Materials processing for diamond-to-diamond reactive material bearing engagements.

Abstract

An apparatus is provided that includes a diamond bearing surface positioned in sliding engagement with an opposing bearing surface of a diamond reactive material. A method of carrying a load in a device, comprising engaging a bearing surface with an opposing bearing surface, the bearing surface comprising polished polycrystalline diamond, the opposing bearing surface comprising a diamond-reactive material that is hardened through material processing.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Patent Application No. 16 / 425,758 (pending), entitled "Material Treatments for Diamond-on-Diamond Reactive Material Bearing Engagements," filed May 29, 2019, which is a continuation-in-part (CIP) of U.S. Patent Application No. 16 / 049,588 (pending), entitled "Cam Follower with Polycrystalline Diamond Engagement Element," filed July 30, 2018, which is itself incorporated herein by reference in its entirety. This application is also a continuation-in-part (CIP) of U.S. Patent Application No. 16 / 049,608 (pending), entitled "Polycrystalline Diamond Radial Bearing," filed July 30, 2018, which is itself incorporated herein by reference in its entirety. This application is also a continuation-in-part (CIP) of U.S. patent application Ser. No. 16 / 049,617, filed Jul. 30, 2018, and entitled “Polycrystalline Diamond Thrust Bearing and Element Thereof,” which is incorporated herein by reference in its entirety.

[0002] The present disclosure relates to material treatments, including surface treatments, for use with devices having diamond-to-diamond reactive material (e.g., diamond-to-steel) bearing engagements, including cam followers, radial bearings, and thrust bearings, systems including same, and methods of making and using same. [Background technology]

[0003] Many components include multiple surfaces in engagement that move relative to one another. An exemplary set of components that include such surfaces are bearings, including cam followers, radial bearings, and thrust bearings.

[0004] Cam followers are used to convert the motion imparted from a cam to another component. For example, the rotary motion of a cylindrical cam can be converted to linear motion by a cam follower. Cam followers are used to engage cams in many mechanisms, including internal combustion engines, valves, pumps, compressors, machining tools, textile processing equipment, downhole rotary steerable systems, downhole agitators, and drilling machines, such as the drilling machine disclosed in U.S. Patent Application Serial No. 15 / 430,254 (the '254 Application), among other mechanisms. The '254 Application, entitled "Drilling Machine," filed February 10, 2017, is incorporated herein by reference in its entirety.

[0005] Cam followers are classified into two main groups including roller cam followers and non-roller cam followers. For roller cam followers, yoke mounted or stud mounted rolling members are used. These rolling members may be of the bushing type or use ball, roller, needle bearings, or combinations thereof. Non-roller cam followers are classified as knife edge, flat surface, or curved shoe, sometimes called mushroom. Table 1 below lists the various cam followers including their associated disadvantages.

[0006] (Table 1) TIFF0007612611000001.tif60154

[0007] Thermally stable polycrystalline diamond (TSP) and polycrystalline diamond sintered bodies (PDC or PCD), with or without tungsten carbide support, may be used in tools such as diamond-tipped tools. It is considered to be averse to use polycrystalline diamond, including thermally stable polycrystalline diamond and polycrystalline diamond sintered bodies, in machining ferrous metals and other metals, alloys, composites, hardfacing, coatings, or platings that contain more than trace amounts of diamond catalyst elements or diamond solvent elements, including cobalt, nickel, ruthenium, rhodium, palladium, chromium, manganese, copper, titanium, or tantalum. Furthermore, this traditional aversion to the use of polycrystalline diamond extends to so-called "superalloys," including iron-, cobalt-, and nickel-based superalloys that contain more than trace amounts of diamond catalyst elements or diamond solvent elements. The face speeds typically used in machining such materials are typically in the range of about 0.2 m / s to about 5 m / s. Although these surface velocities are not particularly high, the loads and associated temperatures at cutting tips and the like often exceed the graphitization temperature of diamond (i.e., about 700°C), which can lead to rapid wear and failure of components such as diamond-tipped tools in the presence of diamond catalyst or diamond solvent elements. Without being bound by theory, it is believed that certain failure mechanisms result from chemical interactions between carbon-containing diamond and carbon-attracting materials during machining. An exemplary reference regarding the aversion of polycrystalline diamond to machining metals or alloys containing diamond catalyst or diamond solvent is U.S. Pat. No. 3,745,623, which is incorporated herein by reference in its entirety. The aversion of polycrystalline diamond to machining materials containing diamond catalyst or diamond solvent has long led to the avoidance of polycrystalline diamond in all applications where there is contact with such materials.

[0008] Copper and titanium were typically not listed in early General Electric literature on diamond synthesis, but were later added. Relevant references include Dobrzhinetskaya and Green, "Diamond Synthesis from Graphite in the Presence of Water and SiO2," II International Geology Review, Vol. 49, 2007, and Sun et al., "Non-metallic catalysts for diamond synthesis under high pressure and high temperature," Science in China, August 1999.

[0009] Additional important references providing information on the background of the technology of this application are taken from the International Journal of Machine Tools & Manufacture, Vol. 46 and Vol. 47, 2005 and 2006, 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". These references report on dynamic friction polishing of PDC surfaces using dry sliding contact under load with a carbon-attracted steel disk. The key findings in these references show that the polishing rate is more sensitive to the sliding speed than the load, and that the rate of thermochemical reaction between the steel disk and the diamond surface is greatly reduced when the surface finish of the diamond surface is improved. The authors also refer to the previous conclusion that the thermochemical reaction between the steel disk and the PDC surface does not occur at sliding speeds less than 10.5 m / s under a pressure of 27 MPa. These references are incorporated herein by reference as if fully set forth.

[0010] Radial bearings are used to carry loads in tools, machines, and components. Polycrystalline diamond radial bearings have been developed, with polycrystalline diamond bearing surfaces mating with non-ferrous superhard materials or more generally closely matching complementary polycrystalline diamond surfaces. An exemplary reference for polycrystalline diamond radial bearings contacting either superhard materials or matching polycrystalline diamond is U.S. Pat. No. 4,764,036 to McPherson and assigned to Smith International Inc., which is incorporated herein by reference in its entirety. As will be understood by those skilled in the art, hardness can be determined, for example, using Brinell hardness according to ASTM E10-14.

[0011] So-called high performance polycrystalline diamond bearings are designed specifically for harsh environments such as downhole drilling pumping environments or wind turbine energy units, and utilize slidingly interlocking overlapping polycrystalline diamond elements. The bearings require a number of polycrystalline diamond elements, each shaped to have a precise profile. For example, the rotor mounted polycrystalline diamond element is shaped to have a convex profile that substantially matches the rotor's outer diameter. The stator polycrystalline diamond element is shaped to have a concave profile that substantially matches the stator's inner diameter. This shaping of the polycrystalline diamond elements requires precise precision and is expensive, requiring, for example, cutting with an electric discharge machining (EDM) laser or diamond grinding. In this case, to ensure a mating sliding engagement, the polycrystalline diamond elements must be mounted in a precise location, with precise alignment, and with a precisely specified height or exposure. The goal in such components is full surface contact of the polycrystalline diamond elements as the bearing area. Thus, the process used to prepare such polycrystalline diamond elements is expensive and time consuming, and the high probability of variations results in scrapped parts. Poor alignment and / or exposure can result in so-called "edge collisions" as the polycrystalline diamond elements rotate relative to one another, potentially creating fractured elements and ultimately resulting in bearing failure.

[0012] A less expensive radial bearing utilizing polycrystalline diamond has been proposed in which a nearly full circumferential array of contoured polycrystalline diamond elements is mounted on the rotor and an ultra-hard material is mounted on the stator. This approach requires fewer polycrystalline diamond elements than the above-mentioned approach, but still requires contouring of the rotor-mounted elements. Furthermore, such so-called ultra-hard materials tend to be brittle and more susceptible to impact damage than the diamond-reactive materials disclosed herein.

[0013] Thrust bearings are used at least primarily to carry axial loads in tools, machines, and components. When polycrystalline diamond bearings were developed, bearing manufacturers spent a long time matching polycrystalline diamond bearing surfaces with either non-ferrous so-called ultrahard materials or more commonly closely facing complementary polycrystalline diamond surfaces. FIG. 20 shows a partial cutaway view of a thrust bearing 2000 with a polycrystalline diamond to polycrystalline diamond interface. Exemplary references on polycrystalline diamond thrust bearings are U.S. Pat. No. 4,468,138 to Nagel, U.S. Pat. No. 9,702,401 to Gonzalez, and U.S. Defense Publication No. T102,90 to Offenbacher, each of which is incorporated herein by reference in its entirety.

[0014] High performance polycrystalline diamond thrust bearings designed specifically for harsh environments such as underground drilling and pumping or wind turbine energy units typically utilize sliding interlocking overlapping polycrystalline diamond elements. The bearing requires multiple polycrystalline diamond elements, each in strict flat engagement with an opposing set of polycrystalline diamond elements. To ensure interlocking sliding engagement, the polycrystalline diamond elements must be mounted at a precisely specified height or exposure. The goal in this prior art is full surface contact on both sides of the polycrystalline diamond elements as the bearing area. Poor alignment and / or exposure can result in point load application, uneven load distribution, or "edge strike" as the polycrystalline diamond elements rotate relative to each other, creating fractured elements and ultimately bearing failure. Polycrystalline diamond is more fragile and more susceptible to impact damage than diamond reactive materials (defined herein below).

[0015] Table 2 below provides a summary of the coefficient of friction for various materials, including polished polycrystalline diamond, under both dry and lubricated static conditions, where the "first material" is the material that is moved against the "second material" to determine its CoF.

