotropy for the predetermined portion of the apparatus is greater than 1; and wherein the strain hardening exponent for the predetermined portion of the apparatus is greater than 0.12. In an exemplary embodiment, the predetermined portion of the apparatus comprises a first steel alloy comprising: 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and 0.02% Cr.
  • the yield point of the predetermined portion of the apparatus is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the apparatus is at least about 65.9 ksi after the radial expansion and plastic deformation.
  • the yield point of the predetermined portion of the apparatus after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the predetermined portion of the apparatus prior to the radial expansion and plastic deformation.
  • the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation is about 1.48.
  • the predetermined portion of the apparatus comprises a second steel alloy comprising: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr.
  • the yield point of the predetermined portion of the apparatus is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the apparatus is at least about 74.4 ksi after the radial expansion and plastic deformation.
  • the yield point of the predetermined portion of the apparatus after the radial expansion and plastic deformation is at least about 28% greater than the yield point of the predetermined portion of the apparatus prior to the radial expansion and plastic deformation.
  • the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation is about 1.04.
  • the predetermined portion of the apparatus comprises a third steel alloy comprising: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16% Cu, 0.05% Ni, and 0.05% Cr.
  • the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation is about 1.92.
  • the predetermined portion of the apparatus comprises a fourth steel alloy comprising: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S, 0.45% Si, 9.1% Ni, and 18.7% Cr.
  • the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation is about 1.34.
  • the yield point of the predetermined portion of the apparatus is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the apparatus is at least about 65.9 ksi after the radial expansion and plastic deformation.
  • the yield point of the predetermined portion of the apparatus after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the predetermined portion of the apparatus prior to the radial expansion and plastic deformation.
  • the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation is at least about 1.48.
  • the yield point of the predetermined portion of the apparatus is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the apparatus is at least about 74.4 ksi after the radial expansion and plastic deformation.
  • the yield point of the predetermined portion of the apparatus after the radial expansion and plastic deformation is at least about 28% greater than the yield point of the predetermined portion of the apparatus prior to the radial expansion and plastic deformation.
  • the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation is at least about 1.04.
  • the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation is at least about 1.92. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is at least about 1.34. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, ranges from about 1.04 to about 1.92. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, ranges from about 47.6 ksi to about 61.7 ksi.
  • the expandability coefficient of the predetermined portion of the apparatus prior to the radial expansion and plastic deformation, is greater than 0.12. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the apparatus is greater than the expandability coefficient of the other portion of the apparatus.
  • the apparatus comprises a wellbore casing. In an exemplary embodiment, the apparatus comprises a pipeline. In an exemplary embodiment, the apparatus comprises a structural support.
  • a radially expandable tubular member apparatus includes a first tubular member; a second tubular member engaged with the first tubular member forming a joint; a sleeve overlapping and coupling the first and second tubular members at the joint; the sleeve having opposite tapered ends and a flange engaged in a recess formed in an adjacent tubular member; and one of the tapered ends being a surface formed on the flange; wherein, prior to a radial expansion and plastic deformation of the apparatus, a predetermined portion of the apparatus has a lower yield point than another portion of the apparatus.
  • the recess includes a tapered wall in mating engagement with the tapered end formed on the flange.
  • the sleeve includes a flange at each tapered end and each tapered end is formed on a respective flange.
  • each tubular member includes a recess.
  • each flange is engaged in a respective one of the recesses.
  • each recess includes a tapered wall in mating engagement with the tapered end formed on a respective one of the flanges.
  • the predetermined portion of the apparatus has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
  • the predetermined portion of the apparatus has a higher ductility prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the apparatus has a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the apparatus has a larger inside diameter after the radial expansion and plastic deformation than other portions of the tubular assembly.
  • the apparatus further includes positioning another apparatus within the preexisting structure in overlapping relation to the apparatus; and radially expanding and plastically deforming the other apparatus within the preexisting structure; wherein, prior to the radial expansion and plastic deformation of the apparatus, a predetermined portion of the other apparatus has a lower yield point than another portion of the other apparatus.
  • the inside diameter of the radially expanded and plastically deformed other portion of the apparatus is equal to the inside diameter of the radially expanded and plastically deformed other portion of the other apparatus.
  • the predetermined portion of the apparatus comprises an end portion of the apparatus.
  • the predetermined portion of the apparatus comprises a plurality of predetermined portions of the apparatus.
  • the predetermined portion of the apparatus comprises a plurality of spaced apart predetermined portions of the apparatus.
  • the other portion of the apparatus comprises an end portion of the apparatus.
  • the other portion of the apparatus comprises a plurality of other portions of the apparatus.
  • the other portion of the apparatus comprises a plurality of spaced apart other portions of the apparatus.
  • the apparatus comprises a plurality of tubular members coupled to one another by corresponding tubular couplings.
  • the tubular couplings comprise the predetermined portions of the apparatus; and wherein the tubular members comprise the other portion of the apparatus.
  • one or more of the tubular couplings comprise the predetermined portions of the apparatus.
  • one or more of the tubular members comprise the predetermined portions of the apparatus.
  • the predetermined portion of the apparatus defines one or more openings.
  • one or more of the openings comprise slots.
  • the anisotropy for the predetermined portion of the apparatus is greater than 1.
  • the anisotropy for the predetermined portion of the apparatus is greater than 1.
  • the strain hardening exponent for the predetermined portion of the apparatus is greater than 0.12.
  • the anisotropy for the predetermined portion of the apparatus is greater than 1; and wherein the strain hardening exponent for the predetermined portion of the apparatus is greater than 0.12.
  • the predetermined portion of the apparatus comprises a first steel alloy comprising: 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu. 0.01% Ni, and 0.02% Cr.
  • the yield point of the predetermined portion of the apparatus is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the apparatus is at least about 65.9 ksi after the radial expansion and plastic deformation.
  • the yield point of the predetermined portion of the apparatus after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the predetermined portion of the apparatus prior to the radial expansion and plastic deformation.
  • the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation is about 1.48.
  • the predetermined portion of the apparatus comprises a second steel alloy comprising: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr.
  • the yield point of the predetermined portion of the apparatus is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the apparatus is at least about 74.4 ksi after the radial expansion and plastic deformation.
  • the yield point of the predetermined portion of the apparatus after the radial expansion and plastic deformation is at least about 28% greater than the yield point of the predetermined portion of the apparatus prior to the radial expansion and plastic deformation.
  • the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation is about 1.04.
  • the predetermined portion of the apparatus comprises a third steel alloy comprising: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16% Cu, 0.05% Ni, and 0.05% Cr.
