Polycrystalline diamond thrust bearings and their components

Abstract

A thrust bearing assembly and method capable of applying higher speeds and loads without initiating thermal chemical reactions. A thrust bearing assembly is provided, including a thrust ring defining a thrust surface and an opposing thrust ring defining an opposing thrust surface. At least one polycrystalline diamond element is coupled to the thrust surface and defines an engagement surface. The opposing thrust ring includes a diamond reactive material. During operation, the engagement surface contacts the opposing thrust surface. Methods for manufacturing, assembling, and using the same, as well as systems and devices including the same, are also provided. [Selected Figure] Figure 2B

Description

[Technical field]

[0001] (CROSS REFERENCE TO RELATED APPLICATIONS) This application claims the benefit of (pending) U.S. Patent Application No. 16 / 049,617, filed July 30, 2018, the entirety of which is hereby incorporated by reference in its entirety.

[0002] This application is a related application to U.S. Patent Application No. 15 / 430,254, entitled "Drilling Machine," filed on February 10, 2017, and owned by the same assignee as this application, which is incorporated herein in its entirety as if fully set forth. This application is also a related application to a co-filed U.S. Patent Application entitled "Roller Ball Assembly with Superhard Elements," a co-filed U.S. Patent Application entitled "Cam Follower with Polycrystalline diamond Engagement Element," and a co-filed U.S. Patent Application entitled "Polycrystalline diamond Radial Bearing," each of which is assigned to the same assignee as this application and is incorporated herein in its entirety as if fully set forth.

[0003] (STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT) Not applicable

[0004] (Technical field) The present disclosure relates to thrust bearings, devices and systems including thrust bearings, and methods of manufacturing, assembling, and using thrust bearings. [Background technology]

[0005] Thrust bearings are used in tools, machines and components to carry at least primarily axial loads. Thermally stable polycrystalline diamond (TSP) and polycrystalline diamond sinters (PDC or PCD), supported or not by tungsten carbide, have been considered contraindicated for use in machining diamond-reactive materials, including iron-based metals and other metals, metal alloys, composites, hardfacing, coatings or platings that contain more than trace amounts of diamond catalyst or solvent elements, including cobalt, nickel, ruthenium, rhodium, palladium, chromium, manganese, copper, titanium or tantalum. Furthermore, this traditional contraindication for the use of polycrystalline diamond extends to so-called "superalloys", including iron-based, cobalt-based and nickel-based superalloys that contain more than trace amounts of diamond catalyst or solvent elements. Surface speeds commonly used in machining such materials are typically in the range of about 0.2 m / s to about 5 m / s. Although these surface speeds are not particularly high, the loads and associated temperatures encountered at cutting tips and the like often exceed the graphitization temperature of diamond (i.e., about 700°C), which, in the presence of diamond catalyst or solvent elements, can lead to rapid wear and failure of components. Without being bound by theory, it is believed that certain failure mechanisms result from chemical interactions between the carbon-containing diamond and the carbon-attracting material being machined. An exemplary reference for the contraindication of polycrystalline diamond for diamond-catalyzed or solvent machining with metals or alloys is U.S. Pat. No. 3,745,623, which is incorporated herein by reference in its entirety. The contraindication of polycrystalline diamond for machining diamond-catalyzed or diamond-solvent-containing materials has long led to the avoidance of polycrystalline diamond in all contact applications with such materials.

[0006] Over time, as polycrystalline diamond bearings have been developed, bearing manufacturers have developed polycrystalline diamond bearings that are fitted with non-ferrous so-called ultra-hard materials, more commonly with closely facing complementary polycrystalline diamond surfaces and polycrystalline diamond bearing surfaces. FIG. 1 shows a partial cross-sectional view of a thrust bearing 100 having a polycrystalline diamond to polycrystalline diamond interface. As used herein, "ultra-hard" materials are defined as materials that are at least as hard as tungsten carbide (e.g., ultra-hard tungsten carbide or tungsten carbide tiles) or harder, including, but not limited to, tungsten carbide, infiltrated tungsten carbide matrix, silicon carbide, silicon nitride, cubic boron nitride, and polycrystalline diamond. As will be understood by those skilled in the art, hardness can be determined using the Brinell scale, such as by ASTM E10-14. References regarding polycrystalline diamond thrust bearings are U.S. Pat. No. 4,468,138 to Nagel; U.S. Pat. No. 4,560,014 to Geczy; U.S. Pat. No. 9,702,401 to Gonzalez; and U.S. Defence Publication T102,90 to Offenbacher, each of which is incorporated herein by reference in its entirety.

[0007] High performance polycrystalline diamond thrust bearings designed specifically for harsh environments such as downhole drilling and pumping or wind turbine energy units typically utilize overlapping polycrystalline diamond elements that slide and fit. This requires a large number of polycrystalline diamond elements, each in precise flush engagement with a set of opposing polycrystalline diamond elements. The polycrystalline diamond elements must be mounted at a precisely defined height or exposure to ensure a fitted sliding engagement. The goal in the prior art is full surface contact of the polycrystalline diamond elements on both sides as the bearing area. Poor alignment and exposure can cause point loads, uneven load distribution, or "edge strikes" as the polycrystalline diamond elements rotate against each other creating broken elements and ultimately bearing failure. Polycrystalline diamond is more fragile and susceptible to impact damage than diamond reactive materials (defined below).

[0008] Table 1 below shows a summary of the coefficients of friction of various materials, including polished polycrystalline diamond, in both dry and lubricated static conditions, where a "first material" is moved against a "second material" to determine the CoF of the first material. Table 1 * TIFF0007601757000001.tif51154 *References include Machinery's Handbook; Sexton TN, Cooley CH, Downhole Oil and Gas Drilling Tools, Wear 2009; 267:1041-5.