[0016] (Table 2 * ) TIFF0007612611000002.tif61154 * References include "Machinerys Handbook", Sexton TN, Cooley CH, "Polycrystalline diamond thrust bearings for down-hole oil and gas drilling tools", Wear 2009, 267, 1041-5.

[0017] It is emphasized that the above figures are based on dry operation in air. When operating in a liquid-cooled lubricated environment, obviously higher speeds and loads can be achieved without initiating thermochemical reactions. Also noted is the lower thermochemical response of the polished polycrystalline diamond surface. [Prior art documents] [Patent documents]

[0018] [Patent Document 1] U.S. Patent Application Serial No. 16 / 049,588 [Patent Document 2] U.S. Patent Application Serial No. 16 / 425,758 [Patent Document 3] U.S. Patent Application Serial No. 16 / 049,608 [Patent Document 4] U.S. Patent Application Serial No. 16 / 049,617 [Patent Document 5] U.S. Patent Application Serial No. 15 / 430,254 [Patent Document 6] U.S. Pat. No. 3,745,623 [Patent Document 7] U.S. Pat. No. 4,764,036 [Patent Document 8] U.S. Pat. No. 4,468,138 [Patent Document 9] U.S. Pat. No. 9,702,401 [Patent Document 10] U.S. Defense Publication No. T102,90 Specification [Patent Document 11] U.S. Pat. No. 5,447,208 [Patent Document 12] U.S. Patent No. 5,653,300 [Patent Document 13] U.S. Pat. No. 8,881,849 [Non-patent literature]

[0019] [Non-Patent Document 1] Dobrzhinetskaya and Green, "Diamond Synthesis from Graphite in the Presence of Water and SiO2," II International Geology Review, Vol. 49, 2007. [Non-Patent Document 2] Sun et al., "Non-metallic catalysts for diamond synthesis under high pressure and high temperature," Science in China, August 1999. [Non-Patent Document 3] "Polishing of polycrystalline diamond by the technique of dynamic friction, part 1: Prediction of the interface temperature rise" and "Part 2, Material removal mechanism", International Journal of Machine Tools & Manufacture, vol. 46 and vol. 47, 2005 and 2006. [Non-Patent Document 4] "Machinerys Handbook", Sexton TN [Non-Patent Document 5] Cooley CH, "Polycrystalline diamond thrust bearings for down-hole oil and gas drilling tools", Wear 2009, 267, 1041-5 Summary of the Invention [Means for solving the problem]

[0020] One embodiment of the present disclosure includes a method of carrying a load in a device. The method includes engaging a bearing surface with an opposing bearing surface. The bearing surface includes polished polycrystalline diamond. The opposing bearing surface includes a diamond reactive material. The diamond reactive material is hardened.

[0021] Another embodiment of the present disclosure includes an apparatus. The apparatus includes a bearing surface comprising polished polycrystalline diamond. The apparatus includes an opposing bearing surface comprising a diamond reactive material. The diamond reactive material is hardened. The bearing surface and the opposing bearing surface are in movable engagement.

[0022] Some aspects of the present disclosure relate to devices, systems, and machines including a cam assembly including a cam and a cam follower. The cam includes opposing diamond reactive engagement surfaces. The cam follower includes a polycrystalline diamond element. The polycrystalline diamond element includes an engagement surface that engages the opposing engagement surface of the cam.

[0023] Additional aspects of the present disclosure include methods of using such cam followers, cam assemblies, and devices, systems, and machines including the same. The method includes providing a cam follower including a polycrystalline diamond element including an engagement surface thereon. The method includes engaging the engagement surface with an opposing diamond reactive engagement surface of a cam.

[0024] Some aspects of the present disclosure include a radial bearing assembly including polycrystalline diamond elements, each of which includes an engagement surface in sliding engagement with an opposing engagement surface, the opposing engagement surface being formed of or including at least some diamond reactive material.

[0025] Another aspect of the present disclosure includes a method of interfacing engagement between components, including between a rotor and a stator, the method including providing a radial bearing assembly including polycrystalline diamond elements, each polycrystalline diamond element having an engagement surface, the method including interfacing the engagement between the rotor and the stator with the polycrystalline diamond elements such that the engagement surface is in sliding engagement with a counter engagement surface including at least some diamond reactive material.

[0026] Yet another aspect of the present disclosure includes a method of designing a radial bearing assembly for a rotor and a stator. The radial bearing assembly includes polycrystalline diamond elements, each of which includes an engagement surface in sliding engagement with a counter engagement surface formed of or containing at least some diamond reactive material. The method includes determining whether a maximum sliding speed of the rotor and stator is lower than a preset limit (e.g., 10.5 m / s). If the maximum sliding speed is lower than the preset limit, the method includes selecting a configuration of radial bearing assemblies in the stator and rotor. The method includes calculating a maximum contact pressure for each polycrystalline diamond element based on a selected number of polycrystalline diamond elements in the selected configuration of radial bearing assemblies in the stator and rotor and an expected load. The calculated maximum contact pressure is optionally multiplied by a safety factor. The method includes determining whether the calculated maximum contact pressure, optionally multiplied by a safety factor, is lower than a preset maximum allowable pressure. If the calculated maximum contact pressure is determined to be less than the preset maximum allowable pressure, the method includes disposing at least a minimum number of polycrystalline diamond elements on the selected configuration of radial bearing assemblies in the stator and rotor, and if this number of polycrystalline diamond elements fits on the selected configuration of radial bearing assemblies in the stator and rotor, the method includes producing an assembly of the radial bearing assemblies, rotor and stator.

[0027] 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 thereon. The thrust bearing assembly includes an opposing thrust face formed of or including at least some diamond reactive material. The thrust face is coupled to the opposing thrust face such that the engagement surface is in contact with the opposing thrust face.

[0028] Another aspect of the present disclosure includes a method of carrying an axial load. The method includes the steps of mating a thrust surface with an opposing thrust surface. The thrust surface includes a polycrystalline diamond element bonded thereto. The polycrystalline diamond element has an engagement surface thereon. The opposing thrust surface is formed of or includes at least some diamond reactive material. The thrust surface is mated with the opposing thrust surface such that the engagement surface is in contact with the opposing thrust surface.

[0029] 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 with the thrust surface to define 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 some diamond reactive material. The engagement surface is in contact with the opposing thrust surface.

[0030] So that the features and advantages of the presently disclosed systems, apparatus, and / or methods may be more particularly understood, a more particular description of the above briefly summarized description can be made by reference to embodiments of these systems, apparatus, and / or methods illustrated in the accompanying drawings, which form a part of this specification. It should be noted, however, that these drawings depict only various exemplary embodiments, and therefore should not be considered as limiting the presently disclosed concepts, as the presently disclosed concepts may include other useful embodiments. [Brief description of the drawings]