  • the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is about 1.92.
  • the predetermined portion of the apparatus comprises a fourth steel alloy comprising: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S, 0.45% Si, 9.1% Ni, and 18.7% Cr.
  • the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation is about 1.34.
  • the yield point of the predetermined portion of the apparatus is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the apparatus is at least about 65.9 ksi after the radial expansion and plastic deformation.
  • the yield point of the predetermined portion of the apparatus after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the predetermined portion of the apparatus prior to the radial expansion and plastic deformation.
  • the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation is at least about 1.48.
  • the yield point of the predetermined portion of the apparatus is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the apparatus is at least about 74.4 ksi after the radial expansion and plastic deformation.
  • the yield point of the predetermined portion of the apparatus after the radial expansion and plastic deformation is at least about 28% greater than the yield point of the predetermined portion of the apparatus prior to the radial expansion and plastic deformation.
  • the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation is at least about 1.04. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is at least about 1.92. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is at least about 1.34. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, ranges from about 1.04 to about 1.92.
  • the yield point of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation ranges from about 47.6 ksi to about 61.7 ksi.
  • the expandability coefficient of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation is greater than 0.12. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the apparatus is greater than the expandability coefficient of the other portion of the apparatus.
  • the apparatus comprises a wellbore casing.
  • the apparatus comprises a pipeline.
  • the apparatus comprises a structural support.
  • a method of joining radially expandable tubular members includes: providing a first tubular member; engaging a second tubular member with the first tubular member to form a joint; providing a sleeve; mounting the sleeve for overlapping and coupling the first and second tubular members at the joint; wherein the first tubular member, the second tubular member, and the sleeve define a tubular assembly; and radially expanding and plastically deforming the tubular assembly; wherein, prior to the radial expansion and plastic deformation, a predetermined portion of the tubular assembly has a lower yield point than another portion of the tubular assembly.
  • the carbon content of the predetermined portion of the tubular assembly is less than or equal to 0.12 percent; and wherein the carbon equivalent value for the predetermined portion of the tubular assembly is less than 0.21. In an exemplary embodiment, the carbon content of the predetermined portion of the tubular assembly is greater than 0.12 percent; and wherein the carbon equivalent value for the predetermined portion of the tubular assembly is less than 0.36.
  • the method further includes: maintaining portions of the first and second tubular member in circumferential compression following a radial expansion and plastic deformation of the first and second tubular members. In an exemplary embodiment, the method further includes: concentrating stresses within the joint during a radial expansion and plastic deformation of the first and second tubular members.
  • the method further includes: maintaining portions of the first and second tubular member in circumferential compression following a radial expansion and plastic deformation of the first and second tubular members; and concentrating stresses within the joint during a radial expansion and plastic deformation of the first and second tubular members.
  • the method further includes: concentrating stresses within the joint.
  • concentrating stresses within the joint comprises using the first tubular member to concentrate stresses within the joint.
  • concentrating stresses within the joint comprises using the second tubular member to concentrate stresses within the joint.
  • concentrating stresses within the joint comprises using the sleeve to concentrate stresses within the joint.
  • concentrating stresses within the joint comprises using the first tubular member and the second tubular member to concentrate stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the first tubular member and the sleeve to concentrate stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the second tubular member and the sleeve to concentrate stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the first tubular member, the second tubular member, and the sleeve to concentrate stresses within the joint. In an exemplary embodiment, at least a portion of the sleeve is comprised of a frangible material. In an exemplary embodiment, the sleeve comprises a variable wall thickness.
  • the method further includes maintaining the sleeve in circumferential tension; and maintaining the first and second tubular members in circumferential compression. In an exemplary embodiment, the method further includes maintaining the sleeve in circumferential tension; and maintaining the first and second tubular members in circumferential compression. In an exemplary embodiment; the method further includes: maintaining the sleeve in circumferential tension; and maintaining the first and second tubular members in circumferential compression.
  • the method further includes: threadably coupling the first and second tubular members at a first location; threadably coupling the first and second tubular members at a second location spaced apart from the first location; providing a plurality of sleeves; and mounting the sleeves at spaced apart locations for overlapping and coupling the first and second tubular members.
  • at least one of the tubular sleeves is positioned in opposing relation to the first threaded coupling; and wherein at least one of the tubular sleeves is positioned in opposing relation to the second threaded coupling.
  • at least one of the tubular sleeves is not positioned in opposing relation to the first and second threaded couplings.
  • the method further includes: threadably coupling the first and second tubular members; and upsetting the threaded coupling.
  • the first tubular member further comprises an annular extension extending therefrom; and wherein the flange of the sleeve defines an annular recess for receiving and mating with the annular extension of the first tubular member.
  • the predetermined portion of the tubular assembly has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
  • the predetermined portion of the tubular assembly has a higher ductility prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
  • the predetermined portion of the tubular assembly has a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the tubular assembly has a larger inside diameter after the radial expansion and plastic deformation than the other portion of the tubular assembly. In an exemplary embodiment, the method further includes: positioning another tubular assembly within the preexisting structure in overlapping relation to the tubular assembly; and radially expanding and plastically deforming the other tubular assembly within the preexisting structure; wherein, prior to the radial expansion and plastic deformation of the tubular assembly, a predetermined portion of the other tubular assembly has a lower yield point than another portion of the other tubular assembly.
  • the inside diameter of the radially expanded and plastically deformed other portion of the tubular assembly is equal to the inside diameter of the radially expanded and plastically deformed other portion of the other tubular assembly.
  • the predetermined portion of the tubular assembly comprises an end portion of the tubular assembly.
  • the predetermined portion of the tubular assembly comprises a plurality of predetermined portions of the tubular assembly.
  • the predetermined portion of the tubular assembly comprises a plurality of spaced apart predetermined portions of the tubular assembly.
  • the other portion of the tubular assembly comprises an end portion of the tubular assembly.
  • the other portion of the tubular assembly comprises a plurality of other portions of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly comprises a plurality of spaced apart other portions of the tubular assembly. In an exemplary embodiment, the tubular assembly comprises a plurality of tubular members coupled to one another by corresponding tubular couplings. In an exemplary embodiment, the tubular couplings comprise the predetermined portions of the tubular assembly; and wherein the tubular members comprise the other portion of the tubular assembly. In an exemplary embodiment, one or more of the tubular couplings comprise the predetermined portions of the tubular assembly. In an exemplary embodiment, one or more of the tubular members comprise the predetermined portions of the tubular assembly.