[0009] Additional important references providing information on the background of the technology of the present application are provided by the International Journal of Machine Tools & Manufacture 46 and 47 entitled "Polishing of polycrystalline diamond by the technique of dynamic friction, part 1: Prediction of the interface temperature rise" and "Part 2, Material removal mechanism" (2005 and 2006). These references report on dynamic friction polishing of PDC surfaces using dry sliding contact under load with a carbon-induced steel disk. The key findings of these references show that the polishing rate is more sensitive to the sliding speed than the load, and that the rate of the thermochemical reaction between the steel disk and the diamond surface is significantly reduced as the surface finish of the diamond surface is improved. The authors refer to Iwai, Manabu & Uematsu, T & Suzuki, K & Yasunaga, N. (2001), "High efficiency polishing of PCD with rotating metal disc", Proceedings of ISAAT2001, pp. 231-238, which concludes that the thermochemical reaction between the steel disc and the PDC surface does not occur at sliding speeds below 10.5 m / s at a pressure of 27 MPa. These references are incorporated herein by reference as if fully set forth. It should be emphasized that the figures above are based on dry operation in air. Clearly, when operating in a liquid-cooled, lubricated environment, higher speeds and loads can be achieved without initiating a thermochemical reaction. It is also noteworthy that the thermochemical response of polished polycrystalline diamond surfaces is low. Copper and titanium were not typically mentioned in early General Electric literature on diamond synthesis, but were added later.Relevant references include "Diamond Synthesis from Graphite in the Presence of Water and SiO2", Dobrzhinetskaya and Green, II International Geology Review Vol. 49, 2007, and "Non-metallic catalysts for diamond synthesis under high pressure and high temperature", Sun et al, Science in China August 1999. [Prior art documents] [Patent documents]

[0010] [Patent Document 1] U.S. Pat. No. 3,745,623 [Patent Document 2] U.S. Pat. No. 4,468,138 [Patent Document 3] U.S. Pat. No. 4,560,014 [Patent Document 4] U.S. Pat. No. 9,702,401 [Patent Document 5] U.S. Pat. No. 5,447,208 [Patent Document 6] U.S. Patent No. 5,653,300 [Non-patent literature]

[0011] [Non-Patent Document 1] "Polishing of polycrystalline diamond by the technique of dynamic friction, part 1: Prediction of the interface temperature rise", Machine Tools&Manufacture46, International Journal [Non-Patent Document 2] "Part 2, Material removal mechanism", Machine Tools&Manufacture47, International Journal [Non-Patent Document 3] Iwai, Manabu & Uematsu, T & Suzuki, K & Yasunaga, N. (2001), "High efficiency polishing of PCD with rotating metal disc", Proceedings of ISAAT2001, 231-238 [Non-Patent Document 4] "Diamond Synthesis from Graphite in the Presence of Water and SiO2", Dobrzhinetskaya and Green, II International Geology Review Vol.49, 2007 [Non-Patent Document 5] "Non-metallic catalysts for diamond synthesis under high pressure and high temperature", Sun et al, Science in China August 1999 Summary of the Invention

[0012] Some aspects of the present disclosure include a thrust bearing assembly. The thrust bearing assembly includes a thrust face having a polycrystalline diamond element. The polycrystalline diamond element has an engagement surface. The thrust bearing assembly includes an opposing thrust face formed from or including at least a portion of a diamond reactive material. The thrust face is coupled to the opposing thrust face such that the engagement surface contacts the opposing thrust face.

[0013] Another aspect of the present disclosure includes a method of carrying an axial load. A method of bonding a thrust face to an opposing thrust face. The thrust faces include polycrystalline diamond elements bonded together. The polycrystalline diamond elements have mating surfaces. The opposing thrust faces are formed of or include at least a portion of a diamond reactive material. The thrust faces are bonded to the opposing thrust faces such that the mating surfaces contact the opposing thrust faces.

[0014] Another aspect of the present disclosure includes a thrust bearing assembly including a thrust ring defining a thrust surface. A polycrystalline diamond element is coupled to the thrust surface and defines an engagement surface. The thrust bearing assembly also includes an opposing thrust ring defining an opposing thrust surface. The opposing thrust ring is formed of or includes at least a portion of a diamond reactive material. The engagement surface is in contact with the opposing thrust surface.

[0015] So that the features and advantages of the systems, apparatus, and / or methods of the present disclosure may be more fully understood, a more particular description, broadly summarized above, has been made by reference to the embodiments illustrated in the accompanying drawings, which form a part of this specification. It should be noted, however, that the drawings are merely illustrative of various exemplary embodiments, and therefore should not be considered as limiting the disclosed concepts, as they may also include other effective embodiments. [Brief description of the drawings]

