Method of applying an axial force to an expansion cone

1. A method of applying an axial force to a first piston positioned within a first piston chamber, comprising:

positioning a second piston within the first piston chamber;

pressurizing the first piston chamber by injecting fluidic materials into the first piston chamber;

displacing the second piston relative to the first piston within the first piston chamber; and

applying an axial force to the first piston using the second piston within the first piston chambers;

wherein the first piston comprises an expansion device for radially expanding and plastically deforming a tubular member.

2. The method of claim 1 , wherein the first and second pistons have annular cross sections.

3. The method of claim 1 , further comprising:

movably coupling the first and second pistons to a tubular support member defining an internal passage.

4. The method of claim 3 , further comprising:

displacing the second piston; and

exhausting fluidic materials displaced by the second piston into the internal passage of the tubular support member.

5. The method of claim 4 , wherein exhausting fluidic materials displaced by the second piston into the internal passage of the tubular support member comprises:

exhausting fluidic materials within an exhaust chamber defined between the second piston and the tubular support member displaced by the second piston into the internal passage of the tubular support member.

6. The method of claim 5 , wherein the first piston chamber and the exhaust chamber have annular cross sections.

7. The method of claim 5 , wherein the cross sectional area of the first piston chamber is greater than the cross sectional area of the exhaust chamber.

8. The method of claim 5 , wherein the operating pressure of the exhaust chamber is less than a portion of the first piston chamber downstream from the first piston.

9. The method of claim 5 , wherein the exhaust chamber is fluidicly isolated from the first piston chamber.

10. The method of claim 3 , wherein the first and second pistons have annular cross sections; and wherein the tubular support member is received within the first and second pistons.

11. The method of claim 10 , further comprising:

displacing the second piston; and

exhausting fluidic materials displaced by the second piston into the internal passage of the tubular support member.

12. The method of claim 11 , wherein exhausting fluidic materials displaced by the second piston into the internal passage of the tubular support member comprises:

exhausting fluidic materials within an exhaust chamber defined between the second piston and the tubular support member displaced by the second piston into the internal passage of the tubular support member.

13. The method of claim 12 , wherein the first piston chamber and the exhaust chamber have annular cross sections.

14. The method of claim 12 , wherein the cross sectional area of the first piston chamber is greater than the cross sectional area of the exhaust chamber.

15. The method of claim 12 , wherein the operating pressure of the exhaust chamber is less than a portion of the first piston chamber downstream from the first piston.

16. The method of claim 12 , wherein the exhaust chamber is fluidicly isolated from the first piston chamber.

17. The method of claim 1 , further comprising:

applying an axial force to the first piston by direct application of the fluidic materials.

18. The method of claim 1 , wherein a portion of the first piston chamber upstream from the first piston has a larger cross sectional area than a portion of the first piston chamber downstream from the first piston.

19. The method of claim 18 , wherein the first piston chamber has an annular cross section.

20. The method of claim 1 , wherein:

the cross sectional area of the first piston is greater than the cross sectional area of the second piston.

21. The method of claim 1 , wherein the expansion device includes one or more outer tapered surfaces for engaging the tubular member.

22. The method of claim 1 , further comprising:

applying an axial force to the first piston by direct application of the fluidic materials;

wherein a portion of the first piston chamber upstream from the first piston has a larger cross sectional area than a portion of the first piston chamber downstream from the first piston; and

wherein the first piston chamber has an annular cross section.

23. The method of claim 1 , further comprising:

movably coupling the first and second pistons to a tubular support member defining an internal passage;

displacing the second piston; and

exhausting fluidic materials within an exhaust chamber defined between the second piston and the tubular support member displaced by the second piston into the internal passage of the tubular support member;

wherein the first piston chamber and the exhaust chamber have annular cross sections;

wherein the tubular support member is received within the first and second pistons;

wherein the cross sectional area of the first piston chamber is greater than the cross sectional area of the exhaust chamber;

wherein the operating pressure of the exhaust chamber is less than a portion of the first piston chamber downstream from the first piston; and

wherein the exhaust chamber is fluidicly isolated from the first piston chamber.

24. The method of claim 1 ,

wherein the cross sectional area of the first piston is greater than the cross sectional area of the second piston; and

wherein the first piston comprises an expansion device including one or more outer tapered surfaces for radially expanding and plastically deforming a tubular member.

25. The method of claim 1 , further comprising:

displacing the second piston toward to the first piston within the first piston chamber.

26. The method of claim 1 , wherein applying an axial force to the first piston using the second piston within the first piston chamber comprises:

impacting the first piston with the second piston within the first piston chamber.

27. A method of displacing an annular expansion cone for radially expanding an expandable tubular member, comprising:

movably coupling the annular expansion cone to a first tubular support member defining an internal passage;

positioning the annular expansion cone within a first annular chamber defined between the expandable tubular member and the first tubular support member;

positioning an annular piston within a second annular chamber defined between the first tubular support member and a second tubular support member;

defining a third annular chamber between the annular piston and the first tubular support member that is fluidicly coupled to the internal passage of the first tubular support member;

injecting fluidic materials into the second annular chamber to displace the annular piston relative to the annular expansion cone within the second annular chamber;

exhausting fluidic materials displaced by the annular piston out of the third annular chamber into the internal passage of the first tubular support member; and

the annular piston impacting and displacing the annular expansion cone relative to the first tubular support member;

wherein the cross sectional area of the second annular chamber is greater than the cross sectional area of the third annular chamber;

wherein the first and second annular chambers are fluidicly isolated from the third annular chamber; and

wherein a cross sectional area of a region of the first annular chamber upstream from the annular expansion cone is greater than a cross sectional area of a region of the first annular chamber downstream from the annular expansion cone.