  • the predetermined portion of the tubular assembly defines one or more openings. In an exemplary embodiment, one or more of the openings comprise slots. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1. In an exemplary embodiment, the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1; and wherein the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12.
  • the predetermined portion of the tubular assembly comprises a first steel alloy comprising: 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and 0.02% Cr.
  • the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 65.9 ksi after the radial expansion and plastic deformation.
  • the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation.
  • the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation is about 1.48.
  • the predetermined portion of the tubular assembly comprises a second steel alloy comprising: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr.
  • the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 74.4 ksi after the radial expansion and plastic deformation.
  • the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 28% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation.
  • the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation is about 1.04.
  • the predetermined portion of the tubular assembly comprises a third steel alloy comprising: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16% Cu, 0.05% Ni, and 0.05% Cr.
  • the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.92.
  • the predetermined portion of the tubular assembly comprises a fourth steel alloy comprising: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S, 0.45% Si, 9.1% Ni, and 18.7% Cr.
  • the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation is about 1.34.
  • the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 65.9 ksi after the radial expansion and plastic deformation.
  • the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation.
  • the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation is at least about 1.48.
  • the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 74.4 ksi after the radial expansion and plastic deformation.
  • the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 28% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation.
  • the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation is at least about 1.04. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.92. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.34. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, ranges from about 1.04 to about 1.92.
  • the yield point of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation ranges from about 47.6 ksi to about 61.7 ksi.
  • the expandability coefficient of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation is greater than 0.12.
  • the expandability coefficient of the predetermined portion of the tubular assembly is greater than the expandability coefficient of the other portion of the tubular assembly.
  • the tubular assembly comprises a wellbore casing.
  • the tubular assembly comprises a pipeline.
  • the tubular assembly comprises a structural support.
  • a method of joining radially expandable tubular members includes: providing a first tubular member; engaging a second tubular member with the first tubular member to form a joint; providing a sleeve having opposite tapered ends and a flange, one of the tapered ends being a surface formed on the flange; mounting the sleeve for overlapping and coupling the first and second tubular members at the joint, wherein the flange is engaged in a recess formed in an adjacent one of the tubular members; wherein the first tubular member, the second tubular member, and the sleeve define a tubular assembly; and radially expanding and plastically deforming the tubular assembly; wherein, prior to the radial expansion and plastic deformation, a predetermined portion of the tubular assembly has a lower yield point than another portion of the tubular assembly.
  • the method further includes: providing a tapered wall in the recess for mating engagement with the tapered end formed on the flange. In an exemplary embodiment, the method further includes: providing a flange at each tapered end wherein each tapered end is formed on a respective flange. In an exemplary embodiment, the method further includes: providing a recess in each tubular member. In an exemplary embodiment, the method further includes: engaging each flange in a respective one of the recesses. In an exemplary embodiment, the method further includes: providing a tapered wall in each recess for mating engagement with the tapered end formed on a respective one of the flanges.
  • the predetermined portion of the tubular assembly has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the tubular assembly has a higher ductility prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the tubular assembly has a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the tubular assembly has a larger inside diameter after the radial expansion and plastic deformation than the other portion of the tubular assembly.
  • the method further includes: positioning another tubular assembly within the preexisting structure in overlapping relation to the tubular assembly; and radially expanding and plastically deforming the other tubular assembly within the preexisting structure; wherein, prior to the radial expansion and plastic deformation of the tubular assembly, a predetermined portion of the other tubular assembly has a lower yield point than another portion of the other tubular assembly.
  • the inside diameter of the radially expanded and plastically deformed other portion of the tubular assembly is equal to the inside diameter of the radially expanded and plastically deformed other portion of the other tubular assembly.
  • the predetermined portion of the tubular assembly comprises an end portion of the tubular assembly.
  • the predetermined portion of the tubular assembly comprises a plurality of predetermined portions of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a plurality of spaced apart predetermined portions of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly comprises an end portion of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly comprises a plurality of other portions of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly comprises a plurality of spaced apart other portions of the tubular assembly. In an exemplary embodiment, the tubular assembly comprises a plurality of tubular members coupled to one another by corresponding tubular couplings.
  • the tubular couplings comprise the predetermined portions of the tubular assembly; and wherein the tubular members comprise the other portion of the tubular assembly.
  • one or more of the tubular couplings comprise the predetermined portions of the tubular assembly.
  • one or more of the tubular members comprise the predetermined portions of the tubular assembly.
  • the predetermined portion of the tubular assembly defines one or more openings.
  • one or more of the openings comprise slots.
  • the anisotropy for the predetermined portion of the tubular assembly is greater than 1. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1.
  • the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1; and wherein the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a first steel alloy comprising: 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and 0.02% Cr.
  • the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 65.9 ksi after the radial expansion and plastic deformation.
  • the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation.
  • the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation is about 1.48.
  • the predetermined portion of the tubular assembly comprises a second steel alloy comprising: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr.
  • the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 74.4 ksi after the radial expansion and plastic deformation.
  • the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 28% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation.
  • the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation is about 1.04.
  • the predetermined portion of the tubular assembly comprises a third steel alloy comprising: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16% Cu, 0.05% Ni, and 0.05% Cr.
  • the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation is about 1.92.
  • the predetermined portion of the tubular assembly comprises a fourth steel alloy comprising: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S, 0.45% Si, 9.1% Ni, and 18.7% Cr.
  • the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation is about 1.34.
  • the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 65.9 ksi after the radial expansion and plastic deformation.
  • the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation.
  • the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation is at least about 1.48.
  • the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 74.4 ksi after the radial expansion and plastic deformation.
  • the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 28% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation.
  • the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation is at least about 1.04.
  • the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation is at least about 1.92. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.34. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, ranges from about 1.04 to about 1.92. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, ranges from about 47.6 ksi to about 61.7 ksi.
  • the expandability coefficient of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is greater than 0.12. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the tubular assembly is greater than the expandability coefficient of the other portion of the tubular assembly.
  • the tubular assembly comprises a wellbore casing. In an exemplary embodiment, the tubular assembly comprises a pipeline. In an exemplary embodiment, the tubular assembly comprises a structural support.
  • An expandable tubular assembly has been described that includes a first tubular member; a second tubular member coupled to the first tubular member; a first threaded connection for coupling a portion of the first and second tubular members; a second threaded connection spaced apart from the first threaded connection for coupling another portion of the first and second tubular members; a tubular sleeve coupled to and receiving end portions of the first and second tubular members; and a sealing element positioned between the first and second spaced apart threaded connections for sealing an interface between the first and second tubular member; wherein the sealing element is positioned within an annulus defined between the first and second tubular members; and wherein, prior to a radial expansion and plastic deformation of the assembly, a predetermined portion of the assembly has a lower yield point than another portion of the apparatus.