[0016] [Figure 1] FIG. 1 is a partial cross-sectional view of a prior art polycrystalline diamond to polycrystalline diamond interfacial thrust bearing. [Figure 2A] FIG. 2 is a top view of a polycrystalline diamond thrust surface of a thrust bearing in accordance with one embodiment of the technology of the present application. [Figure 2B] FIG. 2B is a side view of the polycrystalline diamond thrust face of FIG. 2A in sliding contact with an opposing thrust face formed of or including at least a portion of diamond reactive material. [Figure 3A]FIG. 2 is a top view of a polycrystalline diamond thrust surface of a thrust bearing in accordance with one embodiment of the technology of the present application. [Figure 3B] FIG. 3B is a side view of the polycrystalline diamond thrust face of FIG. 3A in sliding contact with an opposing thrust face formed of or including at least a portion of diamond reactive material. [Figure 4] FIG. 2 is a side view of an exemplary polycrystalline diamond element of one embodiment of the technology of the present application. [Diagram 5] FIG. 2 is a side view of an exemplary polycrystalline diamond element of one embodiment of the technology of the present application. [Figure 6] FIG. 2 is a side view of an exemplary polycrystalline diamond element of one embodiment of the technology of the present application. [Figure 7] FIG. 2 is a side view of an exemplary polycrystalline diamond element of one embodiment of the technology of the present application. [Figure 8] FIG. 2 is a side view of an exemplary polycrystalline diamond element of one embodiment of the technology of the present application. [Figure 9] FIG. 2 is a side view of an unedged polycrystalline diamond element having sharp corners. [Figure 10A] FIG. 13 is a simplified schematic of edge contact between a polycrystalline diamond element subjected to edge treatment and an opposing thrust surface. [Figure 10B] FIG. 13 is a simplified diagram of edge contact between a polycrystalline diamond element having a sharp corner and no edge treatment and an opposing thrust surface. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0017] The systems, apparatus, and methods according to the present disclosure will now be described more fully with reference to the accompanying drawings, which show various exemplary embodiments. However, the concepts according to the present disclosure may be embodied in many different forms and should not be construed as limited by the exemplary embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the various concepts to those skilled in the art and the best and preferred methods of implementation.

[0018] Certain aspects of the present disclosure include thrust bearings and thrust bearing assemblies, as well as apparatus and systems including the same, and methods of manufacturing, assembling and using the same, in which one thrust face is formed of or comprises at least a portion of polycrystalline diamond and the other opposing thrust face is formed of or comprises at least a portion of diamond reactive material.

[0019] (Diamond reactive materials) As used herein, a "diamond reactive material" is a material that contains more than a trace amount of diamond catalyst or diamond solvent. As used herein, a "diamond reactive material" is a material that contains more than a trace amount of diamond catalyst or diamond solvent. As used herein, a diamond reactive material that contains more than a "trace amount" of diamond catalyst or diamond solvent comprises at least 2 weight percent (wt.%) of diamond reactive material. In some embodiments, the diamond reactive material disclosed herein comprises 2-100 wt.%, or 5-95 wt.%, or 10-90 wt.%, or 15-85 wt.%, or 20-80 wt.%, or 25-75 wt.%, or 25-70 wt.%, or 30-65 wt.%, or 35-60 wt.%, or 40-55 wt.%, or 45-50 wt.% of diamond catalyst or diamond solvent. As used herein, a "diamond catalyst" is a chemical element, compound, or material that can catalyze the graphitization of polycrystalline diamond, such as under load and at a temperature equal to or above the graphitization temperature of diamond (i.e., about 700°C). As used herein, a "diamond solvent" is a chemical element, compound, or material that can solubilize polycrystalline diamond, such as under load and at a temperature equal to or above the graphitization temperature of diamond. Thus, diamond reactive materials include materials that, under load and at a temperature equal to or above the graphitization temperature of diamond, can lead to wear, and possibly rapid wear, and failure of components formed of or including at least a portion of polycrystalline diamond, such as diamond-tipped tools.

[0020] Diamond reactive materials include, but are not limited to, metals, metal alloys, and composites that contain more than trace amounts of diamond catalyst or solvent elements. In some embodiments, diamond reactive materials are in the form of hardened surfaces, coatings, or platings. For example, but not limited to, diamond reactive materials can be iron, cobalt, nickel, ruthenium, rhodium, palladium, chromium, manganese, copper, titanium, tantalum, or alloys thereof. In some embodiments, diamond reactive materials are superalloys, including but not limited to iron-based, cobalt-based, and nickel-based superalloys. In certain embodiments, diamond reactive materials are not and / or do not include (i.e., specifically exclude) so-called "superhard materials". As will be understood by those skilled in the art, "superhard materials" are a category of materials that are defined by the hardness of the material, which can be determined according to the Brinell, Rockwell, Knoop, and / or Vickers scales. For example, superhard materials include materials that have a hardness value of more than 40 gigapascals (GPa) when measured by the Vickers hardness test. As used herein, ultra-hard materials include materials that are at least as hard as tungsten carbide tiles and / or ultra-hard tungsten carbide as determined according to one of these hardness scales, such as the Brinell scale. Those skilled in the art will understand that, for example, Brinell scale testing can be performed according to ASTM E10-14, Vickers hardness testing can be performed according to ASTM E384, Rockwell hardness testing can be performed according to ASTM E18, and Knoop hardness testing can be performed according to ASTM E384. "Ultra-hard materials" as disclosed herein include, but are not limited to, tungsten carbide (e.g., tile or ultra-hard), infiltrated tungsten carbide matrix, silicon carbide, silicon nitride, cubic boron nitride, and polycrystalline diamond. Thus, in some aspects, the "diamond reactive material" is composed partially or entirely of a material (e.g., a metal, metal alloy, composite material) that is softer (less hard) than a superhard material, such as less hard than tungsten carbide (e.g., tile or superhard) when determined according to one of these hardness tests, such as the Brinell scale.

[0021] (Interface between polycrystalline diamond and diamond reactive material) In some aspects, the present disclosure provides that the polycrystalline diamond element interfaces the engagement between the thrust surface and the opposing thrust surface with the diamond reactive material in contact. For example, the polycrystalline diamond element can be positioned and arranged on one thrust surface to contact the other opposing thrust surface, where the other opposing thrust surface is formed or includes at least a portion of the diamond reactive material. The polycrystalline diamond element can have an engagement surface for engaging with the opposing engagement surface of the diamond reactive material. As used herein, "engagement surface" refers to a surface of a material (e.g., polycrystalline diamond or diamond reactive material) that is positioned and arranged within a thrust bearing assembly such that the engagement surface interfaces the contact between two components (e.g., between the thrust surface and the opposing thrust surface) during operation of the thrust bearing assembly. "Engagement surface" can also be referred to herein as "thrust bearing surface" or "axial bearing surface" or "thrust surface".

