Connection members including shape memory materials, downhole tools including the connection members, and methods of forming the downhole tools

Abstract

A downhole valve system for use in a borehole is disclosed. The downhole valve system includes a first downhole component formed of a brittle material, a second downhole component, and a connection member. The connection member formed from a shape memory material and includes: an outer surface including an outer diameter; an inner surface including an inner diameter, one of the outer and inner diameter modifiable by applying a stimulus to the shape memory material; and a connection feature, complimentary of a connection feature of the second downhole component, formed on one of the outer surface and the inner surface. The connection member secured to the first downhole component at a corresponding surface of the one of the inner and outer diameter and to the second downhole component via the first connection feature and the second connection feature to connect the second downhole component to the first downhole component.

What is claimed is: 
     
         1 . A downhole system for use in a borehole, the downhole system comprising:
 a first downhole component made from a brittle material and including a longitudinal axis, the first downhole component comprises a fracture toughness K 1C  lower than 20 MPa·m 1/2 ;   a second downhole component; and   a connection member formed from a shape memory material comprising: an outer surface including an outer diameter; and an inner surface including an inner diameter, one of the outer diameter and the inner diameter modifiable by applying a stimulus to the shape memory material; the connection member secured to the first downhole component at a first corresponding surface of the one of the inner diameter and the outer diameter, and the connection member secured to the second downhole component at a second corresponding surface of the one of the inner diameter and the outer diameter to connect the second downhole component to the first downhole component.   
     
     
         2 . The downhole system of  claim 1 , wherein the shape memory material comprises a nickel-titanium-niobium alloy (NiTiNb). 
     
     
         3 . The downhole system of  claim 1 , wherein the connection member is secured to the first downhole component at the corresponding surface of the one of the inner diameter and the outer diameter via an interference fit. 
     
     
         4 . The downhole system of  claim 1 , wherein the second downhole component comprises a first connection feature and the connection member comprises a second connection feature complimentary of the first connection feature. 
     
     
         5 . The downhole system of  claim 4 , wherein the first connection feature comprises threads. 
     
     
         6 . The downhole system of  claim 1 , wherein the brittle material is chosen from among a ceramic and a hard metal. 
     
     
         7 . The downhole system of  claim 1 , wherein the shape memory material is modifiable between a first state and a second state by applying the stimulus, the connection member comprising a smaller inner diameter while in the first state than the inner diameter in the second state. 
     
     
         8 . The downhole system of  claim 1 , wherein the connection member is configured to be in direct contact with a downhole fluid. 
     
     
         9 . The downhole system of  claim 1 , wherein the connection member includes a body, the body including the inner surface and the outer surface, and wherein the connection member includes a chamfer formed in the body at an edge of one of the inner surface and the outer surface. 
     
     
         10 . The downhole system of  claim 1 , wherein at least one of the connection member and the first downhole component comprises a textured surface. 
     
     
         11 . A method of forming a downhole tool, the method comprising:
 providing a first downhole component made from a brittle material and including a longitudinal axis, the first downhole component comprises a fracture toughness K 1C  lower than 20 MPa·m 1/2 , and a second downhole component; and   connecting the second downhole component to the first downhole component with a connection member formed from a shape memory material and comprising: an outer surface including an outer diameter; and an inner surface including an inner diameter, one of the outer diameter and the inner diameter modifiable by applying a stimulus to the shape memory material; the connection member secured to the first downhole component at a first corresponding surface of the one of the inner diameter and the outer diameter, and the connection member secured to the second downhole component at a second corresponding surface of the one of the inner diameter and the outer diameter to connect the second downhole component to the first downhole component.   
     
     
         12 . The method of  claim 11 , wherein the shape memory material comprises a nickel-titanium-niobium alloy (NiTiNb). 
     
     
         13 . The method of  claim 11 , wherein securing the connection member to the first downhole component at the corresponding surface of the one of the inner diameter and the outer diameter includes forming an interference fit. 
     
     
         14 . The method of  claim 11 , wherein the second downhole component comprises a first connection feature and the connection member comprises a second connection feature complimentary of the first connection feature. 
     
     
         15 . The method of  claim 14 , wherein the first connection feature comprises threads. 
     
     
         16 . The method of  claim 11 , wherein the brittle material is chosen from among a ceramic and a hard metal. 
     
     
         17 . The method of  claim 11 , wherein the shape memory material is modifiable between a first state and a second state by applying the stimulus, and connecting the second downhole component to the first downhole component with a connection member includes arranging the connection member relative to the first downhole component while in the second state, applying the stimulus to the shape memory material to modify the shape memory material from the second state to the first state and securing the connection member to the first downhole component. 
     
     
         18 . The method of  claim 11 , wherein the connection member is configured to be in direct contact with a downhole fluid 
     
     
         19 . The method of  claim 11 , wherein the connection member includes a body, the body including the inner surface and the outer surface, and wherein the connection member includes a chamfer formed in the body at an edge of one of the inner surface and the outer surface. 
     
     
         20 . The method of  claim 11 , further comprising forming a textured surface in at least one of the connection member and the first downhole component.