[0031] [Figure 1] FIG. 2 is an isometric view of a cam follower according to certain aspects of the present disclosure. [Figure 2A] FIG. 2 is an isometric view of a cam assembly including a cam follower in sliding engagement with a cam actuation rotor according to certain aspects of the present disclosure. [Figure 2B] FIG. 2B is a cross-sectional view of the cam assembly of FIG. 2A. [Diagram 3]1 is a cross-sectional view of a cam assembly including a cam follower having a planar polycrystalline diamond element in sliding engagement with a cam in accordance with certain aspects of the present disclosure. [Figure 4] 1 is a cross-sectional view of a cam assembly including a cam follower having a dome-shaped polycrystalline diamond element in sliding engagement with a cam in accordance with certain aspects of the present disclosure. [Diagram 5] FIG. 1 depicts a cam follower engaged with a cam without edge or point contact. [Figure 6] FIG. 1 depicts a cam assembly having a solid lubricant source. [Figure 7] 1 is a flow diagram illustrating general criteria for using the techniques disclosed herein. [Figure 8A] FIG. 2 is a partial side view of a rotor and stator radial bearing assembly according to an embodiment of the technology of this application. [Figure 8B] FIG. 8B is a cross-sectional view of the rotor and stator radial bearing assembly of FIG. 8A taken along line AA. [Figure 9A] FIG. 2 is a partial side view of a rotor and stator radial bearing assembly according to an embodiment of the technology of this application. [Figure 9B] FIG. 9B is a cross-sectional view of the assembly of FIG. 9A taken along line BB. [Figure 10A] FIG. 2 is a partial side view of a rotor and stator radial bearing assembly according to an embodiment of the technology of this application. [Figure 10B] FIG. 4B is a cross-sectional view of the assembly of FIG. 4A taken along line CC. [Figure 11A] FIG. 2 is a partial side view of a rotor and stator radial bearing assembly according to an embodiment of the technology of this application. [Figure 11B] FIG. 11B is a cross-sectional view of the assembly of FIG. 11A taken along line DD. [Figure 12A] FIG. 2 is a partial side view of a rotor and stator radial bearing assembly according to an embodiment of the technology of this application. [Figure 12B] FIG. 12B is a cross-sectional view of the assembly of FIG. 12A taken along line EE. [Figure 13A]FIG. 2 is a partial side view of a rotor and stator radial bearing assembly according to an embodiment of the technology of this application. [Figure 13B] FIG. 13B is a cross-sectional view of the assembly of FIG. 13A taken along line FF. [Figure 14A] FIG. 2 is a partial side view of a rotor and stator radial bearing assembly according to an embodiment of the technology of this application. [Figure 14B] FIG. 14B is a cross-sectional view of the assembly of FIG. 14A taken along line GG. [Figure 15A] FIG. 2 is a partial side view of a rotor and stator radial bearing assembly according to an embodiment of the technology of this application. [Figure 15B] FIG. 15B is a cross-sectional view of the assembly of FIG. 15A taken along line HH. [Figure 16A] FIG. 2 is a partial side view of a rotor and stator radial bearing assembly according to an embodiment of the technology of this application. [Figure 16B] FIG. 16B is a top cross-sectional view of the assembly of FIG. 16A taken along line II. [Figure 17A] FIG. 2 is a partial side view of a rotor and stator radial bearing assembly according to an embodiment of the technology of this application. [Figure 17B] FIG. 17B is a cross-sectional view of the assembly of FIG. 17A taken along line JJ. [Figure 18A] FIG. 2 is a partial side view of a rotor and stator radial bearing assembly according to an embodiment of the technology of this application. [Figure 18B] FIG. 18B is a cross-sectional view of the assembly of FIG. 18A taken along line KK. [Figure 19A] FIG. 2 is a partial side view of a rotor and stator radial bearing assembly according to an embodiment of the technology of this application. [Figure 19B] FIG. 19B is a cross-sectional view of the assembly of FIG. 19A taken along line LL. [Figure 20] FIG. 1 is a partial cut-away view of a prior art polycrystalline diamond to polycrystalline diamond interface thrust bearing. [Figure 21A] FIG. 2 is a top view of a polycrystalline diamond thrust surface of a thrust bearing according to an embodiment of the technology of this application. [Figure 21B] FIG. 21B is a side view of the polycrystalline diamond thrust face of FIG. 21A in sliding contact with an opposing thrust face formed of or including at least some diamond reactive material. [Figure 22A] FIG. 2 is a top view of a polycrystalline diamond thrust surface of a thrust bearing according to an embodiment of the technology of this application. [Figure 22B] FIG. 23B is a side view of the polycrystalline diamond thrust face of FIG. 23A in sliding contact with an opposing thrust face formed of or including at least some diamond reactive material. [Figure 23] FIG. 2 is a side view of an exemplary polycrystalline diamond element of an embodiment of the technology of this application. [Figure 24] FIG. 2 is a side view of an exemplary polycrystalline diamond element of an embodiment of the technology of this application. [Diagram 25] FIG. 2 is a side view of an exemplary polycrystalline diamond element of an embodiment of the technology of this application. [Figure 26] FIG. 2 is a side view of an exemplary polycrystalline diamond element of an embodiment of the technology of this application. [Figure 27] FIG. 2 is a side view of an exemplary polycrystalline diamond element of an embodiment of the technology of this application. [Figure 28] FIG. 2 is a side view of a polycrystalline diamond element without edge treatment and with sharp corners. [Figure 29A] FIG. 1 is a simplified depiction of edge contact between a polycrystalline diamond element subjected to edge treatment and an opposing thrust surface. [Figure 29B] FIG. 1 is a simplified depiction of edge contact between a polycrystalline diamond element having no edge treatment and a sharp corner and an opposing thrust surface. [Figure 30A] FIG. 2 depicts a bearing surface before surface treatment. [Figure 30B] FIG. 30B depicts the bearing surface of FIG. 30A after surface treatment. [Figure 31A] FIG. 2 depicts a bearing body prior to material processing. [Figure 31B] FIG. 31B depicts the bearing body of FIG. 31A after material processing. [Diagram 32] 1 is a graph of load and CoF during burnishing of the shaft in Example 3. [Figure 33A] 1 is an image of the shaft of Example 3. [Figure 33B] 1 is an image of the shaft of Example 3. [Figure 33C] 1 is an image of the shaft of Example 3. [Figure 33D] FIG. 11 is a schematic diagram of a shaft according to a third embodiment. [Figure 33E] 1 is an image of the shaft of Example 3.

[0032] The systems, apparatus, and methods according to the present disclosure will now be described more fully below with reference to the accompanying drawings, which show various exemplary embodiments. However, the concepts according to the present disclosure can be embodied in many different forms and should not be construed as being 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 and the best and preferred modes of implementation to those skilled in the art. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0033] Certain embodiments of the present disclosure include devices having multiple surfaces in mutually moving engagement (e.g., diamond-on-steel engagement), including bearing surfaces such as cam followers, radial bearings, thrust bearings, and systems including same, as well as methods of making, assembling, and using same. Some embodiments of the present disclosure provide for material treated (e.g., surface treated) devices, methods of material treatment, and methods of making, assembling, and using same.

[0034] Definitions, Examples, and Criteria Lapped and Polished - As used herein, a face is defined as "highly lapped" if it has a face finish of about 20 μin, such as a face finish of 20 μin or a face finish ranging from about 18 μin to about 22 μin. As used herein, a face is defined as "polished" if it has a face finish finer than about 10 μin or from about 2 μin to about 10 μin. As used herein, a face is defined as "highly polished" if it has a face finish finer than about 2 μin or from about 0.5 μin to less than about 2 μin. As will be appreciated by those skilled in the art, face finish can be measured using a profilometer or an atomic force microscope. A polycrystalline diamond polished to a face finish of 0.5 μin has about half the coefficient of friction of a standard lapped polycrystalline diamond with a face finish of 20-40 μin. US Pat. Nos. 5,447,208 and 5,653,300 to Lund et al., which are incorporated herein by reference in their entireties, provide disclosures relating to polishing polycrystalline diamond.

[0035] Diamond reaction material-As used herein, "diamond reaction material" is a material that contains more than a trace amount of diamond catalyst or diamond solvent.As used herein, diamond reaction material that contains more than a trace amount of diamond catalyst or diamond solvent contains at least 2 weight percent (wt%) of diamond reaction material.In some embodiments, the diamond reaction material disclosed herein contains 2wt% to 100wt%, 5wt% to 95wt%, 10wt% to 90wt%, 15wt% to 85wt%, 20wt% to 80wt%, 25wt% to 75wt%, 25wt% to 70wt%, 30wt% to 65wt%, 35wt% to 60wt%, 40wt% to 55wt%, 45wt% to 50wt% of diamond catalyst or diamond solvent. As used herein, a "diamond catalyst" is, for example, a chemical element, compound, or material that functions to catalyze the graphitization of polycrystalline diamond under load and at 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 functions to solubilize polycrystalline diamond under load and at or above the graphitization temperature of diamond. Thus, diamond reaction materials include materials that can cause wear, sometimes rapid wear, and failure of components such as diamond-tipped tools formed of polycrystalline diamond under load and at or above the graphitization temperature of diamond. Diamond reaction materials include, but are not limited to, metals, alloys, and composites that contain more than trace amounts of diamond catalyst elements or diamond solvent elements. In some embodiments, the diamond reaction materials are in the form of hardfacing, coating, or plating. For example, without limitation, the diamond reactive material can be iron, cobalt, nickel, ruthenium, rhodium, palladium, chromium, manganese, copper, titanium, tantalum, aluminum, or alloys thereof, hi some embodiments, the diamond reactive material is steel or cast iron.In some embodiments, the diamond reactant material is a superalloy, including but not limited to iron-based, cobalt-based, and nickel-based superalloys. In certain embodiments, the diamond reactant material is not and / or does not include (i.e., specifically excludes) so-called "super-hard materials."

[0036] Superhard materials - As will be appreciated by those skilled in the art, "superhard materials" are a class of materials defined by the hardness of the material, which may be determined according to Brinell, Rockwell, Knoop, and / or Vickers hardness. For example, superhard materials include materials having a hardness value greater than 40 gigapascals (GPa) as measured by the Vickers hardness test. As used herein, superhard materials include materials that are at least as hard as tungsten carbide tiles and / or tungsten carbide cemented carbides, for example, when determined according to one of these hardness scales, e.g., Brinell hardness. It will be appreciated by those skilled in the art that Brinell hardness testing may be performed, for example, according to ASTM E10-14, Vickers hardness testing may be performed, for example, according to ASTM E384, Rockwell hardness testing may be performed, for example, according to ASTM E18, and Knoop hardness testing may be performed, for example, according to ASTM E384. The "superhard material" disclosed herein includes, but is not limited to, tungsten carbide (e.g., tile or hard metal), infiltrated tungsten carbide matrix, silicon carbide, silicon nitride, cubic boron nitride, and polycrystalline diamond. Thus, in some embodiments, the "diamond reaction material" is partially or entirely composed of a material (e.g., metal, alloy, composite) that is softer (less hard) than the superhard material, e.g., less hard than tungsten carbide (e.g., tile or hard metal), as determined according to one of the hardness tests described above, e.g., Brinell hardness. As will be understood by those skilled in the art, hardness can be determined using Brinell hardness according to ASTM E10-14, etc. As will be understood by those skilled in the art, a "superalloy" is a high-strength alloy that can withstand high temperatures.

[0037] Engagement Surface - As used herein, "engagement surface" means a surface of a material (e.g., polycrystalline diamond or diamond-reactive material) positioned and arranged in an assembly (e.g., in a bearing assembly) to interface contact between two components of the assembly (e.g., between a stator and a rotor, between a thrust surface and an opposing thrust surface, or between a cam and a cam follower) during operation of the assembly. As used herein, "engagement surface" may also be referred to as a "bearing surface," "thrust bearing surface," "axial bearing surface," "thrust surface," "opposing engagement surface," or other surface depending on the particular application.