[0022] In some embodiments, the opposing engagement surface comprises or consists of at least 2 wt.%, or 2-100 wt.%, or 5-95 wt.%, or 10-90 wt.%, or 15-85 wt.%, or 20-80 wt.%, or 25-75 wt.%, or 25-70 wt.%, or 30-65 wt.%, or 35-60 wt.%, or 40 to 55 wt.%, or 45 to 50 wt.% diamond reactive material. In certain applications, the polycrystalline diamond element or at least its engagement surface is lapped or polished, and optionally highly lapped or polished. Although highly polished polycrystalline diamond elements are preferred in at least some applications, the scope of the present disclosure is not limited to highly polished polycrystalline diamond elements, but includes highly lapped or polished polycrystalline diamond elements. As used herein, a surface is defined as "highly lapped" if it has a surface finish of 20 μin or about 20 μin, such as a surface finish ranging from about 18 to about 22 μin. As used herein, a surface is defined as "polished" if it has a surface finish of less than about 10 μin or from about 2 to about 10 μin. As used herein, a surface is defined as "highly polished" if it has a surface finish of less than about 2 μin, or from about 0.5 μin to less than about 2 μin. In some embodiments, the engagement surface has a surface finish of 0.5 μin to 40 μin, 2 μin to 30 μin, 5 μin to 20 μin, 8 μin to 15 μin, or less than 20 μin, or less than 10 μin, less than 2 μin, or any range therebetween. A polycrystalline diamond polished to a surface finish of 0.5 μin has a coefficient of friction that is about half that of a standard lapped polycrystalline diamond with a surface finish of 20 to 40 μin. U.S. Patent Nos. 5,447,208 and 5,653,300 to Lund et al., which are incorporated herein by reference in their entireties, provide disclosures regarding the polishing of polycrystalline diamond. As will be appreciated by those skilled in the art, surface finish can be measured with a profilometer or atomic force microscopy.

[0023] (Example thrust bearing) Turning now to the figures, exemplary, non-limiting embodiments of thrust bearings are described. Similar reference numbers refer to similar elements throughout the figures. For example, in Figures 2A and 2B, reference number 202 refers to the mating surface of the polycrystalline diamond element, and in Figures 3A and 3B, reference number 302 refers to the mating surface of the polycrystalline diamond element.

[0024] FIG. 2A shows a top view of a thrust ring 220 having a thrust face 201 according to one embodiment of the technology of the present application. The thrust face 220 (also referred to as a polycrystalline diamond thrust face) includes polycrystalline diamond elements 202 embedded, attached, or otherwise bonded and / or engaged within the thrust face 220. The polycrystalline diamond elements 202 can be directly attached to the thrust face 220 via methods known in the art, including but not limited to brazing, gluing, press fitting, shrink fitting, or screwing. Although the thrust face 220 is shown and described as having three polycrystalline diamond elements 202, one skilled in the art will understand that the thrust face 220 can include more or less than three polycrystalline diamond elements 202. Also, although the spacing between the polycrystalline diamond elements 202 is shown to be equally spaced, one skilled in the art will understand that it can be uniform or non-uniform. Furthermore, one skilled in the art will understand that the spacing between the polycrystalline diamond elements 202 can be more or less than that shown in FIG. 2A.

[0025] Each polycrystalline diamond element 202 includes an engagement surface 222. The engagement surface 222 may be a lapped, polished, highly lapped, or highly polished surface layer of polycrystalline diamond. In some embodiments, the engagement surface 222 may be flat or convex.

[0026] 2B shows thrust bearing assembly 200 including thrust face 201 of thrust ring 220 in sliding contact with opposing thrust face 204 of opposing thrust ring 203. Thrust ring 203 and opposing thrust face 204 are formed of or include at least a portion of diamond reactive material. Thus, during operation, when thrust bearing assembly 200 is carrying a load, engagement surface 222 is in sliding contact with opposing thrust face 204 (also referred to as the opposing engagement surface).

[0027] Although both thrust rings 220 and 203 are shown having a ring shape, those skilled in the art will appreciate that the thrust surfaces disclosed herein may be formed on thrust components of other shapes suitable for thrust bearings depending on the particular application.

[0028] 3A shows a top view of a thrust ring 320 having a thrust face 302 bonded to a plurality of polycrystalline diamond elements 302 in accordance with one embodiment of the technology of the present application. In this embodiment, the thrust face 302 is configured with 12 polycrystalline diamond elements 302, each having an engagement surface 322.

[0029] FIG. 3B shows a thrust bearing assembly 300 in a side view including the thrust face 302 of FIG. 3A in sliding contact with a thrust face 304 such that the engagement surface 322 is in sliding contact with an opposing thrust face 304 formed of or including at least a portion of a diamond reactive material.

[0030] (Polycrystalline diamond layer with edge radius) 4 shows a side view of an exemplary polycrystalline diamond element 402 of one embodiment of the technology of the present application. In this example, the polycrystalline diamond element 402 includes a polycrystalline diamond layer 424 supported by a tungsten carbide substrate 426. The diamond-to-substrate interface line is indicated at 405.

[0031] Opposite the interface between the polycrystalline diamond layer 424 and the tungsten carbide substrate 426 (i.e., opposite the diamond-substrate interface line 405), an engagement surface 422 is formed on the polycrystalline diamond layer 424. The engagement surface 422 may be a lapped, polished, highly lapped, or highly polished upper surface of the polycrystalline diamond layer 424. As shown, along the side edge 428 from the diamond-substrate interface line 405 to the engagement surface 422, the polycrystalline diamond layer 424 has a relatively large edge radius 406. Those skilled in the art will appreciate that the polycrystalline diamond layers disclosed herein are not limited to this particular shape, nor are they limited to being supported on tungsten carbide or not supported at all.