  • the predetermined portion of the assembly has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the assembly has a higher ductility prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the assembly has a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the assembly has a larger inside diameter after the radial expansion and plastic deformation than other portions of the tubular assembly.
  • the assembly further includes: positioning another assembly within the preexisting structure in overlapping relation to the assembly; and radially expanding and plastically deforming the other assembly within the preexisting structure; wherein, prior to the radial expansion and plastic deformation of the assembly, a predetermined portion of the other assembly has a lower yield point than another portion of the other assembly.
  • the inside diameter of the radially expanded and plastically deformed other portion of the assembly is equal to the inside diameter of the radially expanded and plastically deformed other portion of the other assembly.
  • the predetermined portion of the assembly comprises an end portion of the assembly.
  • the predetermined portion of the assembly comprises a plurality of predetermined portions of the assembly.
  • the predetermined portion of the assembly comprises a plurality of spaced apart predetermined portions of the assembly.
  • the other portion of the assembly comprises an end portion of the assembly.
  • the other portion of the assembly comprises a plurality of other portions of the assembly.
  • the other portion of the assembly comprises a plurality of spaced apart other portions of the assembly.
  • the assembly comprises a plurality of tubular members coupled to one another by corresponding tubular couplings.
  • the tubular couplings comprise the predetermined portions of the assembly; and wherein the tubular members comprise the other portion of the assembly.
  • one or more of the tubular couplings comprise the predetermined portions of the assembly.
  • one or more of the tubular members comprise the predetermined portions of the assembly.
  • the predetermined portion of the assembly defines one or more openings.
  • one or more of the openings comprise slots.
  • the anisotropy for the predetermined portion of the assembly is greater than 1.
  • the anisotropy for the predetermined portion of the assembly is greater than 1.
  • the strain hardening exponent for the predetermined portion of the assembly is greater than 0.12.
  • the anisotropy for the predetermined portion of the assembly is greater than 1; and wherein the strain hardening exponent for the predetermined portion of the assembly is greater than 0.12.
  • the predetermined portion of the assembly comprises a first steel alloy comprising: 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and 0.02% Cr.
  • the yield point of the predetermined portion of the assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the assembly is at least about 65.9 ksi after the radial expansion and plastic deformation.
  • the yield point of the predetermined portion of the assembly after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the predetermined portion of the assembly prior to the radial expansion and plastic deformation.
  • the anisotropy of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation is about 1.48.
  • the predetermined portion of the assembly comprises a second steel alloy comprising: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr.
  • the yield point of the predetermined portion of the assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the assembly is at least about 74.4 ksi after the radial expansion and plastic deformation.
  • the yield point of the predetermined portion of the assembly after the radial expansion and plastic deformation is at least about 28% greater than the yield point of the predetermined portion of the assembly prior to the radial expansion and plastic deformation.
  • the anisotropy of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation is about 1.04.
  • the predetermined portion of the assembly comprises a third steel alloy comprising: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16% Cu, 0.05% Ni, and 0.05% Cr.
  • the anisotropy of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation, is about 1.92.
  • the predetermined portion of the assembly comprises a fourth steel alloy comprising: 0.02% C, 1.31% Mn, 0.02% P, 0.001% Si 0.45% Si, 9.1% Ni, and 18.7% Cr.
  • the anisotropy of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation is about 1.34.
  • the yield point of the predetermined portion of the assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the assembly is at least about 65.9 ksi after the radial expansion and plastic deformation.
  • the yield point of the predetermined portion of the assembly after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the predetermined portion of the assembly prior to the radial expansion and plastic deformation.
  • the anisotropy of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation is at least about 1.48.
  • the yield point of the predetermined portion of the assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the assembly is at least about 74.4 ksi after the radial expansion and plastic deformation.
  • the yield point of the predetermined portion of the assembly after the radial expansion and plastic deformation is at least about 28% greater than the yield point of the predetermined portion of the assembly prior to the radial expansion and plastic deformation.
  • the anisotropy of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation is at least about 1.04. In an exemplary embodiment, the anisotropy of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation, is at least about 1.92. In an exemplary embodiment, the anisotropy of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation, is at least about 1.34. In an exemplary embodiment, the anisotropy of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation, ranges from about 1.04 to about 1.92.
  • the yield point of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation ranges from about 47.6 ksi to about 61.7 ksi.
  • the expandability coefficient of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation is greater than 0.12.
  • the expandability coefficient of the predetermined portion of the assembly is greater than the expandability coefficient of the other portion of the assembly.
  • the assembly comprises a wellbore casing.
  • the assembly comprises a pipeline.
  • the assembly comprises a structural support.
  • the annulus is at least partially defined by an irregular surface.
  • the annulus is at least partially defined by a toothed surface.
  • the sealing element comprises an elastomeric material.
  • the sealing element comprises a metallic material.
  • the sealing element comprises an elastomeric and a metallic material.
  • a method of joining radially expandable tubular members includes providing a first tubular member; providing a second tubular member; providing a sleeve; mounting the sleeve for overlapping and coupling the first and second tubular members; threadably coupling the first and second tubular members at a first location; threadably coupling the first and second tubular members at a second location spaced apart from the first location; sealing an interface between the first and second tubular members between the first and second locations using a compressible sealing element, wherein the first tubular member, second tubular member, sleeve, and the sealing element define a tubular assembly; and radially expanding and plastically deforming the tubular assembly; wherein, prior to the radial expansion and plastic deformation, a predetermined portion of the tubular assembly has a lower yield point than another portion of the tubular assembly.
  • the sealing element includes an irregular surface. In an exemplary embodiment, the sealing element includes a toothed surface. In an exemplary embodiment, the sealing element comprises an elastomeric material. In an exemplary embodiment, the sealing element comprises a metallic material. In an exemplary embodiment, the sealing element comprises an elastomeric and a metallic material. In an exemplary embodiment, the predetermined portion of the tubular assembly has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the tubular assembly has a higher ductility prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
  • the predetermined portion of the tubular assembly has a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the tubular assembly has a larger inside diameter after the radial expansion and plastic deformation than the other portion of the tubular assembly. In an exemplary embodiment, the method further includes: positioning another tubular assembly within the preexisting structure in overlapping relation to the tubular assembly; and radially expanding and plastically deforming the other tubular assembly within the preexisting structure; wherein, prior to the radial expansion and plastic deformation of the tubular assembly, a predetermined portion of the other tubular assembly has a lower yield point than another portion of the other tubular assembly.