[0038] Polycrystalline Diamond - In some embodiments, the polycrystalline diamond elements disclosed herein can have diameters as small as 3 mm (about 1.8'') or as large as 75 mm (about 3''), for example, depending on the application and the configuration and diameter of the engagement cam. Some of the polycrystalline diamond elements disclosed herein will have diameters from 8 mm (about 5 / 16'') to 25 mm (about 1''). Those skilled in the art will understand that the polycrystalline diamond elements are not limited to these particular diamonds and may vary in size and shape depending on the particular application. In some aspects, the polycrystalline diamond elements are unleached, leached, leached and refilled, chemical vapor deposition (CVD) coated, or processed by various techniques known in the art. In certain applications, the polycrystalline diamond elements disclosed herein have a high cobalt content transition layer between the outer polycrystalline diamond face and the tungsten carbide support slug. In some applications, the polycrystalline diamond element disclosed herein may not be supported by tungsten carbide and can be a separate polycrystalline diamond body that is substantially "free-standing" and directly mounted (e.g., on a cam follower body or bearing component).In the embodiment in which the polycrystalline diamond element is a flat-faced or dome-shaped polycrystalline diamond element, the polycrystalline diamond element can be mounted in such a way that it can rotate around its own axis.For a non-limiting example of the method that allows the polycrystalline diamond element to rotate around its own axis while in face contact with diamond reactive material, see US Patent No. 8,881,849 to Shen et al.

[0039] In some embodiments, the polycrystalline diamond element disclosed herein is not shaped to fit exactly with the opposing engagement surface.In certain embodiments, the sliding interface contact area of ​​the engagement surface of the polycrystalline diamond element is less than 80%, less than 75%, less than 70%, or less than 60% of the total area of ​​the polycrystalline diamond element.As used herein, the "contact area" of the engagement surface refers to the area of ​​the engagement surface that is in contact with the opposing engagement surface.

[0040] Polycrystalline diamond elements are most commonly available in a cylindrical shape, although it will be understood that the techniques of this 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.

[0041] In some aspects, the polycrystalline diamond element is subjected to edge radius treatment. The edge radius treatment of polycrystalline diamond element is known in the art. In some embodiments of the technology of this application that uses flat or concave polycrystalline diamond element, it is preferable to use the edge radius treatment of such polycrystalline diamond element. One purpose of using edge radius treatment is to reduce or avoid the possibility that the outer edge cuts or scratches the outer boundary of the linear engagement area between a given polycrystalline diamond element and an opposing engagement surface (e.g., curved surface).

[0042] Hardened and Unhardened Materials and Surfaces - As used herein, a "hardened material" is a material that has been subjected to hardening resulting in an increase in the hardness of the material at least at the surface of the material, where the hardness is determined by Brinell, Knoop, and / or Vickers hardness. That is, the material has a first hardness before undergoing hardening and a second hardness that is higher than the first hardness after undergoing hardening. The hardness increase may be throughout the material or may be an increase in hardness of only a portion of the material, such as one or more surfaces of the material. As described in more detail elsewhere herein, various processes can be used to increase the hardness of a material either uniformly throughout the material or individually at the surfaces of the material. Some exemplary processes described in more detail below include cold working and work hardening processes such as burnishing and shot peening, and heat treatment processes such as through hardening, case hardening, and sub-zero cryogenic freezing.

[0043] As used herein, an "uncured material" is a material that has not been subjected to curing such that no increase in the hardness of the material occurs.

[0044] Plated Surfaces, Unplated Surfaces, Coated Surfaces, and Uncoated Surfaces - As used herein, "plated surfaces" and "coated surfaces" are surfaces that have been plated or coated, respectively, resulting in the presence of a plated or coated layer on the surface. As described in more detail elsewhere herein, various processes can be used to apply a plated or coated layer to a surface. Some exemplary processes, described in more detail below, include electrolytic and electroless plating, including chromium plating, phosphating, deposition, including physical vapor deposition (PVD) and chemical vapor deposition (CVD), and anodizing.

[0045] As used herein, an "unplated surface" and an "uncoated surface" are surfaces that have not been plated or coated, respectively, such that the surface is devoid of a plating or coating, respectively.

[0046] Cladding - As used herein, a "clad surface" is a surface that has been cladded, resulting in the presence of cladding on the surface. As described in more detail elsewhere herein, various processes can be used to add cladding to a surface. Some exemplary processes, described in more detail below, include roll bonding, laser cladding, and explosion welding.

[0047] As used herein, an "unclad surface" is a surface that has not been cladded such that the surface lacks any cladding thereon.

[0048] Cam Follower Certain aspects of the present disclosure include cam followers and cam assemblies, as well as devices and systems including same and methods of using same. The cam follower can be a fixed cam follower. In some such aspects, the fixed cam follower has a lower coefficient of friction than existing fixed type cam followers.

[0049] The cam followers disclosed herein can have a higher load capacity than existing roller-type cam followers, and thus, in some embodiments, the cam followers disclosed herein are stronger and longer lasting than existing roller-type followers.

[0050] A cam follower according to certain aspects of the present disclosure will be described with reference to FIG. 1. Cam follower 105 includes a cam follower body 104. Cam follower body 104 may be constructed of any of a variety of materials known to those of skill in the art. Cam follower body 104 has a first end 106 and a second end 108. Those skilled in the art will appreciate that cam follower body 104 is not limited to the particular shape shown in FIG. 1, but may have any of a variety of other suitable shapes depending on the particular application and use.

[0051] At a second end 108, the cam follower body 104 is bonded to or integral with a polycrystalline diamond element 102 made of polycrystalline diamond. In some embodiments, the polycrystalline diamond element 102 is comprised of thermally stable polycrystalline diamond or polycrystalline diamond sintered bodies that may or may not be supported by tungsten carbide.

[0052] The polycrystalline diamond elements 102 are attached to the cam follower body 104 through fixtures 103. The polycrystalline diamond elements 102 may be attached to the cam follower body 104 by any of a variety of attachment methods, including, but not limited to, gluing, brazing, LS bonding, press fit, or another attachment means or method known in the art.

[0053] The polycrystalline diamond element 102 includes an engagement surface 101. The engagement surface 101 may be a polycrystalline diamond layer. The engagement surface 101 may be a flat surface, as shown in FIG. 1. In other embodiments, the engagement surface 101 is not a flat surface. In some embodiments, the engagement surface 101 is a lapped or polished, optionally highly lapped or highly polished, surface of the polycrystalline diamond element 102. Although highly polished polycrystalline diamond elements are preferred for at least some applications, the scope of the present disclosure is not limited to highly polished polycrystalline diamond elements and includes highly lapped or polished polycrystalline diamond elements. In some embodiments, the engagement surface 101 has a face finish that ranges from 0.5 μin to 40 μin, 2 μin to 30 μin, 5 μin to 20 μin, or 8 μin to 15 μin, or any range between these values.

[0054] Although the polycrystalline diamond elements 102 are shown as being approximately disk-shaped and disposed on the second end 108 of the cam follower body 104, one skilled in the art will appreciate that the polycrystalline diamond elements 102 may be any of a variety of shapes and may be disposed in other configurations on the cam follower body 104 depending on the particular application and use.

[0055] Cam Follower - Assembly Certain aspects of the present disclosure include cam assemblies including a cam follower engaged with a cam (cam actuating component), as well as devices and systems including the same, and methods of use thereof. A cam assembly according to certain aspects of the present disclosure is described with reference to Figures 2A-6, in which like reference numbers refer to like elements. For example, an exemplary cam follower is identified in Figure 1 with the reference number "105" and in Figures 2A and 2B with the reference number "205."

[0056] FIG. 2A is an isometric view of cam assembly 200, and FIG. 2B is a cross-sectional view of cam assembly 200. With reference to FIGS. 2A and 2B, cam assembly 200 includes cam follower 205. As with cam follower 105, cam follower 205 includes cam follower body 204 having a first end 206 and a second end 208, with polycrystalline diamond element 202 coupled to cam follower body 204 at second end 208 through fixture 203. Engagement surface 201 of cam follower 205 is in sliding engagement with opposing engagement surface 211 of cam 216, shown in these figures as a cam actuating rotor. Although cam 216 is shown in FIG. 2A as a cam actuating rotor, one skilled in the art will appreciate that the cams disclosed herein can be any of a variety of sliding or rotating components.

[0057] In some embodiments, the planar surface defined by engagement surface 201 when engaged with counter engagement surface 211 may be at an angle relative to the plane defined by counter engagement surface 211 such that less than the entire surface of engagement surface 201 engages counter engagement surface 211. According to one embodiment of the present disclosure, engagement surface 201 is illustrative of a planar polycrystalline diamond element.

[0058] 2B shows the cam rotation centerline at 207. As the cam 216 rotates about the rotation centerline at 207, the opposing engagement surface 211 engages and slides across the engagement surface 201. The opposing engagement surface 211, and optionally the entire cam 106, may be constructed of a diamond reactive material.

[0059] In some embodiments, the opposing engagement surface comprises or consists of at least 2% by weight diamond reactive material, or 2% to 100% by weight, 5% to 95% by weight, 10% to 90% by weight, 15% to 85% by weight, 20% to 80% by weight, 25% to 75% by weight, 25% to 70% by weight, 30% to 65% by weight, 35% to 60% by weight, 40% to 55% by weight, or 45% to 50% by weight diamond reactive material.

[0060] 3 is a cross-sectional view of a cam assembly 300 including an exemplary planar polycrystalline diamond cam follower 305 according to one embodiment of the present disclosure. In accordance with one embodiment of the present disclosure, the cam follower 305 is in sliding engagement with a diamond reactive material of an exemplary cam 316. As the cam 316 rotates about a center of rotation 307, the opposing engagement surface 311 moves in a sliding manner over the engagement surface 301.

