Abstract: A riser section for joining to another riser section to form a drilling riser includes a weld region generated by welding a first riser tube to a second riser tube. The weld region includes a fusion zone in which material of the first riser tube coalesces with material of the second riser tube, and a heat-affected zone adjacent the fusion zone. The riser section also includes a cover positioned over the weld region and welded to the first riser tube and to the second riser tube such that the cover covers the fusion zone and the heat-affected zone to protect the zones. The cover may be a solid piece of material that is welded to the riser tubes, or the cover may be a bead of weld filler material that is welded (melted and deposited) onto the weld region of each of the riser tubes.

Abstract: A method for making a riser component includes: positioning a coupler adjacent and end of a tube such that a region of the coupler forms an interface with the tube's end, wherein the region includes a material (in some embodiments an aluminum alloy), and the tube's end includes a groove and another material (in some embodiments a steel alloy) that is different than the region's material; heating the region of the coupler to increase the region's malleability; and exerting pressure on the region of the coupler to plastically deform the region to insert some of the region's material into the groove in the tube's end. By fixing the coupler to the tube in this manner, the coupler may be strongly secured to the tube, and thus able to withstand high, dynamic loads frequently experienced in service. Also, the material of the coupler may be different than the material of the tube, and thus the material of the coupler may be lighter than the material of the tube.