Method of creating a casing in a borehole

A method of creating a casing in a borehole located in a subterranean formation, comprising:

• installing a tubular liner containing a tubular expansion cone in the borehole, wherein the wall thickness of the tubular liner is reduced proximate the tubular expansion cone;
• injecting fluidic material into the tubular liner through the tubular expansion cone;
• pressurizing an interior region of the tubular liner;
• radially expanding and extruding the tubular liner off of the tubular expansion cone;
• and
• reducing the required radial expansion and extrusion forces during an initial stage of the radial expansion and extrusion;
• wherein an interface between the tubular liner and the tubular expansion cone does not include a fluid tight seal.

A method of creating a casing in a borehole located in a subterranean formation, comprising:

• installing a tubular liner and a mandrel in the borehole;
• injecting a hardenable fluidic sealing material into an annular region located between the borehole and the exterior of the tubular liner;
• injecting a non hardenable fluidic material into an interior region of the tubular liner below the mandrel;
• pressurizing a portion of an interior region of the tubular liner;
• and
• radially expanding at least a portion of the liner in the borehole by extruding at least a portion of the liner off of the mandrel;
• wherein an interface between the tubular liner and the mandrel does not include a fluid tight seal;
• and
• wherein the injecting of the non hardenable fluidic material is provided at reduced operating pressures and flow rates during an end portion of the extruding.

A method of creating a casing in a borehole located in a subterranean formation, comprising:

• installing a tubular liner and a mandrel in the borehole;
• injecting fluidic material into the borehole;
• pressurizing a portion of an interior region of the tubular liner;
• and
• radially expanding at least a portion of the liner in the borehole by extruding at least a portion of the liner off of the mandrel;
• wherein an interface between the tubular liner and the mandrel does not include a fluid tight seal;
• and
• wherein the wall thickness of an unexpanded portion of the tubular liner is variable.

A method of joining a second tubular member to a first tubular member, the first tubular member having an inner diameter greater than an outer diameter of the second tubular member, comprising:

• positioning a mandrel within an interior region of the second tubular member;
• pressurizing a portion of the interior region of the second tubular member;
• and
• extruding the second tubular member off of the mandrel into engagement with the first tubular member;
• wherein an interface between the mandrel and the second tubular member does not include a fluid tight seal;
• and
• wherein the pressurizing of the portion of the interior region of the second tubular member is provided at operating pressures ranging from about 500 to 9,000 psi.

A method of creating a casing in a borehole located in a subterranean formation, comprising:

• installing a tubular liner and a mandrel in the borehole;
• injecting fluidic material into the borehole;
• pressurizing a portion of an interior region of the tubular liner;
• radially expanding at least a portion of the liner in the borehole by extruding at least a portion of the liner off of the mandrel;
• and
• equalizing the operating pressures on the interior and exterior surfaces of an end of the tubular liner;
• wherein an interface between the tubular liner and the mandrel does not include a fluid tight seal.

A method of joining a second tubular member to a first tubular member, the first tubular member having an inner diameter greater than an outer diameter of the second tubular member, comprising:

• positioning a mandrel within an interior region of the second tubular member;
• pressurizing a portion of the interior region of the second tubular member;
• extruding the second tubular member off of the mandrel into engagement with the first tubular member;
• and
• equalizing the operating pressures on the interior and exterior surfaces of an end of the second tubular member;
• wherein an interface between the mandrel and the second tubular member does not include a fluid tight seal.

A wellbore casing, comprising:

• a tubular liner, the tubular liner formed by the process of:
• extruding the tubular liner off of a mandrel;
• and
• equalizing the operating pressures on the interior and exterior surfaces of an end of the tubular liner during the extruding of the tubular liner;
• and
• an annular body of a cured fluidic sealing material coupled to the tubular liner;
• wherein an interface between the tubular liner and the mandrel does not include a fluid tight seal.

A method of creating a casing in a borehole located in a subterranean formation, comprising:

• installing a tubular liner and a mandrel in the borehole;
• injecting fluidic material into the borehole;
• pressurizing a portion of an interior region of the tubular liner;
• radially expanding at least a portion of the liner in the borehole by extruding at least a portion of the liner off of the mandrel;
• and
• slowing the mandrel using an end of the tubular liner;
• wherein an interface between the tubular liner and the mandrel does not include a fluid tight seal.

A method of joining a second tubular member to a first tubular member, the first tubular member having an inner diameter greater than an outer diameter of the second tubular member, comprising:

• positioning a mandrel within an interior region of the second tubular member;
• pressurizing a portion of the interior region of the second tubular member;
• extruding the second tubular member off of the mandrel into engagement with the first tubular member;
• and
• slowing the mandrel using an end of the second tubular member;
• wherein an interface between the mandrel and the second tubular member does not include a fluid tight seal.

A wellbore casing, comprising:

• a tubular liner, the tubular liner formed by the process of:
• extruding the tubular liner off of a mandrel;
• and slowing the mandrel during the extruding using an end of the tubular liner;
• an annular body of a cured fluidic sealing material coupled to the tubular liner;
• and
• wherein an interface between the tubular liner and the mandrel does not include a fluid tight seal.