[0061] FIG. 4 is a cross-sectional view of a cam assembly 400 including a cam follower 405 having a dome-shaped polycrystalline diamond element 402 having an engagement surface 401 in sliding engagement with a counter engagement surface 411 of a cam 416 while the cam 416 rotates about a center of rotation 407.

[0062] Cam Follower - Polycrystalline Diamond Element In certain aspects of the present disclosure, it is possible to provide for the avoidance of edge or point contact between the polycrystalline diamond element and the cam. For example, flat-faced polycrystalline diamond elements can be used for the interface (i.e., engagement between the engagement surface and the counter-engagement surface) when the cam lobe geometry is such that only surface contact with the polycrystalline diamond occurs. In other aspects, the sometimes more complex cam lobe geometry, unlike that described above, may require differently shaped polycrystalline diamond elements, such as dome-shaped, hemispherical, ovoid, cylindrical, parabolic, blunt conical, blunt chisel-shaped, or other forms of polycrystalline diamond elements. Regardless of the particular shape of the polycrystalline diamond element, the polycrystalline diamond element can be lapped or polished using methods known in the art. Referring to FIG. 5, a cam follower 505 is shown with an engagement surface 501 in contact with a counter-engagement surface 511 of a cam 516. The edge or point 503 of the polycrystalline diamond element is not in contact with the counter-engagement surface 511 (i.e., edge or point contact is avoided).

[0063] Cam Followers - Solid Lubricant Source In certain applications, the polycrystalline diamond element and the engagement surface of the polycrystalline diamond element that slidingly interfaces with the opposing cam actuation engagement surface can be augmented with a solid lubricant source. The solid lubricant source can be, for example, but is not limited to, a graphite or hexagonal boron nitride rod or inclusion in either an energized or unenergized state in contact with the opposing cam actuation engagement surface that includes at least a portion of the diamond reaction material. Figure 6 shows an exemplary cam assembly 600 that is the same as Figure 3, except that the cam assembly 600 includes a solid lubricant source 650 in contact with the opposing engagement surface 311.

[0064] Cam follower - treatment of opposing engagement surfaces In some embodiments, the opposing mating surface of the diamond reaction material is pre-saturated with carbon (e.g., before mating with the mating surface). Such pre-saturation reduces the ability of the diamond reaction material to attract carbon by graphitizing the surface of the polycrystalline diamond. Pre-saturation of the diamond reaction material surface can be achieved by any method known in the art.

[0065] In some aspects, the opposing mating surface is borided, nitrided, or case hardened. Without being bound by theory, it is believed that such treatment of the opposing mating surface improves the performance of that surface.

[0066] Cam Followers - Applications The cam followers and cam assemblies disclosed herein can be used in any of a variety of applications, including high performance applications in internal combustion engines, including but not limited to diesel engines, gasoline engines, high performance race car and boat engines, mining machines, various machining tools, and the like, and other applications. In certain aspects, the cam followers disclosed herein are high performance cam followers capable of reliable application in harsh environments, such as underground environments. The cam followers disclosed herein can be high performance cam followers capable of application in unlubricated, dusty, and / or vacuum environments, including but not limited to mining, aerospace, non-air, wind storm, or agricultural environments.

[0067] In certain applications, the cam followers disclosed herein can be operated in sliding engagement with diamond reactive materials without the graphitization and associated wear and failure of the polycrystalline diamond components.

[0068] Radial bearings Certain aspects of the present disclosure include radial bearings and radial bearing assemblies, and devices and systems including the same, as well as methods of using the same. For convenience, the following description provides an outer stator component and an inner rotor component. However, those skilled in the art will understand that in each of the exemplary embodiments disclosed herein, the inner component can be held stationary and the outer component can rotate. Furthermore, those skilled in the art will understand that while the description of the present disclosure relates to a rotor and stator configuration, the technology disclosed herein is not limited to such applications, but can be applied in a variety of other applications, including separate bearings having inner and outer rings, both of which rotate, or one or the other of which is held stationary.

[0069] Radial bearings - Polycrystalline diamond and diamond reaction material interface In some aspects, the present disclosure provides that the engagement between the rotor and the stator is interfaced with a polycrystalline diamond element that is in contact with the diamond reactive material.For example, the polycrystalline diamond element can be positioned and arranged on the stator for sliding contact with the rotor, where the rotor is formed or includes at least some diamond reactive material.Alternatively, the polycrystalline diamond element can be positioned and arranged on the rotor for sliding contact with the stator that is formed or includes at least some diamond reactive material.The polycrystalline diamond element can have an engagement surface for engagement with the opposing engagement surface of the diamond reactive material.

[0070] In some embodiments, the opposing engagement surface comprises or consists of at least 2% by weight diamond reactive material, or 2% to 100% by weight, 5% to 95% by weight, 10% to 90% by weight, 15% to 85% by weight, 20% to 80% by weight, 25% to 75% by weight, 25% to 70% by weight, 30% to 65% by weight, 35% to 60% by weight, 40% to 55% by weight, or 45% to 50% by weight diamond reactive material.

[0071] In certain applications, the polycrystalline diamond elements, or at least their mating surfaces, are lapped or polished, and optionally highly lapped or highly 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.

[0072] Radial bearings - Evaluation criteria 7 shows a flow chart 700 of a symbolic generalized set of evaluation criteria for using the technology of this application for dry, unlubricated environments. As shown in box 701, it is first evaluated whether the maximum sliding speed for the application is less than 10.5 m / s. As used herein, "sliding speed," also referred to as "sliding interface speed," is the speed at which two contacting components move relative to each other (e.g., the speed at which a rotor in contact with a stator moves relative to the stator).

[0073] If the maximum sliding speed is determined to be not lower than 10.5 m / s, then the evaluation target application is determined to not be a suitable candidate for the use of polycrystalline diamond elements in sliding engagement with diamond reactive materials because the sliding speed is too high, as shown in box 702. Those skilled in the art will understand that in a lubricated or wet environment, the sliding interface speed may be significantly higher than in a dry, unlubricated environment (as is the case for the evaluation herein).

[0074] If the maximum sliding speed is determined to be less than 10.5 m / s, then a configuration (e.g., shape, size, and arrangement) of the polycrystalline diamond elements is selected depending on the particular application at hand, as shown in box 703. Box 703 illustrates various non-limiting polycrystalline diamond element configurations for sliding engagement with diamond reactive material in various bearing configurations. For example, planar polycrystalline diamond elements can be selected for use on a stator engaging a cylindrical rotor formed of or including at least some diamond reactive material, or convex polycrystalline diamond elements can be selected for use on a stator engaging a cylindrical rotor formed of or including at least some diamond reactive material, or polycrystalline diamond elements having concave or at least slightly concave surfaces can be selected for use on a stator engaging a cylindrical rotor formed of or including at least some diamond reactive material, or polycrystalline diamond elements having convex or at least slightly convex surfaces can be selected for use on a rotor engaging a cylindrical stator formed of or including at least some diamond reactive material, or polycrystalline diamond elements having convex or at least slightly convex surfaces can be selected for use on a stator engaging a grooved rotor formed of or including at least some diamond reactive material. or one can select chisel shaped polycrystalline diamond elements for use on a stator that engages a grooved rotor formed of or including at least some diamond reaction material, or one can select dome shaped or hemispherical shaped polycrystalline diamond elements for use on a stator that engages a conical rotor formed of or including at least some diamond reaction material, or one can select planar polycrystalline diamond elements for use on a conical stator that engages a conical rotor formed of or including at least some diamond reaction material, or one can select polycrystalline diamond elements having a convex or at least slightly convex surface for use on a conical stator that engages a conical stator formed of or including at least some diamond reaction material,Or polycrystalline diamond elements can be selected having concave or at least slightly concave surfaces for use on a conical stator that engages a conical rotor formed or containing at least some diamond reaction material, or polycrystalline diamond elements can be selected having concave or at least slightly concave surfaces for use on a spherical rotor that engages a spherical stator formed or containing at least some diamond reaction material, or polycrystalline diamond elements can be selected having flat, convex, or at least slightly convex surfaces for use on a spherical stator that engages a spherical rotor formed or containing at least some diamond reaction material. Those skilled in the art will understand that the disclosure of the present invention is not limited to these particular selected shapes and selected contours, and that the shapes, including the surface contours, of the rotor, stator, polycrystalline diamond elements, and other application-specific components may vary depending on the particular application.

[0075] After selecting the configuration as shown in box 703, the maximum contact pressure per polycrystalline diamond element is calculated. The maximum contact pressure per polycrystalline diamond element is calculated based on the number of polycrystalline diamond elements and expected loads, including radial, axial, bending or other loads, as shown in box 704. The maximum contact pressure can be determined by methods known to those skilled in the art.

[0076] After calculation of the maximum contact pressure per polycrystalline diamond element, the calculated maximum contact pressure per polycrystalline diamond element is multiplied by a safety factor, as shown in box 705. Application of a safety factor above or exceeding the maximum pressure determined in box 704 can be set and applied, for example, at the designer's discretion. Thus, the safety factor, when applied, specifies a lower pressure per polycrystalline diamond element relative to the maximum contact pressure per polycrystalline diamond element.

[0077] In box 706, it is determined whether the calculated maximum pressure is lower than the maximum allowable pressure for the expected number of cycles of the device. As will be understood by those skilled in the art, the fatigue of the diamond reactive material is the limiting factor. The load is applied to the diamond / diamond reactive material (e.g., metal) interface. The more PDC elements in the assembly, the lower the instantaneous load on the metal. To facilitate making the determination in box 706, the SN curve (contact stress versus number of cycles) can be used.