  • the inside diameter of the radially expanded and plastically deformed other portion of the tubular assembly is equal to the inside diameter of the radially expanded and plastically deformed other portion of the other tubular assembly.
  • the predetermined portion of the tubular assembly comprises an end portion of the tubular assembly.
  • the predetermined portion of the tubular assembly comprises a plurality of predetermined portions of the tubular assembly.
  • the predetermined portion of the tubular assembly comprises a plurality of spaced apart predetermined portions of the tubular assembly.
  • the other portion of the tubular assembly comprises an end portion of the tubular assembly.
  • the other portion of the tubular assembly comprises a plurality of other portions of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly comprises a plurality of spaced apart other portions of the tubular assembly. In an exemplary embodiment, the tubular assembly comprises a plurality of tubular members coupled to one another by corresponding tubular couplings. In an exemplary embodiment, the tubular couplings comprise the predetermined portions of the tubular assembly; and wherein the tubular members comprise the other portion of the tubular assembly. In an exemplary embodiment, one or more of the tubular couplings comprise the predetermined portions of the tubular assembly. In an exemplary embodiment, one or more of the tubular members comprise the predetermined portions of the tubular assembly.
  • the predetermined portion of the tubular assembly defines one or more openings. In an exemplary embodiment, one or more of the openings comprise slots. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1. In an exemplary embodiment, the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1; and wherein the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12.
  • the predetermined portion of the tubular assembly comprises a first steel alloy comprising: 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and 0.02% Cr.
  • the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 65.9 ksi after the radial expansion and plastic deformation.
  • the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation.
  • the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation is about 1.48.
  • the predetermined portion of the tubular assembly comprises a second steel alloy comprising: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr.
  • the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 74.4 ksi after the radial expansion and plastic deformation.
  • the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 28% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation.
  • the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation is about 1.04.
  • the predetermined portion of the tubular assembly comprises a third steel alloy comprising: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16% Cu, 0.05% Ni, and 0.05% Cr.
  • the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.92.
  • the predetermined portion of the tubular assembly comprises a fourth steel alloy comprising: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S, 0.45% Si, 9.1% Ni, and 18.7% Cr.
  • the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation is about 1.34.
  • the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 65.9 ksi after the radial expansion and plastic deformation.
  • the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation.
  • the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation is at least about 1.48.
  • the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 74.4 ksi after the radial expansion and plastic deformation.
  • the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 28% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation.
  • the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation is at least about 1.04. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.92. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.34. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, ranges from about 1.04 to about 1.92.
  • the yield point of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation ranges from about 47.6 ksi to about 61.7 ksi.
  • the expandability coefficient of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation is greater than 0.12.
  • the expandability coefficient of the predetermined portion of the tubular assembly is greater than the expandability coefficient of the other portion of the tubular assembly.
  • the tubular assembly comprises a wellbore casing.
  • the tubular assembly comprises a pipeline.
  • the tubular assembly comprises a structural support.
  • the sleeve comprises: a plurality of spaced apart tubular sleeves coupled to and receiving end portions of the first and second tubular members.
  • the first tubular member comprises a first threaded connection; wherein the second tubular member comprises a second threaded connection; wherein the first and second threaded connections are coupled to one another; wherein at least one of the tubular sleeves is positioned in opposing relation to the first threaded connection; and wherein at least one of the tubular sleeves is positioned in opposing relation to the second threaded connection.
  • the first tubular member comprises a first threaded connection; wherein the second tubular member comprises a second threaded connection; wherein the first and second threaded connections are coupled to one another; and wherein at least one of the tubular sleeves is not positioned in opposing relation to the first and second threaded connections.
  • the carbon content of the tubular member is less than or equal to 0.12 percent; and wherein the carbon equivalent value for the tubular member is less than 0.21.
  • the tubular member comprises a wellbore casing.
  • the tubular member comprises a wellbore casing.
  • a method of selecting tubular members for radial expansion and plastic deformation includes: selecting a tubular member from a collection of tubular member; determining a carbon content of the selected tubular member; determining a carbon equivalent value for the selected tubular member, and if the carbon content of the selected tubular member is less than or equal to 0.12 percent and the carbon equivalent value for the selected tubular member is less than 0.21, then determining that the selected tubular member is suitable for radial expansion and plastic deformation.
  • a method of selecting tubular members for radial expansion and plastic deformation includes: selecting a tubular member from a collection of tubular member; determining a carbon content of the selected tubular member, determining a carbon equivalent value for the selected tubular member; and if the carbon content of the selected tubular member is greater than 0.12 percent and the carbon equivalent value for the selected tubular member is less than 0.36, then determining that the selected tubular member is suitable for radial expansion and plastic deformation.
  • An expandable tubular member has been described that includes: a tubular body; wherein a yield point of an inner tubular portion of the tubular body is less than a yield point of an outer tubular portion of the tubular body.
  • the yield point of the inner tubular portion of the tubular body varies as a function of the radial position within the tubular body.
  • the yield point of the inner tubular portion of the tubular body varies in an linear fashion as a function of the radial position within the tubular body.
  • the yield point of the inner tubular portion of the tubular body varies in an non-linear fashion as a function of the radial position within the tubular body.
  • the yield point of the outer tubular portion of the tubular body varies as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the outer tubular portion of the tubular body varies in an linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the outer tubular portion of the tubular body varies in an non-linear fashion as a function of the radial position within the tubular body.
  • the yield point of the inner tubular portion of the tubular body varies as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies as a function of the radial position within the tubular body.
  • the yield point of the inner tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body.
  • the yield point of the inner tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body.
  • the yield point of the inner tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body.
  • the yield point of the inner tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body.
  • the rate of change of the yield point of the inner tubular portion of the tubular body is different than the rate of change of the yield point of the outer tubular portion of the tubular body.
  • the rate of change of the yield point of the inner tubular portion of the tubular body is different than the rate of change of the yield point of the outer tubular portion of the tubular body.
  • a method of manufacturing an expandable tubular member includes: providing a tubular member; heat treating the tubular member; and quenching the tubular member; wherein following the quenching, the tubular member comprises a microstructure comprising a hard phase structure and a soft phase structure.
  • the provided tubular member comprises, by weight percentage, 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, 0.02% Cr, 0.05% V, 0.01% Mo, 0.01% Nb, and 0.01% Ti.