[0032] (Polycrystalline diamond layer with arcuate edges) FIG. 5 shows a side view of an exemplary polycrystalline diamond element 502 of one embodiment of the technology of the present application. In this example, the polycrystalline diamond layer 524 is supported by a tungsten carbide substrate 526 and forms an interface at the diamond-substrate interface line 505. The polycrystalline diamond element 502 is substantially similar to the polycrystalline diamond element 402, except that the polycrystalline diamond layer 524 has a more arcuate edge 507 compared to the edge radius 406. The arcuate edge 507 of the polycrystalline diamond layer 524 can be provided via an arcuate edge treatment, as is known in the art. Side edges 528 are also shown.

[0033] (Polycrystalline diamond layer with large edge radius) FIG. 6 shows a side view of an exemplary polycrystalline diamond element 602 of one embodiment of the technology of the present application. In this example, the polycrystalline diamond layer 624 is supported by a tungsten carbide substrate 626, with the diamond-substrate interface line shown at 605. The polycrystalline diamond element 602 is substantially similar to the polycrystalline diamond element 402, except that the polycrystalline diamond layer 624 has a large radius edge 607. The large radius edge 607 can be provided via a large radius edge treatment, as known in the art. A side edge 628 is also shown.

[0034] (Polycrystalline diamond layer with large edge radius) FIG. 7 shows a side view of an exemplary polycrystalline diamond element 702 of one embodiment of the technology of the present application. In this example, the polycrystalline diamond layer 724 is supported by a tungsten carbide substrate 726, with the diamond-substrate interface line shown at 705. The polycrystalline diamond element 702 is substantially similar to the polycrystalline diamond element 602, except that the polycrystalline diamond layer 724 has a larger radius edge 709, which can be provided via a large radius edge treatment, as known in the art. In this example, the edge radius begins at the tungsten carbide substrate 726 at the junction 710, rather than the polycrystalline diamond layer 724 as in the case of the polycrystalline diamond element 602. A side edge 728 is also shown.

[0035] (Polycrystalline diamond layer with multi-component edges) 8 shows a side view of an exemplary polycrystalline diamond element 802 of one embodiment of the technology of the present application. In this example, polycrystalline diamond layer 824 is carried by a tungsten carbide substrate 826, with the diamond-to-substrate interface line shown at 805. Polycrystalline diamond layer 824 has been treated with a multi-component edge treatment that includes an edge radius 811 leading to a chamfer angle 812 connected to an additional edge radius 813.

[0036] Thus, in some embodiments, the thrust bearing of the present application is a high performance thrust bearing, in which the diamond reactive material of the opposing thrust surface is in sliding contact with at least one polycrystalline diamond element attached to another thrust surface. The polycrystalline diamond element of the thrust surface is preferably planar, but may be convex. Furthermore, although three or more polycrystalline diamond elements are preferred, the technology of the present application can be implemented with as few as one or two polycrystalline diamond elements. The use of a single polycrystalline diamond element in sliding contact with the surface of the opposing diamond reactive material may also result in a reduction in the coefficient of friction between the thrust bearing surfaces (thrust surfaces), which may act to destroy or reduce galling between the surfaces.

[0037] At least some embodiments of the thrust bearing disclosed herein are suitable for use in harsh environments.At least some embodiments of the thrust bearing disclosed herein are less susceptible to polycrystalline diamond fracture compared to the thrust bearing with polycrystalline diamond and polycrystalline diamond engagement.Therefore, the thrust bearing provided by the technology of the present application is a thrust bearing suitable for harsh environments with improved service value compared to the thrust bearing with polycrystalline diamond and polycrystalline diamond engagement.

[0038] (Edge Contact Elimination) An important performance criterion of at least some embodiments of the thrust bearings disclosed herein is that they are configured (i.e., positioned, arranged) to eliminate edge contact between the polycrystalline diamond bearing element and the opposing component (i.e., the opposing thrust surface) formed or including at least some diamond reactive material. One preferred method for achieving this important performance criterion is to use polycrystalline diamond elements with relatively large edge radii. The edge radii of the polycrystalline diamond elements are such that in the event of tilting or misalignment of one or both thrust surfaces, the edge radii of the polycrystalline diamond elements present a blunt surface to the opposing thrust surface formed or including at least some diamond reactive material, rather than presenting a sharp edge that may lead to machining or cutting or scribing of the surface of the diamond reactive material. Without limiting the disclosure, in certain embodiments, conventional chamfered polycrystalline diamond edge treatments are not preferred.

[0039] The polycrystalline diamond edge treatment shown and described with reference to Figures 4-8 provides a non-limiting method of blunting the edges of the other planar surfaces (engagement surfaces 422, 522, 622, 722, 822) of each polycrystalline diamond element. Such blunting of the planar edges prevents machining or cutting from occurring between the opposing thrust surfaces, such as when either the polycrystalline diamond thrust surface (engagement surface) and the opposing thrust surface of the diamond reactive material are tilted or misaligned. If such tilting or misalignment occurs and the polycrystalline diamond layer of the polycrystalline diamond element has a sharp edge 930 rather than a treated edge, as shown in Figure 9, the sharp edge 930 may machine or cut the opposing thrust surface or otherwise engage the opposing thrust surface undesirably. Also shown in the depiction of the polycrystalline diamond element 902 in Figure 9 are the engagement surface 922, side edge 928, polycrystalline diamond layer 924, diamond-to-substrate interface line 905, and tungsten carbide substrate 926.