[0078] Each time it is determined in box 706 that the calculated pressure is not below the maximum allowable pressure, additional polycrystalline diamond elements are placed in the design configuration selected in box 703, as shown in box 707. After these additional polycrystalline diamond elements are placed, the resulting modified design configuration is evaluated as in boxes 704 and 705, and then again determined by the criteria of box 706.

[0079] Each time it is determined that the pressure calculated in Box 706 is below the maximum allowable pressure, a proposed design configuration is provided, as shown in Box 708, by placing at least the minimum number of polycrystalline diamond elements indicated as required by the preceding Boxes 701-706 on the components of the selected design configuration in Box 703 (e.g., mounting a minimum number of polycrystalline diamond elements on the stator or rotor).

[0080] In box 709, it is determined whether a minimum number of polycrystalline diamond elements will fit on the selected configuration in box 703 for each of box 708. If it is determined that a minimum number of polycrystalline diamond elements will fit on the selected configuration in box 703, then a bearing assembly is manufactured in the rotor and stator as shown in box 110. If it is determined that a minimum number of polycrystalline diamond elements will not fit on the selected configuration in box 703, then it is determined that the selected configuration in box 703 is not a suitable candidate for use of polycrystalline diamond elements in sliding engagement with the diamond reactive material for each of box 702.

[0081] The designer of the bearing configuration may have the option (not shown) of selecting an alternative bearing configuration from box 703 if the minimum number of polycrystalline diamond elements required does not end up fitting on the initially selected design configuration. Alternatively, a safety factor may be reduced to reduce the minimum number of polycrystalline diamond elements required. Those skilled in the art will appreciate that the criteria shown in Figure 7 are exemplary only, and that other criteria may be evaluated depending on the particular application, and that in at least some applications some of the criteria shown in Figure 7 may be excluded without departing from the scope of the present disclosure.

[0082] Various exemplary rotor and stator radial bearing assemblies are described below with reference to Figures 8A-19B, where like reference numbers refer to like elements. For example, an exemplary assembly is identified in Figures 8A and 8B with the reference number "800" and in Figures 9A and 9B with the reference number "900."

[0083] Radial bearings - stators with planar polycrystalline diamond elements Figure 8A is a partial side view of a rotor and stator radial bearing assembly, and Figure 8B is a cross-sectional view of the rotor and stator radial bearing assembly of Figure 8A taken along line AA. Rotor and stator radial bearing assembly 800 will now be described with reference to both Figures 8A and 8B.

[0084] The rotor and stator radial bearing assembly 800 includes a stator 802 engaged with a rotor 803. Four planar polycrystalline diamond elements 801 are fitted into the stator 802 to define a sliding engagement between the stator 802 and the rotor 803, where the rotor 803 is formed of or includes at least some diamond reactive material. The polycrystalline diamond elements 801 are disposed (e.g., mechanically fitted) within the stator 802 into loading ports 804, which are ports formed in and / or disposed within the stator body 811. For example, and without limitation, each polycrystalline diamond element 801 may be press-fit, glued, brazed, screwed, or otherwise mounted onto the stator 802 (or rotor in other applications) by methods known to those skilled in the art. Those skilled in the art will appreciate that the present disclosure is not limited to these particular attachment methods or use of ports in the stator body, and that the polycrystalline diamond elements may be attached to the stator or rotor by any of a variety of methods. Additionally, although shown as including uniformly spaced planar polycrystalline diamond elements, one skilled in the art will appreciate that the number, spacing, arrangement, shape, and size of the polycrystalline diamond elements may vary depending on any number of various design criteria, including but not limited to those illustrated in Figure 7. In some embodiments, the polycrystalline diamond elements are comprised of thermally stable polycrystalline diamond or polycrystalline diamond sinters that may or may not be supported by tungsten carbide.

[0085] Each polycrystalline diamond element 801 includes an engagement surface 813 (shown as a flat surface in this view) and the rotor 803 includes an opposing engagement surface 815. The polycrystalline diamond elements 801 are disposed on the stator 802 in firm contact with the rotor 803 so as to restrict lateral movement of the rotor 803 during operation while allowing free sliding rotation of the rotor 803. The polycrystalline diamond elements 801 are positioned and arranged such that the engagement surface 813 is in contact (e.g., sliding contact) with the opposing engagement surface 815. That is, the engagement surface 813 and the opposing engagement surface 815 interface the sliding contact between the rotor 803 and the stator 802.

[0086] Figures 8A and 8B show rotors and stators as may be considered for use in downhole pumps or motors. However, it will be understood that those skilled in the art can design and manufacture radial bearings for other applications, as well as individual radial bearings, in the same or similar manner according to the present disclosure. Non-limiting proximal and distal dimensions for such individual bearings are shown in dashed lines 805 in Figure 8A. Optionally, as shown in Figure 8B, through bores 807 are provided in rotor 803 that can be used, for example, for individual bearings. As can be seen in Figure 8B, polycrystalline diamond elements 801 are provided in stator 802 to radially support rotor 803 and define a sliding engagement.

[0087] 8A and 8B show an assembly including four polycrystalline diamond elements 801, one skilled in the art will understand that fewer than four polycrystalline diamond elements, such as three polycrystalline diamond elements, or more than four polycrystalline diamond elements may be used based on the particular application and configuration, e.g., the space available on the stator or rotor for such polycrystalline diamond elements. Furthermore, while Figures 8A and 8B show a single circumferential set of polycrystalline diamond elements 801, one skilled in the art will understand that one or more additional circumferential sets of polycrystalline diamond elements may be disposed on the stator (or rotor) to increase the lateral support and lateral load acceptance capabilities of the bearing assembly.

[0088] Radial bearings - stators with convex polycrystalline diamond elements Figures 9A and 9B show a rotor and stator radial bearing assembly 900 that is substantially similar to Figures 8A and 8B, except that the polycrystalline diamond elements 901 have convex engagement surfaces 913 rather than the flat planar engagement surfaces of Figures 8A and 8B.

[0089] 9A and 9B, the rotor-stator radial bearing 900 includes a convex polycrystalline diamond element 901 fitted into the stator body 911 of the stator 902 to define a sliding engagement with the rotor 903 formed or including at least some diamond reactive material. The polycrystalline diamond element 901 is placed in the stator 902 through a loading port 904 and can be press-fit, glued, brazed, screwed, or otherwise attached using methods known to those skilled in the art. The polycrystalline diamond element 901 is placed in a secure contact position with the rotor 903 to limit lateral movement of the rotor 903 during operation while allowing free sliding rotation of the rotor 903. As is clear from FIG. 9B, the polycrystalline diamond element 901 is disposed in the stator 902 to radially support the rotor 903 and define a sliding engagement therewith. FIG. 9B also shows an optional through bore 907 that can be used for a separate bearing.

[0090] 9A and 9B show a rotor and stator as may be used in a downhole pump or motor, other assemblies including individual radial bearing assemblies can be designed and manufactured in the same or substantially the same manner. Non-limiting proximal and distal dimensions for such individual bearings are shown in dashed lines 905. Furthermore, while FIGS. 9A and 9B show four polycrystalline diamond elements 901, one skilled in the art will understand that fewer (e.g., three) or more polycrystalline diamond elements can be disposed on the stator 902. Furthermore, while FIGS. 9A and 9B show a single circumferential set of polycrystalline diamond elements 901, one skilled in the art will understand that one or more additional circumferential sets of polycrystalline diamond elements can be disposed on the stator to increase the lateral support and lateral load acceptance capabilities of the bearing assembly.

[0091] As with assembly 800 , in operation, engagement surface 913 interfaces with opposing engagement surface 915 to carry the load between rotor 903 and stator 902 .

[0092] Stator with concave polycrystalline diamond elements Figures 10A and 10B show a rotor and stator radial bearing assembly 1000 that is substantially similar to Figures 8A-9B, except that the polycrystalline diamond element 1001 has a concave or at least slightly concave engagement surface 1013 rather than the flat planar engagement surface of Figures 8A and 8B or the convex engagement surface of Figures 9A and 9B.

[0093] Slightly concave polycrystalline diamond elements 1001 are fitted into the stator body 1011 of the stator 1002 to define a sliding engagement with the rotor 1003. The polycrystalline diamond elements 1001 are provided in the stator 1002 through a loading port 1004. The polycrystalline diamond elements 1001 may be press-fit, glued, brazed, screwed or otherwise attached using methods known to those skilled in the art. The polycrystalline diamond elements 1001 are positioned in firm contact with the rotor 1003 to restrict lateral movement of the rotor 1003 during operation while allowing free sliding rotation of the rotor 1003.

[0094] As in the assembly 900, in operation, the engagement surface 1013 interfaces with the counter engagement surface 1015 to carry the load between the rotor 1003 and the stator 1002. The at least slight concavity of each polycrystalline diamond element 1001 is oriented with the axis of the concavity in line with the circumferential rotation of the rotor 1003, thereby ensuring that there is no edge contact between the polycrystalline diamond element 1001 and the rotor 1003, and defining a linear surface contact between the polycrystalline diamond element 1001 and the rotor 1003 approximately by the deepest part of the concavity. That is, the engagement between the polycrystalline diamond element 1001 and the rotor 1003 is only interfaced by the engagement surface 1013 and the counter engagement surface 1015 such that the edge or point 1017 of the polycrystalline diamond element 1001 does not contact the rotor 1003. Thus, only linear surface contact occurs between the polycrystalline diamond element 1001 and the rotor 1003, and no edge or point contact occurs. As can be seen in Figure 10B, polycrystalline diamond elements 1001 are disposed in the stator 1002 to radially support and define a sliding engagement with the rotor 1003. Figure 10B also shows an optional through bore 1007 such as may be used for a separate bearing.