28. A method of applying an axial force to a first piston positioned within a first piston chamber, comprising:

positioning a second piston within the first piston chamber;

displacing the second piston relative to the first piston within the first piston chamber; and

applying an axial force to the first piston using the second piston within the first piston chamber;

wherein the first piston is coupled to an expansion device for radially expanding and plastically deforming a tubular member.

29. A method of applying an axial force to a first piston positioned within a first piston chamber, comprising:

positioning a second piston within the first piston chamber; and

applying an axial force to the first piston by impacting the first piston with the second piston within the first piston chamber;

wherein the first piston is coupled to an expansion device for radially expanding and plastically deforming a tubular member.

30. The method of claim 29 , further comprising:

applying an axial force to the first piston through the direct application of fluid pressure.

31. The method of claim 29 , further comprising:

displacing the second piston relative to the first piston within the first piston chamber;

applying an axial force to the first piston by impacting the first piston with the second piston within the first piston chamber; and

then displacing the first and second pistons together within the first piston chamber.

32. A method of applying an axial force to a first piston positioned within a first piston chamber, comprising:

positioning a second piston within the first piston chamber;

pressurizing the first piston chamber by injecting fluidic materials into the first piston chamber;

displacing the second piston relative to the first piston within the first piston chamber;

applying an axial force to the first piston using the second piston within the first piston chamber; and

movably coupling the first and second pistons to a tubular support member defining an internal passage.

33. The method of claim 32 , further comprising:

displacing the second piston; and

exhausting fluidic materials displaced by the second piston into the internal passage of the tubular support member.

34. The method of claim 33 , wherein exhausting fluidic materials displaced by the second piston into the internal passage of the tubular support member comprises:

exhausting fluidic materials within an exhaust chamber defined between the second piston and the tubular support member displaced by the second piston into the internal passage of the tubular support member.

35. The method of claim 34 , wherein the first piston chamber and the exhaust chamber have annular cross sections.

36. The method of claim 34 , wherein the cross sectional area of the first piston chamber is greater than the cross sectional area of the exhaust chamber.

37. The method of claim 34 , wherein the operating pressure of the exhaust chamber is less than a portion of the first piston chamber downstream from the first piston.

38. The method of claim 34 , wherein the exhaust chamber is fluidicly isolated from the first piston chamber.

39. The method of claim 32 , wherein the first and second pistons have annular cross sections; and wherein the tubular support member is received within the first and second pistons.

40. The method of claim 39 , further comprising:

displacing the second piston; and

exhausting fluidic materials displaced by the second piston into the internal passage of the tubular support member.

41. The method of claim 40 , wherein exhausting fluidic materials displaced by the second piston into the internal passage of the tubular support member comprises:

exhausting fluidic materials within an exhaust chamber defined between the second piston and the tubular support member displaced by the second piston into the internal passage of the tubular support member.

42. The method of claim 41 , wherein the first piston chamber and the exhaust chamber have annular cross sections.

43. The method of claim 41 , wherein the cross sectional area of the first piston chamber is greater than the cross sectional area of the exhaust chamber.

44. The method of claim 41 , wherein the operating pressure of the exhaust chamber is less than a portion of the first piston chamber downstream from the first piston.

45. The method of claim 41 , wherein the exhaust chamber is fluidicly isolated from the first piston chamber.

46. A method of applying an axial force to a first piston positioned within a first piston chamber, comprising:

positioning a second piston within the first piston chamber;

pressurizing the first piston chamber by injecting fluidic materials into the first piston chamber;

displacing the second piston relative to the first piston within the first piston chamber; and

applying an axial force to the first piston using the second piston within the first piston chamber;

wherein a portion of the first piston chamber upstream from the first piston has a larger cross sectional area than a portion of the first piston chamber downstream from the first piston.

47. The method of claim 46 , wherein the first piston chamber has an annular cross section.

48. A method of applying an axial force to a first piston positioned within a first piston chamber, comprising:

positioning a second piston within the first piston chamber;

pressurizing the first piston chamber by injecting fluidic materials into the first piston chamber;

displacing the second piston relative to the first piston within the first piston chamber;

applying an axial force to the first piston using the second piston within the first piston chamber;

movably coupling the first and second pistons to a tubular support member defining an internal passage;

displacing the second piston; and

exhausting fluidic materials within an exhaust chamber defined between the second piston and the tubular support member displaced by the second piston into the internal passage of the tubular support member;

wherein the first piston chamber and the exhaust chamber have annular cross sections;

wherein the tubular support member is received within the first and second pistons;

wherein the cross sectional area of the first piston chamber is greater than the cross sectional area of the exhaust chamber;

wherein the operating pressure of the exhaust chamber is less than a portion of the first piston chamber downstream from the first piston; and

wherein the exhaust chamber is fluidicly isolated from the first piston chamber.