  • the provided tubular member comprises, by weight percentage, 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, 0.03% Cr, 0.04% V, 0.01% Mo, 0.03% Nb, and 0.01% Ti.
  • the provided tubular member comprises, by weight percentage, 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.06% Cu, 0.05% Ni, 0.05% Cr, 0.03% V, 0.03% Mo, 0.01% Nb, and 0.01% Ti.
  • the provided tubular member comprises a microstructure comprising one or more of the following: martensite, pearlite, vanadium carbide, nickel carbide, or titanium carbide.
  • the provided tubular member comprises a microstructure comprising one or more of the following: pearlite or pearlite striation.
  • the provided tubular member comprises a microstructure comprising one or more of the following: grain pearlite, widmanstatten martensite, vanadium carbide, nickel carbide, or titanium carbide.
  • the heat treating comprises heating the provided tubular member for about 10 minutes at 790° C.
  • the quenching comprises quenching the heat treated tubular member in water.
  • the tubular member comprises a microstructure comprising one or more of the following: ferrite, grain pearlite, or martensite. In an exemplary embodiment, following the quenching, the tubular member comprises a microstructure comprising one or more of the following: ferrite, martensite, or bainite. In an exemplary embodiment, following the quenching, the tubular member comprises a microstructure comprising one or more of the following: bainite, pearlite, or ferrite. In an exemplary embodiment, following the quenching, the tubular member comprises a yield strength of about 67 ksi and a tensile strength of about 95 ksi.
  • the tubular member comprises a yield strength of about 82 ksi and a tensile strength of about 130 ksi. In an exemplary embodiment, following the quenching, the tubular member comprises a yield strength of about 60 ksi and a tensile strength of about 97 ksi. In an exemplary embodiment, the method further includes: positioning the quenched tubular member within a preexisting structure; and radially expanding and plastically deforming the tubular member within the preexisting structure.
  • An expandable tubular member has been described that includes: a steel alloy comprising: 0.07% Carbon, 1.64% Manganese, 0.011% Phosphor, 0.001% Sulfur, 0.23% Silicon, 0.5% Nickel, 0.51% Chrome, 0.31% Molybdenum, 0.15% Copper, 0.021% Aluminum, 0.04% Vanadium, 0.03% Niobium, and 0.007% Titanium.
  • An expandable tubular member has been described that includes: a collapse strength of approximately 70 ksi and comprising: 0.07% Carbon, 1.64% Manganese, 0.011% Phosphor, 0.001% Sulfur, 0.23% Silicon, 0.5% Nickel, 0.51% Chrome, 0.31% Molybdenum, 0.15% Copper, 0.021% Aluminum, 0.04% Vanadium, 0.03% Niobium, and 0.007% Titanium, wherein, upon radial expansion and plastic deformation, the collapse strength increases to approximately 110 ksi.
  • An expandable tubular member has been described that includes: an outer surface and means for increasing the collapse strength of a tubular assembly when the expandable tubular member is radially expanded and plastically deformed against a preexisting structure, the means coupled to the outer surface.
  • the means comprises a coating comprising a soft metal.
  • the means comprises a coating comprising aluminum.
  • the means comprises a coating comprising aluminum and zinc.
  • the means comprises a coating comprising plastic.
  • the means comprises a material wrapped around the outer surface of the tubular member.
  • the material comprises a soft metal.
  • the material comprises aluminum.
  • the means comprises a coating of varying thickness. In an exemplary embodiment, the means comprises a non uniform coating. In an exemplary embodiment, the means comprises a coating having multiple layers. In an exemplary embodiment, the multiple layers are selected from the group consisting of a soft metal, a plastic, a composite material, and combinations thereof.
  • a preexisting structure for accepting an expandable tubular member includes: a passage defined by the structure, an inner surface on the passage and means for increasing the collapse strength of a tubular assembly when an expandable tubular member is radially expanded and plastically deformed against the preexisting structure, the means coupled to the inner surface.
  • the means comprises a coating comprising a soft metal.
  • the means comprises a coating comprising aluminum.
  • the coating comprises aluminum and zinc.
  • the means comprises a coating comprising a plastic.
  • the means comprises a coating comprising a material lining the inner surface of the tubular member.
  • the material comprises a soft metal.
  • the material comprises aluminum.
  • the means comprises a coating of varying thickness.
  • the means comprises a non uniform coating.
  • the means comprises a coating having multiple layers.
  • the multiple layers are selected from the group consisting of a soft metal, a plastic, a composite material, and combinations thereof.
  • An expandable tubular assembly has been described that includes: a structure defining a passage therein, an expandable tubular member positioned in the passage and means for increasing the collapse strength of the assembly when the expandable tubular member is radially expanded and plastically deformed against the structure, the means positioned between the expandable tubular member and the structure.
  • the structure comprises a wellbore casing.
  • the structure comprises a tubular member.
  • the means comprises an interstitial layer comprising a soft metal.
  • the means comprises an interstitial layer comprising aluminum.
  • the means comprises an interstitial layer comprising aluminum and zinc.
  • the means comprises an interstitial layer comprising a plastic.
  • the means comprises an interstitial layer comprising a material wrapped around an outer surface of the expandable tubular member.
  • the material comprises a soft metal.
  • the material comprises aluminum.
  • the means comprises an interstitial layer comprising a material lining an inner surface of the structure.
  • the material comprises a soft metal.
  • the material comprises aluminum.
  • the means comprises an interstitial layer of varying thickness.
  • the means comprises a non uniform interstitial layer.
  • the means comprises an interstitial layer having multiple layers. In an exemplary embodiment, the multiple layers are selected from the group consisting of a soft metal, a plastic, a composite material, and combinations thereof.
  • the structure is in circumferential tension.
  • a tubular assembly has been described that includes: a structure defining a passage therein, an expandable tubular member positioned in the passage and an interstitial layer positioned between the structure and expandable tubular member, wherein the collapse strength of the assembly with the interstitial layer is at least 20% greater than the collapse strength without the interstitial layer.
  • the structure comprises a wellbore casing.
  • the structure comprises a tubular member.
  • the interstitial layer comprises aluminum.
  • the interstitial layer comprises aluminum and zinc.
  • the interstitial layer comprises plastic.
  • the interstitial layer has a varying thickness. In an exemplary embodiment, the interstitial layer is non uniform.
  • the interstitial layer comprises multiple layers.
  • the multiple layers are selected from the group consisting of a soft metal, a plastic, a composite material, and combinations thereof.