[0095] Although Figures 10A and 10B show a rotor and stator as might be used in a downhole pump or motor, assemblies including individual radial bearing assemblies can be designed and manufactured in the same or substantially the same manner. Non-limiting proximal and distal dimensions for such individual bearings are shown in dashed lines 1005. Furthermore, although Figures 10A and 10B show four polycrystalline diamond elements 1001, one skilled in the art will understand that fewer (e.g., three) or more polycrystalline diamond elements can be disposed on the stator 1002. Furthermore, although Figures 10A and 10B show a single circumferential set of polycrystalline diamond elements 1001, one skilled in the art will understand that one or more additional circumferential sets of polycrystalline diamond elements can be disposed on the stator to increase the lateral support and lateral load acceptance capabilities of the bearing assembly.

[0096] Radial bearings - rotors with convex polycrystalline diamond elements Figures 11A and 11B show a rotor and stator radial bearing assembly 1100 that is substantially similar to Figures 9A and 9B, except that a polycrystalline diamond element 1101 having a convex dome-shaped engagement surface 1113 is provided on the rotor 1103 rather than on the stator.

[0097] Convex polycrystalline diamond elements 1101 are fitted into the rotor body 1123 of the rotor 1103 to define a sliding engagement with the stator 1102 formed or including at least some diamond reactive material. The polycrystalline diamond elements 1101 are mounted in the rotor 1103 in sockets 1104 formed and / or located in the rotor body 1123. The polycrystalline diamond elements 1101 can be press-fit, glued, brazed, screwed or otherwise attached using methods known to those skilled in the art. The polycrystalline diamond elements 1101 are placed in a positive contact position against the stator 1102 to limit the lateral movement of the rotor 1103 during operation while allowing the rotor 1103 to freely slide rotate. As is clear from FIG. 11B, the polycrystalline diamond elements 1101 are mounted in the rotor 1103 to radially support the stator 1102 and define a sliding engagement therewith. FIG. 11B also shows an optional through bore 1107 that may be used for the individual bearings.

[0098] Although Figures 11A and 11B show a rotor and stator as may be used in a downhole pump or motor, other assemblies, including individual radial bearing assemblies, may be designed and manufactured in the same or substantially the same manner. Non-limiting proximal and distal dimensions for such individual bearings are shown in dashed lines 1105. Furthermore, although Figures 11A and 11B show four polycrystalline diamond elements 1101, one skilled in the art will understand that fewer (e.g., three) or more polycrystalline diamond elements may be disposed on the rotor 1103. Furthermore, although Figures 11A and 11B show a single circumferential set of polycrystalline diamond elements 1101, one skilled in the art will understand that one or more additional circumferential sets of polycrystalline diamond elements may be disposed on the rotor to increase the lateral support and lateral load acceptance capabilities of the bearing assembly.

[0099] As noted above, in contrast to the embodiment illustrated in FIGS. 8A-10B, in the embodiment illustrated in FIGS. 11A and 11B, the engagement surface 1113 is on the rotor 1103 and the opposing engagement surface 1115 is on the stator 1102.

[0100] Radial bearings - stators with chisel-shaped polycrystalline diamond elements 12A and 12B show a rotor and stator radial bearing assembly 1200 having a chisel-shaped polycrystalline diamond element 1201 fitted into a stator body 1211 of a stator 1202 to define a sliding engagement with a rotor 1203 formed of or including at least some diamond reactive material. The polycrystalline diamond element 1201 is disposed in the stator 1202 through a loading port 1204 formed and / or located in the stator body 1211. The polycrystalline diamond element 1201 may be press-fit, glued, brazed, screwed, or otherwise attached using methods known to those skilled in the art.

[0101] The polycrystalline diamond elements 1201 are positioned in a positive contact position within the radial / thrust face grooves 1206 of the rotor 1203 to restrict lateral and axial movement of the rotor 1203 during operation while allowing free sliding rotation of the rotor 1203. The chisel-shaped polycrystalline diamond elements 1201 are positioned, arranged, shaped, sized and oriented to slidingly engage within the mating radial / thrust face grooves 1206 of the rotor 1203. The chisel-shaped polycrystalline diamond elements 1201 include an engagement surface (defined by the chisel-shaped polycrystalline diamond elements 1201) that interfaces in contact with a counter engagement surface, in this case a surface of the radial / thrust face groove 1206. As is evident from FIG. 12B, the chisel-shaped polycrystalline diamond elements 1201 are disposed on the stator 1202 to radially and axially support the rotor 1203 and define a sliding engagement therewith. Figure 12B also shows an optional through bore 1207 that may be used for a separate bearing. The embodiment shown in Figures 12A and 12B may further function as a rotor lock.

[0102] Although Figures 12A and 12B show a rotor and stator as may be used in a downhole pump or motor, other assemblies, including individual radial bearing assemblies, may be designed and manufactured in the same or substantially the same manner. Non-limiting proximal and distal dimensions for such individual bearings are shown in dashed lines 1205. Furthermore, although Figures 12A and 12B show four polycrystalline diamond elements 1201, one skilled in the art will understand that fewer (e.g., three) or more polycrystalline diamond elements 1201 may be disposed on the stator 1202. Furthermore, although Figures 12A and 12B show a single circumferential set of polycrystalline diamond elements 1201, one skilled in the art will understand that one or more additional circumferential sets of polycrystalline diamond elements may be disposed on the stator to increase the lateral and axial support and lateral and axial load bearing capabilities of the bearing assembly.

[0103] Stator with dome-shaped or hemispherical polycrystalline diamond elements Figures 13A and 13B show a rotor and stator radial bearing assembly 1300 that is substantially similar to Figures 13A and 13B, except that the polycrystalline diamond elements 1301 have dome-shaped or hemispherical engagement surfaces 1313 rather than chisel-shaped polycrystalline diamond elements.

[0104] A dome-shaped or hemispherical polycrystalline diamond element 1301 is fitted into the stator housing 1311 of the stator 1302 to define a sliding engagement with the rotor 1303. The polycrystalline diamond element 1301 is provided to the stator 1302 through a loading port 1304 formed and / or located in the stator body 1311. The polycrystalline diamond element 1301 can be press-fit, glued, brazed, screwed, or otherwise attached using methods known to those skilled in the art. The polycrystalline diamond element 1301 is placed in a secure contact position against the radial / thrust face groove 1306 of the rotor 1303 to restrict the lateral and axial movement of the rotor 1303 during operation while allowing the rotor 1303 to freely slide rotate. The dome-shaped or hemispherical polycrystalline diamond element 1301 slidingly engages the mating radial / thrust face groove 1306 of the rotor 1303. The domed or hemispherical polycrystalline diamond element 1301 defines an engagement surface that interfaces with a counter engagement surface, in this case the surface of the radial / thrust face groove 1306. As can be seen in Fig. 13B, the domed or hemispherical polycrystalline diamond element 1301 is disposed on the stator 1302 to radially and axially support the rotor 1303 and define a sliding engagement therewith. Fig. 13B also shows an optional through bore 1307, such as may be used for a separate bearing. The embodiment shown in Figs. 13A and 13B may further function as a rotor lock.

[0105] Although Figures 13A and 13B show a rotor and stator as might be used in a downhole pump or motor, other assemblies, including individual radial bearing assemblies, can be designed and manufactured in the same or substantially the same manner. Non-limiting proximal and distal dimensions for such individual bearings are shown in dashed lines 1305. Furthermore, although Figures 13A and 13B show four polycrystalline diamond elements 1301, one skilled in the art will understand that fewer (e.g., three) or more polycrystalline diamond elements can be disposed on the stator 1302. Furthermore, although Figures 13A and 13B show a single circumferential set of polycrystalline diamond elements, one skilled in the art will understand that one or more additional circumferential sets of polycrystalline diamond elements can be disposed on the stator to increase the lateral and axial support and lateral and axial load bearing capabilities of the bearing assembly.

[0106] Radial bearings - stators with planar polycrystalline diamond elements 14A and 14B show a rotor and stator radial bearing assembly 1400 including planar polycrystalline diamond elements 1401 fitted into a stator body 1411 of a stator 1402 to define a sliding engagement with a rotor 1403 formed of or including at least some diamond reactive material. The polycrystalline diamond elements 1401 are mounted to the stator 1402 through loading ports 1404 formed and / or located in the stator body 1411. The polycrystalline diamond elements 1401 may be press-fit, glued, brazed, screwed, or otherwise attached using methods known to those skilled in the art.

[0107] The polycrystalline diamond element 1401 is positioned in firm contact against the radial / thrust conical surface 1406 of the rotor 1403 so as to limit lateral and upward axial movement of the rotor 1403 during operation while allowing free sliding rotation of the rotor 1403.

[0108] The planar polycrystalline diamond elements 1401 slidingly engage a mating radial / thrust conical surface of the rotor 1403 such that the engagement surface 1413 contacts and interfaces with the opposing engagement surface 1406. As can be seen in Figure 14B, the polycrystalline diamond elements 1401 are disposed on the stator 1402 to radially and axially support the rotor 1403 and define a sliding engagement therewith.

[0109] 14A and 14B show four polycrystalline diamond elements 1401, one skilled in the art will understand that fewer (e.g., three) or more polycrystalline diamond elements can be disposed on the stator 1402. Additionally, while Figures 14A and 14B show a single circumferential set of polycrystalline diamond elements 1401, one skilled in the art will understand that one or more additional circumferential sets of polycrystalline diamond elements can be disposed on the stator to increase the lateral and axial support and lateral and axial load-accommodating capabilities of the bearing assembly.