[0040] Figures 10A and 10B show the use of edged and non-edged polycrystalline diamond elements, respectively. Figure 10A depicts a portion of a thrust bearing assembly 1000a, showing a polycrystalline diamond element 1002a in sliding contact with a thrust ring 1003a (only a portion of which is shown). In Figure 10A, the thrust ring 1003a is tilted or misaligned relative to the polycrystalline diamond element 1002a, such that the plane defined by the thrust surface 1004a is at an angle to the plane defined by the engagement surface 1022a. Thus, the thrust surface 1004a has engaged the edge 1050 of the polycrystalline diamond element 1002a.

[0041] Similar to FIG. 10A, FIG. 10B shows a portion of a thrust bearing assembly 1000b, showing polycrystalline diamond element 1002b in sliding contact with thrust ring 1003b (only a portion of which is shown). In FIG. 10B, thrust ring 1003b is tilted or misaligned with polycrystalline diamond element 1002b such that the plane defined by thrust surface 1004b is at an angle to the plane defined by engagement surface 1022b. Thus, thrust surface 1004b has engaged edge 1030 of polycrystalline diamond element 1002b. However, because polycrystalline diamond element 1002a has undergone edge treatment, edge 1050 is dull compared to sharp edge 1030. Because edge 1030 is sharp, edge 1030 may machine or cut thrust surface 1004b or otherwise engage undesirably. However, in the embodiment shown in FIG. 10A, the edge 1050 is blunt, thereby reducing or eliminating the occurrence of such machining or cutting.

[0042] In certain embodiments, the thrust bearings disclosed herein include a polycrystalline diamond layer having an edge radius that is at least 0.050 inch radius. In certain embodiments, the thrust bearings disclosed herein include a polycrystalline diamond layer having an edge radius that is at least 0.060 inch radius, or at least 0.070 inch radius, or at least 0.080 inch radius, or at least 0.090 inch radius.

[0043] (Polycrystalline Diamond Element) In certain applications, the polycrystalline diamond elements disclosed herein have an increased cobalt content transition layer between the outer polycrystalline diamond face and the supporting tungsten carbide slug, as is known in the art.

[0044] The polycrystalline diamond elements may be supported by tungsten carbide, or may be unsupported, "stand-alone" polycrystalline diamond elements attached directly to the bearing component (eg, thrust ring).

[0045] The polycrystalline diamond elements may be unleached, leached, leached and backfilled, thermally stable, coated by chemical vapor deposition (CVD), or treated in a variety of ways known in the art.

[0046] (Polycrystalline Diamond Elements - Shape, Size, and Arrangement) The polycrystalline diamond elements can have diameters as small as 3 mm (about 1 / 8 inch) or as large as 75 mm (about 3 inches), depending on the application and configuration and diameter of the bearing. Typically, the polycrystalline diamond elements have diameters of from 8 mm (about 5 / 16 inch) to 25 mm (about 1 inch).

[0047] Polycrystalline diamond elements are most commonly available in a cylindrical shape, although it will be understood that the techniques of the present application may be practiced with polycrystalline diamond elements that are square, rectangular, oval, any of the shapes described herein with reference to the figures, or any other suitable shape known in the art.

[0048] In some applications, the polycrystalline diamond elements are deployed in a ring along the bearing component (i.e., thrust ring). The polycrystalline diamond bearing elements of the present technology can be deployed in a ring around the deployed thrust surface. A non-limiting example is a ring of five planar polycrystalline diamond bearing elements for engaging with an opposing thrust surface formed or including at least a portion of diamond reactive material. Without being bound by theory, a comparable thrust bearing having a polycrystalline diamond thrust surface to polycrystalline diamond thrust surface (as opposed to a polycrystalline diamond thrust surface to diamond reactive material thrust surface) may require more than 20 or even more than 30 total polycrystalline diamond elements to carry the axial load. Thus, some embodiments of the present technology provide a polycrystalline diamond thrust bearing with a larger spacing between individual polycrystalline diamond elements than is achievable in a thrust bearing having a polycrystalline diamond thrust to polycrystalline diamond thrust surface contact. The technology of the present application allows the polycrystalline diamond elements to be arranged in any pattern, layout, spacing or staggering to provide the desired support without concern for the need for overlapping contact with a polycrystalline diamond surface on the opposing bearing surface.

[0049] (Polycrystalline Diamond Element - Installation) As previously mentioned, the polycrystalline diamond element may be attached directly to the bearing element (e.g., thrust ring) via methods known in the art, including but not limited to brazing, gluing, press fitting, shrink fitting, or threaded. The polycrystalline diamond element may be attached to another ring or rings. The ring or rings may then be deployed onto the bearing element via methods known in the art, including but not limited to gluing, press fitting, thread locking, or brazing.

[0050] The planar or domed polycrystalline diamond elements can be mounted so that they can rotate about their own axis. See U.S. Patent No. 8,881,849 to Shen et al. as a non-limiting example of how a polycrystalline diamond element can be made to rotate about its own axis while in face contact with the target material.

[0051] (Treatment of opposing mating surfaces) In some embodiments, the opposing mating surfaces of the diamond reactive material are pre-saturated with carbon (e.g., before mating with the mating surfaces). Such pre-saturation reduces the diamond reactive material's ability to attract carbon through graphitization of the surface of the polycrystalline diamond. Pre-saturation of the surface contact area of ​​the diamond reactive material can be achieved through any method known in the art.

[0052] In certain applications, a solid lubricant source, for example graphite or hexagonal boron nitride sticks or inclusions, whether excited or unexcited, is in contact with an opposing mating surface that is formed of or includes at least a portion of diamond reactive material.

[0053] In a lubricated environment, a bearing assembly can benefit from the hydrodynamic effects of the lubricant to create clearance between moving and stationary elements of the bearing assembly.

