Downhole Expandable Tubular Centrifugal Casting Expansion
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Solution Overview
Problem
Existing downhole expandable tubulars face challenges in expanding to larger diameters without increasing thickness, as they are prone to rupture due to material flaws or process errors, and their manufacturing process often results in varying strength and ductility due to welding.
Innovation Solution
A downhole expandable tubular made from a machined metal blank, using centrifugal or spin casting to create projections and grooves without welding, allowing for expansion up to 75% without fracturing, while maintaining uniform material properties and avoiding the deterioration caused by welded seams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the thickness of the expandable tubular is increased to expand to larger diameters, then the expansion capability is improved, but the device complexity and material usage increase
Solution Approach 1:
The patent applies parameter changes by modifying the material properties through a specific manufacturing process (centrifugal casting with controlled cooling) to achieve superior mechanical properties. The process parameters including cooling rate, casting speed, and material composition are optimized to produce a tubular with enhanced ductility and strength, enabling expansion to larger diameters without increasing thickness.
2Productivity
If welding is used to join tubular sections, then the manufacturing efficiency is improved, but the material uniformity and reliability deteriorate due to varying strength and ductility
Solution Approach 1:
The patent merges the entire tubular structure into a single monolithic piece manufactured by centrifugal casting, eliminating the need for welding multiple sections together. This integration approach ensures uniform material properties throughout the entire tubular length, avoiding the strength and ductility variations introduced by welded joints, while maintaining manufacturing efficiency through the continuous casting process.
3Ease of manufacture
If the tubular is made with standard manufacturing processes, then the ease of manufacture is improved, but the quality and resistance to rupture deteriorate due to material flaws
Solution Approach 1:
The patent changes the manufacturing parameters by employing centrifugal casting with controlled cooling rates and material composition. This process creates a homogeneous microstructure with minimized defects, producing high-quality tubulars that are resistant to rupture under expansion stresses, while remaining manufacturable through an established industrial process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables the downhole expandable tubular to expand significantly without fracturing, maintaining high ductility and uniform material quality, outperforming prior art by achieving up to 75% expansion compared to 15-30% in existing technologies.
Implementation Method 1
The metal tubular blank may be made by centrifugal or spin casting
Data Source
AI summary
The present invention relates to a downhole expandable tubular to be expanded in a well downhole from a first outer diameter to a second outer diameter to abut against an inner face of a casing or borehole, the downhole expandable tubular having an axial extension, wherein the downhole expandable tubular is made of metal and is machined from one metal tubular blank, providing the downhole expandable tubular with at least one circumferential projection. Furthermore, the present invention relates to an annular barrier, to a downhole completion comprising a downhole expandable tubular according to the present invention, to a downhole completion comprising a well tubular structure and an annular barrier according to the present invention and to a manufacturing method for the manufacture of the downhole expandable tubular according to the present invention.