  • the structure is in circumferential tension.
  • a tubular assembly has been described that includes: a structure defining a passage therein, an expandable tubular member positioned in the passage and an interstitial layer positioned between the structure and expandable tubular member, wherein the collapse strength of the assembly with the interstitial layer is at least 30% greater than the collapse strength without the interstitial layer.
  • the structure comprises a wellbore casing.
  • the structure comprises a tubular member.
  • the interstitial layer comprises aluminum.
  • the interstitial layer comprises aluminum and zinc.
  • the interstitial layer comprises plastic.
  • the interstitial layer has a varying thickness. In an exemplary embodiment, the interstitial layer is non uniform.
  • the interstitial layer comprises multiple layers.
  • the multiple layers are selected from the group consisting of a soft metal, a plastic, a composite material, and combinations thereof.
  • the structure is in circumferential tension.
  • a tubular assembly has been described that includes: a structure defining a passage therein, an expandable tubular member positioned in the passage and an interstitial layer positioned between the structure and expandable tubular member, wherein the collapse strength of the assembly with the interstitial layer is at least 40% greater than the collapse strength without the interstitial layer.
  • the structure comprises a wellbore casing.
  • the structure comprises a tubular member.
  • the interstitial layer comprises aluminum.
  • the interstitial layer comprises aluminum and zinc.
  • the interstitial layer comprises plastic.
  • the interstitial layer has a varying thickness. In an exemplary embodiment, the interstitial layer is non uniform.
  • the interstitial layer comprises multiple layers.
  • the multiple layers are selected from the group consisting of a soft metal, a plastic, a composite material, and combinations thereof.
  • the structure is in circumferential tension.
  • a tubular assembly has been described that includes: a structure defining a passage therein, an expandable tubular member positioned in the passage and an interstitial layer positioned between the structure and expandable tubular member, wherein the collapse strength of the assembly with the interstitial layer is at least 50% greater than the collapse strength without the interstitial layer.
  • the structure comprises a wellbore casing.
  • the structure comprises a tubular member.
  • the interstitial layer comprises aluminum.
  • the interstitial layer comprises aluminum and zinc.
  • the interstitial layer comprises plastic.
  • the interstitial layer has a varying thickness. In an exemplary embodiment, the interstitial layer is non uniform.
  • the interstitial layer comprises multiple layers.
  • the multiple layers are selected from the group consisting of a soft metal, a plastic, a composite material, and combinations thereof.
  • the structure is in circumferential tension.
  • An expandable tubular assembly has been described that includes: an outer tubular member comprising a steel alloy and defining a passage, an inner tubular member comprising a steel alloy and positioned in the passage and an interstitial layer between the inner tubular member and the outer tubular member, the interstitial layer comprising an aluminum material lining an inner surface of the outer tubular member, whereby the collapse strength of the assembly with the interstitial layer is greater than the collapse strength of the assembly without the interstitial layer.
  • a method for increasing the collapse strength of a tubular assembly includes: providing a preexisting structure defining a passage therein, providing an expandable tubular member, coating the expandable tubular member with an interstitial material, positioning the expandable tubular member in the passage defined by the preexisting structure and expanding the expandable tubular member such that the interstitial material engages the preexisting structure, whereby the collapse strength of the preexisting structure and expandable tubular member with the interstitial material is greater than the collapse strength of the preexisting structure and expandable tubular member without the interstitial material.
  • the preexisting structure comprises a wellbore casing.
  • the preexisting structure comprises a tubular member.
  • the coating comprises applying a soft metal layer on an outer surface of the expandable tubular member.
  • the coating comprises applying an aluminum layer on an outer surface of the expandable tubular member.
  • the coating comprises applying an aluminum/zinc layer on an outer surface of the expandable tubular member.
  • the coating comprises applying a plastic layer on an outer surface of the expandable tubular member.
  • the coating comprises wrapping a material around an outer surface of the expandable tubular member.
  • the material comprises a soft metal.
  • the material comprises aluminum.
  • the expanding results in the expansion of the preexisting structure.
  • the expansion places the preexisting structure in circumferential tension.
  • a method for increasing the collapse strength of a tubular assembly includes: providing a preexisting structure defining a passage therein, providing an expandable tubular member, coating the preexisting structure with an interstitial material, positioning the expandable tubular member in the passage defined by the preexisting structure and expanding the expandable tubular member such that the interstitial material engages the expandable tubular member, whereby the collapse strength of the preexisting structure and expandable tubular member with the interstitial material is greater than the collapse strength of the preexisting structure and expandable tubular member without the interstitial material.
  • the preexisting structure is a wellbore casing.
  • the preexisting structure is a tubular member.
  • the coating comprises applying a soft metal layer on a surface of the passage in the preexisting structure.
  • the coating comprises applying an aluminum layer on a surface of the passage in the preexisting structure.
  • the coating comprises applying an aluminum/zinc layer on a surface of the passage in the preexisting structure.
  • the coating comprises applying a plastic layer on a surface of the passage in the preexisting structure.
  • the coating comprises lining a material around a surface of the passage in the preexisting structure.
  • the material comprises a soft metal.
  • the material comprises aluminum.
  • the expanding results in the expansion of the preexisting structure.
  • the expanding places the preexisting structure in circumferential tension.
  • An expandable tubular member has been described that includes: an outer surface and an interstitial layer on the outer surface, wherein the interstitial layer comprises an aluminum material resulting in a required expansion operating pressure of approximately 3900 psi for the tubular member.
  • the expandable tubular member comprises an expanded 75 ⁇ 8 inch diameter tubular member.
  • An expandable tubular assembly has been described that includes: an outer surface and an interstitial layer on the outer surface, wherein the interstitial layer comprises an aluminum/zinc material resulting in a required expansion operating pressure of approximately 3700 psi for the tubular member.
  • the expandable tubular member comprises an expanded 75 ⁇ 8 inch diameter tubular member.
  • An expandable tubular assembly has been described that includes: an outer surface and an interstitial layer on the outer surface, wherein the interstitial layer comprises an plastic material resulting in a required expansion operating pressure of approximately 3600 psi for the tubular member.
  • the expandable tubular member comprises an expanded 75 ⁇ 8 inch diameter tubular member.
  • An expandable tubular assembly has been described that includes: a structure defining a passage therein, an expandable tubular member positioned in the passage and an interstitial layer positioned between the expandable tubular member and the structure, wherein the interstitial layer has a thickness of approximately 0.05 inches to 0.15 inches.
  • the interstitial layer comprises aluminum.