[0054] Exemplary Tests With the objective of developing a robust cam follower interface for use in Applicants' previously referenced U.S. Patent Application Serial No. 15 / 430,254 (the "254 Application") "Drilling Machine," Applicants designed and constructed an advanced test bench. The test bench employed a 200 RPM electric gear motor driving a hard-faced iron rotor mandrel inside a hard-faced iron stator housing. The mandrel incorporated a non-hard-faced offset cam cylinder midway along its length. The rotor / stator assembly was supplied with circulating fluid using a positive displacement pump. Candidate cam follower interface mechanisms were placed in sealing contact and under load with the cam cylinder of the rotor mandrel. Using the test bench, the candidate interface mechanisms were tested for survivability and wear under loads ranging from 500 to 3000 lbf in either clean water or sand-laden drilling fluid.

[0055] Applicants have conducted testing of iron cam cylinders in sliding contact with polished polycrystalline diamond surfaces without any deleterious effects or apparent chemical interactions. At least some diamond-reactive materials, such as iron materials, are attractive for bearing applications due to ready availability, ease of forming and machining, high modulus, and lower cost than so-called ultra-hard materials.

[0056] A testing program conducted by applicants has demonstrated that a successful load interface between polycrystalline diamond and diamond reactive materials can be utilized in bearing applications, even at relatively high loads and high RPM speeds.

[0057] The key finding is that the polycrystalline diamond can make sliding contact with the diamond reactive material at typical bearing loads and speeds required in many applications unless the polycrystalline diamond elements are in edge or point contact with the diamond reactive material, which may lead to machining and chemical interactions. This unexpected and surprising success of Applicants' tests led to the development of a new high performance radial bearing.

[0058] The test program included testing of curved ferrous surfaces in high load face linear area contact with planar polycrystalline diamond under rotation. The tests produced a slightly discoloured Hertzian contact area on the face of the PDC approximately 0.250 inches wide along the entire 1 / 2 inch wide face of the polycrystalline diamond. The width of the contact area can be explained by cam offset, vibrations in the system and slight deformation of the ferrous metal under load. The total contact area of ​​the 1 / 2 inch polycrystalline diamond element faces at a given time is estimated to be approximately 7% or less of the total area of ​​the polycrystalline diamond element faces. The configuration employed in the tests shows that even a small surface area on the face of the polycrystalline diamond element can be subjected to large loads.

[0059] Further testing of a spherical iron ball under load and rotation against a planar polycrystalline diamond face produced a small discolored Hertzian contact area approximately 0.030 in diameter in the center of the polycrystalline diamond element. As with the contact description above, without being bound by theory, it is believed that the discoloration diameter is the result of slight vibrations of the test apparatus and slight deformation of the iron metal under load.

[0060] Table 2 below provides data summarizing tests performed by applicant on various configurations of sliding interfaces. Table 2 TIFF0007601757000002.tif197153

[0061] Tests 1 and 2 summarize the unsuccessful testing of an individual steel ball rolling in a steel cup under load. Test 3 summarizes the results of a passing test of a steel ball carried by a single polished PDC element in a steel cup. Test 4 summarizes the extremely passing test of a single steel ball carried by an array of three polished polycrystalline diamond elements in a steel cup. Tests 5-9 summarize more stringent testing of a single polished polycrystalline diamond element each in sliding contact with a rotating iron cam surface. Test 10 summarizes a comparative test of a single polished polycrystalline diamond element and a single unpolished polycrystalline diamond element each in sliding contact with a rotating iron cam surface. The final test shows a significant increase in the coefficient of friction when an unpolished polycrystalline diamond element is used. The conditions and results shown in Table 2 are representative of the possible uses of polycrystalline diamond in diamond reactive materials, are not limiting, and should not be considered as fully encompassing the technology of this application.

[0062] (Test conclusion) Without being bound by theory, running the cam and cam follower in a liquid cooled, lubricated environment during operation allows for higher speeds and loads to be applied without initiating thermo-chemical reactions. Furthermore, the polished polycrystalline diamond surface, in particular, exhibits a low thermo-chemical response.

[0063] From the above description and figures, it can be readily appreciated that the bearing assembly techniques of the present application can be used in a wide range of applications, including downhole environments. The techniques provided herein also have broad application in other industrial applications.

[0064] Furthermore, although illustrated and described in relation to engagement between the surfaces of a thrust bearing assembly, those skilled in the art will appreciate that the disclosure is not limited to this particular application and that the concepts disclosed herein may be applied to engagement between the surface of any diamond reactive material engaged with the surface of a diamond material.

[0065] Although the present embodiments and advantages have been described in detail, it should be understood that various changes, substitutions, and alterations can be made herein without departing from the spirit and scope of the present disclosure. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the processes, machines, manufacture, compositions of matter, means, methods, and steps described herein. Those skilled in the art will readily appreciate from this disclosure that currently existing or later developed processes, machines, manufacture, compositions of matter, means, methods, or steps that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein can be utilized in accordance with the present disclosure. It is therefore intended that the appended claims include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps. [Explanation of symbols]

[0066] 200 Thrust bearing assembly 201 Thrust surface 202 Engagement surface of polycrystalline diamond element 203 Opposing Thrust Ring 204 Opposing Thrust Surfaces 220 Thrust Ring 222 Engagement surface

Claims

1. 1. A thrust bearing assembly comprising: a thrust surface including a polycrystalline diamond element, the polycrystalline diamond element having an engagement surface; an opposing thrust surface comprising a metal surface having a diamond reactive material thereon, the diamond reactive material being metal and comprising at least 2 wt. % diamond catalyst or diamond solvent based on the total weight of the diamond reactive material; Equipped with the mating surface of the thrust face being in sliding contact with the metal surface of the opposing thrust face.

2. 2. The thrust bearing assembly of claim 1, wherein the mating surface of said polycrystalline diamond element is flat.

3. 2. The thrust bearing assembly of claim 1, wherein the mating surface of said polycrystalline diamond element is convex.

4. 2. The thrust bearing assembly of claim 1, wherein the mating surfaces of the polycrystalline diamond elements are highly lapped, polished or highly polished.

5. 2. The thrust bearing assembly of claim 1, wherein the mating surfaces of the polycrystalline diamond elements have a surface finish of 10 in Ra or less.

6. 2. The thrust bearing assembly of claim 1, wherein the opposing mating surfaces are saturated with carbon.

7. 2. The thrust bearing assembly of claim 1 further comprising a solid lubricant on said opposing thrust faces.

8. The thrust bearing assembly of claim 1 , wherein the diamond reactive material comprises iron, cobalt, nickel, ruthenium, rhodium, palladium, chromium, manganese, copper, titanium, or tantalum.

9. A thrust bearing assembly as described in claim 1, wherein the diamond reactive material comprises iron, cobalt, nickel, ruthenium, rhodium, palladium, manganese, copper, or tantalum.

10. A thrust bearing assembly as described in claim 1, wherein the diamond reactive material comprises cobalt, nickel, ruthenium, rhodium, palladium, or tantalum.

11. The thrust bearing assembly comprises: a thrust ring having said thrust surface and having said polycrystalline diamond elements bonded thereto; opposing thrust rings having opposing thrust faces; The thrust bearing assembly of claim 1 comprising:

12. 2. The thrust bearing assembly of claim 1, wherein an edge of the mating surface of the polycrystalline diamond element has an edge radius.

13. 13. The thrust bearing assembly of claim 12, wherein said edge radius is at least a 0.050 inch radius.

14. A thrust bearing assembly as described in claim 1, wherein the thrust surface engages with the opposing thrust surface such that contact between the metal surface and an edge of the engagement surface is eliminated.

15. 2. The thrust bearing assembly of claim 1, wherein said mating surface has a dull edge.

16. 2. The thrust bearing assembly of claim 1, wherein the metal is softer than the superhard material.

17. 2. The thrust bearing assembly of claim 1, wherein said metal is a metal alloy.

18. The thrust bearing assembly of claim 1 , wherein the diamond reactive material comprises an iron alloy.

19. 2. The thrust bearing assembly of claim 1, wherein said thrust face includes a plurality of polycrystalline diamond elements, each engagement surface being in sliding contact with said metal surface, said plurality of polycrystalline diamond elements being spaced apart.

20. A thrust bearing assembly as described in claim 1, wherein the polycrystalline diamond element has a polycrystalline diamond sintered body.

21. A thrust bearing assembly as described in claim 20, wherein the polycrystalline diamond sintered body is supported on a tungsten carbide substrate.

22. A thrust bearing assembly as described in claim 1, wherein the polycrystalline diamond element is embedded within or attached to the thrust surface.

23. A thrust bearing assembly as described in claim 1, wherein the polycrystalline diamond element is attached directly to the thrust surface.

24. A thrust bearing assembly as described in claim 23, wherein the polycrystalline diamond element is attached directly to the thrust surface by brazing, adhesive, press fitting, shrink fitting or screwing.

25. A thrust bearing assembly as described in claim 1, wherein the polycrystalline diamond element is a stand-alone polycrystalline diamond element.

26. 1. A method for carrying an axial load, comprising: providing a thrust surface having a polycrystalline diamond element bonded thereto, the polycrystalline diamond element having an engagement surface; lapping, polishing, or lapping and polishing the engagement surface; engaging the thrust surface with an opposing thrust surface; % diamond catalyst or diamond solvent based on the total weight of the diamond reactive material, and the mating surface of the thrust surface is in sliding contact with the metal surface of the opposing thrust surface.

27. 27. The method of claim 26, wherein mating the thrust surface with the opposing thrust surface includes avoiding edge and point contact between the polycrystalline diamond element and the opposing thrust surface.

28. 27. The method of claim 26, further comprising the step of treating an edge of the mating surface of the polycrystalline diamond element to provide an edge radius prior to bonding the thrust surface and the opposing thrust surface.

29. 30. The method of claim 28, wherein the edge radius is at least a 0.050 inch radius.

30. 27. The method of claim 26, further comprising the step of saturating the opposing thrust face with carbon prior to bonding the thrust face and the opposing thrust face.

31. 27. The method of claim 26, further comprising the step of lubricating the opposing thrust surface with a solid lubricant prior to joining the thrust surface and the opposing thrust surface.

32. 27. The method of claim 26, wherein the diamond reactive material comprises iron, cobalt, nickel, ruthenium, rhodium, palladium, chromium, manganese, copper, titanium, or tantalum.

33. 27. The method of claim 26, wherein the step of lapping, polishing, or lapping and polishing the engagement surface is performed until the engagement surface has a surface finish of 20 μin Ra or less.

34. 1. An assembly comprising: A stand-alone polycrystalline diamond body having an engagement surface, the engagement surface of the polycrystalline diamond body being polished; an opposing element including a metal surface having a diamond reactive material, the diamond reactive material being a softer metal than the ultra-hard material; Equipped with The diamond reactive material comprises at least 2 wt. % diamond catalyst or diamond solvent based on the total weight of the diamond reactive material; An assembly in which the engagement surface is in sliding contact with the metal surface, receives an axial load from the metal surface, and the polycrystalline diamond body engages the opposing element such that contact between the metal surface and an edge of the engagement surface is eliminated.

35. 35. The assembly of claim 34, wherein the mating surfaces have a surface finish of 20 in Ra or less.

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