  • An expandable tubular assembly has been described that includes: a structure defining a passage therein, an expandable tubular member positioned in the passage and an interstitial layer positioned between the expandable tubular member and the structure, wherein the interstitial layer has a thickness of approximately 0.07 inches to 0.13 inches.
  • the interstitial layer comprises aluminum and zinc.
  • An expandable tubular assembly has been described that includes: a structure defining a passage therein, an expandable tubular member positioned in the passage and an interstitial layer positioned between the expandable tubular member and the structure, wherein the interstitial layer has a thickness of approximately 0.06 inches to 0.14 inches.
  • the interstitial layer comprises plastic.
  • An expandable tubular assembly has been described that includes: a structure defining a passage therein, an expandable tubular member positioned in the passage and an interstitial layer positioned between the expandable tubular member and the structure, wherein the interstitial layer has a thickness of approximately 1.6 mm to 2.5 mm between the structure and the expandable tubular member.
  • the interstitial layer comprises plastic.
  • An expandable tubular assembly has been described that includes: a structure defining a passage therein, an expandable tubular member positioned in the passage and an interstitial layer positioned between the expandable tubular member and the structure, wherein the interstitial layer has a thickness of approximately 2.6 mm to 3.1 mm between the structure and the expandable tubular member.
  • the interstitial layer comprises aluminum.
  • An expandable tubular assembly has been described that includes: a structure defining a passage therein, an expandable tubular member positioned in the passage and an interstitial layer positioned between the expandable tubular member and the structure, wherein the interstitial layer has a thickness of approximately 1.9 mm to 2.5 mm between the structure and the expandable tubular member.
  • the interstitial layer comprises aluminum and zinc.
  • An expandable tubular assembly has been described that includes: a structure defining a passage therein, an expandable tubular member positioned in the passage, an interstitial layer positioned between the expandable tubular member and the structure and a collapse strength greater than approximately 20000 psi.
  • the structure comprises a tubular member comprising a diameter of approximately 95 ⁇ 8 inches.
  • the expandable tubular member comprises diameter of approximately 75 ⁇ 8 inches.
  • the expandable tubular member has been expanded by at least 13%.
  • the interstitial layer comprises a soft metal.
  • the interstitial layer comprises aluminum.
  • the interstitial layer comprises aluminum and zinc.
  • An expandable tubular assembly has been described that includes: a structure defining a passage therein, an expandable tubular member positioned in the passage, an interstitial layer positioned between the expandable tubular member and the structure and a collapse strength greater than approximately 14000 psi.
  • the structure comprises a tubular member comprising a diameter of approximately 95 ⁇ 8 inches.
  • the expandable tubular member comprises diameter of approximately 75 ⁇ 8 inches.
  • the expandable tubular member has been expanded by at least 13%.
  • the interstitial layer comprises a plastic.
  • a method for determining the collapse resistance of a tubular assembly includes: measuring the collapse resistance of a first tubular member, measuring the collapse resistance of a second tubular member, determining the value of a reinforcement factor for a reinforcement of the first and second tubular members and multiplying the reinforcement factor by the sum of the collapse resistance of the first tubular member and the collapse resistance of the second tubular member.
  • An expandable tubular assembly has been described that includes: a structure defining a passage therein, an expandable tubular member positioned in the passage and means for modifying the residual stresses in at least one of the structure and the expandable tubular member when the expandable tubular member is radially expanded and plastically deformed against the structure, the means positioned between the expandable tubular member and the structure.
  • the structure comprises a wellbore casing.
  • the structure comprises a tubular member.
  • the means comprises an interstitial layer comprising a soft metal.
  • the means comprises an interstitial layer comprising aluminum.
  • the means comprises an interstitial layer comprising aluminum and zinc.
  • the means comprises an interstitial layer comprising a plastic. In an exemplary embodiment, the means comprises an interstitial layer comprising a material wrapped around an outer surface of the expandable tubular member. In an exemplary embodiment, the material comprises a soft metal. In an exemplary embodiment, the material comprises aluminum. In an exemplary embodiment, the means comprises an interstitial layer comprising a material lining an inner surface of the structure. In an exemplary embodiment, the material comprises a soft metal. In an exemplary embodiment, the material comprises aluminum. In an exemplary embodiment, the means comprises an interstitial layer of varying thickness. In an exemplary embodiment, the means comprises a non uniform interstitial layer. In an exemplary embodiment, the means comprises an interstitial layer having multiple layers. In an exemplary embodiment, the multiple layers are selected from the group consisting of a soft metal, a plastic, a composite material, and combinations thereof. In an exemplary embodiment, the structure is in circumferential tension.
  • teachings of the present illustrative embodiments may be used to provide a wellbore casing, a pipeline, or a structural support.
  • the elements and teachings of the various illustrative embodiments may be combined in whole or in part in some or all of the illustrative embodiments.
  • one or more of the elements and teachings of the various illustrative embodiments may be omitted, at least in part, and/or combined, at least in part, with one or more of the other elements and teachings of the various illustrative embodiments.

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US10/570,417 2003-09-05 2004-09-07 Expandable tubular Abandoned US20060283603A1 (en)

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US50043503P 2003-09-05 2003-09-05
US58537004P 2004-07-02 2004-07-02
US59802004P 2004-08-02 2004-08-02
US60067904P 2004-08-11 2004-08-11
US60150204P 2004-08-13 2004-08-13
US10/570,417 US20060283603A1 (en) 2003-09-05 2004-09-07 Expandable tubular
PCT/US2004/028887 WO2005086614A2 (fr) 2003-09-05 2004-09-07 Tubulaire extensible

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US20060283603A1 true US20060283603A1 (en) 2006-12-21

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US (1) US20060283603A1 (fr)
BR (1) BRPI0414115A (fr)
CA (1) CA2537242A1 (fr)
GB (3) GB2425137B (fr)
NO (1) NO20061504L (fr)
WO (1) WO2005086614A2 (fr)

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Also Published As

Publication number Publication date
GB0603995D0 (en) 2006-04-05
GB0724262D0 (en) 2008-01-30
GB2441467B (en) 2008-06-04
GB2425137A (en) 2006-10-18
WO2005086614A3 (fr) 2012-12-13
GB0724263D0 (en) 2008-01-23
WO2005086614A2 (fr) 2005-09-22
GB2425137B (en) 2008-03-19
NO20061504L (no) 2006-05-05
CA2537242A1 (fr) 2005-09-22
GB2441696A (en) 2008-03-12
GB2441467A (en) 2008-03-05
BRPI0414115A (pt) 2006-10-31

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