[0110] Radial bearings - stators with convex polycrystalline diamond elements 15A and 15B show a rotor and stator radial bearing assembly 1500 that is substantially similar to that of FIGS. 14A and 14B, except that the polycrystalline diamond elements 1501 have convex mating surfaces 1513 rather than planar mating surfaces.

[0111] Convex polycrystalline diamond elements 1501 are fitted into a stator body 1511 of a stator 1502 to define a sliding engagement with a rotor 1503. The polycrystalline diamond elements 1501 are disposed in the stator 1502 through loading ports 1504 formed and / or located in the stator body 1511. The polycrystalline diamond elements 1501 may be press-fit, glued, brazed, screwed, or otherwise attached using methods known to those skilled in the art.

[0112] The convex polycrystalline diamond element 1501 is positioned in firm contact with the radial / thrust conical surface 1506 of the rotor 1503 so as to limit lateral and upward axial movement of the rotor 1503 during operation while allowing free sliding rotation of the rotor 1503. The polycrystalline diamond element 1501 slidingly engages the mating radial / thrust conical surface of the rotor 1503 such that the engagement surface 1513 contacts and interfaces with the opposing engagement surface 1506.

[0113] As can be seen in FIG. 15B, convex polycrystalline diamond elements 1501 are disposed on the stator 1502 to radially and axially support the rotor 1503 and define a sliding engagement therewith.

[0114] 15A and 15B show four polycrystalline diamond elements 1501, one skilled in the art will understand that fewer (e.g., three) or more polycrystalline diamond elements can be disposed on the stator 1502. Additionally, while Figures 15A and 15B show a single circumferential set of polycrystalline diamond elements 1501, one skilled in the art will understand that one or more additional circumferential sets of polycrystalline diamond elements can be disposed on the stator to increase the lateral and axial support and lateral and axial load-bearing capabilities of the bearing assembly.

[0115] Radial bearings - rotors with convex polycrystalline diamond elements 16A and 16B show a rotor and stator radial and thrust bearing assembly 1600 including a convex polycrystalline diamond element 1601 fitted into a rotor body 1623 of a rotor 1603 to define a sliding engagement with a stator 1602 formed of or including at least some diamond reactive material. The polycrystalline diamond element 1601 is seated within the rotor 1603 in a socket 1604 formed and / or located within the rotor body 1623. The polycrystalline diamond element 1601 may be press-fit, glued, brazed, screwed, or otherwise attached using methods known to those skilled in the art.

[0116] The convex polycrystalline diamond elements 1601 are positioned in a positive contact position within the radial / thrust conical surface 1606 of the stator 1602 such that during operation they restrict lateral and upward axial movement of the rotor 1603 while allowing free sliding rotation of the rotor 1603. The convex polycrystalline diamond elements 1601 slidingly engage the mating radial / thrust conical surface of the stator 1602 such that the engagement surface 1613 contacts and interfaces with the opposing engagement surface 1606. As can be seen from FIG. 16B, the convex polycrystalline diamond elements 1601 are disposed on the rotor 1603 to radially and axially support and define a sliding engagement therewith of the target material stator 1602.

[0117] 16A and 16B show four polycrystalline diamond elements 1601, one skilled in the art will appreciate that fewer (e.g., three) or more polycrystalline diamond elements can be disposed on the rotor 1603. Additionally, while Figures 16A and 16B show a single circumferential set of polycrystalline diamond elements 1601, one skilled in the art will appreciate that one or more additional circumferential sets of polycrystalline diamond elements can be disposed on the rotor to increase the lateral and axial support and lateral and axial load-bearing capabilities of the bearing assembly.

[0118] Radial bearings - stators with planar polycrystalline diamond elements 17A and 17B show a rotor and stator radial and thrust bearing assembly 1700 including concave or at least slightly concave polycrystalline diamond elements 1701 fitted into a stator body 1711 of a stator 1702 to define a sliding engagement with a rotor 1703 formed of or including at least some diamond reactive material. The polycrystalline diamond elements 1701 are disposed in the stator 1702 through loading ports 1704 formed and / or positioned through the stator 1702. The polycrystalline diamond elements 1701 may be press-fit, glued, brazed, screwed, or otherwise attached using methods known to those skilled in the art.

[0119] The polycrystalline diamond element 1701 is positioned in a positive contact position within the radial / thrust conical surface 1706 of the rotor 1703 such that during operation it limits lateral and upward axial movement of the rotor 1703 while allowing free sliding rotation of the rotor 1703. The polycrystalline diamond element 1701 is oriented with the axis of the concave surface in line with the circumferential rotation of the rotor 1703, thus ensuring limited linear surface contact approximately with the deepest portion of the concave surface. The slightly concave polycrystalline diamond element 1701 slidingly engages the mating radial / thrust conical surface of the rotor 1703 such that the engagement surface 1713 contacts and interfaces with the opposing engagement surface 1706.

[0120] As can be seen in FIG. 17B, slightly concave polycrystalline diamond elements 1701 are disposed on the stator 1702 to radially and axially support and define a sliding engagement with the rotor 1703.

[0121] 17A and 17B show four polycrystalline diamond elements 1701, one skilled in the art will understand that fewer (e.g., three) or more polycrystalline diamond elements can be disposed on the stator 1702. Additionally, while Figures 17A and 17B show a single circumferential set of polycrystalline diamond elements 1701, one skilled in the art will understand that one or more additional circumferential sets of polycrystalline diamond elements can be disposed on the stator to increase the lateral and axial support and lateral and axial load-accommodating capabilities of the bearing assembly.

[0122] Radial bearings - rotors with convex polycrystalline diamond elements 18A and 14B show a rotor and stator radial and thrust bearing assembly 1800 including convex polycrystalline diamond elements 1801 fitted into a rotor body 1823 of a rotor 1803 to define a sliding engagement with a stator 1802. The polycrystalline diamond elements 1801 are seated within the rotor 1803 in sockets 1804 formed and / or located within the rotor body 1823. The polycrystalline diamond elements 1801 may be press-fit, glued, brazed, screwed, or otherwise attached using methods known to those skilled in the art.

[0123] The convex polycrystalline diamond element 1801 is placed in a positive contact position within the radial / thrust concave curved surface 1806 of the stator 1802 such that during operation it limits the lateral and upward axial movement of the rotor 1803 while allowing free sliding rotation of the rotor 1803. The convex polycrystalline diamond element 1801 slidingly engages the mating radial / thrust concave curved surface of the stator 1802 such that the engagement surface 1813 engages the radial / thrust concave curved surface 1806. In the embodiment of Figures 18A and 18B, the radial / thrust concave curved surface 1806 is or forms a counter engagement surface. In the assembly 1800, the contact area on the convex polycrystalline diamond element 1801 is approximately circular. However, one skilled in the art will understand that the polycrystalline diamond element is not limited to having such a contact area.

[0124] As can be seen in FIG. 18B, convex polycrystalline diamond elements 1801 are disposed on rotor 1803 to radially and axially support stator 1802 and define a sliding engagement therewith.

[0125] 18A and 18B show four polycrystalline diamond elements 1801, one skilled in the art will understand that fewer (e.g., three) or more polycrystalline diamond elements can be disposed on the rotor 1803. Additionally, while Figures 18A and 18B show a single circumferential set of polycrystalline diamond elements 1801, one skilled in the art will understand that one or more additional circumferential sets of polycrystalline diamond elements can be disposed on the rotor to increase the lateral and axial support and lateral and axial load-accommodating capabilities of the bearing assembly.

[0126] Radial bearings - stators with planar polycrystalline diamond elements 19A and 19B show partial side views of a rotor and stator radial and thrust bearing assembly 1900 including a flat (or dome shaped, not shown) polycrystalline diamond element 1901 fitted into a stator body 1911 of a stator 1902 to define a sliding engagement with a rotor 1903 formed of or including at least some diamond reactive material. The polycrystalline diamond element 1901 is disposed in the stator 1902 through a loading port 1904 formed and / or located in the stator body 1911. The polycrystalline diamond element 1901 may be press fitted, glued, brazed, screwed or otherwise attached using methods known to those skilled in the art.

[0127] The polycrystalline diamond element 1901 is placed in positive contact with the radial / thrust convex curved surface 1906 of the rotor 1903 during operation to restrict lateral and upward axial movement of the rotor 1903 while allowing free sliding rotation of the rotor 1903. The radial / thrust convex curved surface 1906 is or forms a counter engagement surface. The polycrystalline diamond element 1901 slidingly engages the radial / thrust convex curved surface 1906 of the rotor 1903 such that the engagement surface 1913 engages the counter engagement surface (i.e. the radial / thrust convex curved surface 1906). In the assembly 1900, the contact area on the flat or dome-shaped polycrystalline diamond element is typically circular. However, one skilled in the art will appreciate that the polycrystalline diamond element can have a different contact area.

[0128] As can be seen in FIG. 19B, planar polycrystalline diamond elements 1901 are disposed on a stator 1902 to radially and axially support a rotor 1903 and define a sliding engagement therewith.

[0129] 19A and 19B show four polycrystalline diamond elements 1901, one skilled in the art will understand that fewer (e.g., three) or more polycrystalline diamond elements can be disposed on the stator 1902. Additionally, while Figures 19A and 19B show a single circumferential set of polycrystalline diamond elements 1901, one skilled in the art will understand that one or more additional circumferential sets of polycrystalline diamond elements can be disposed on the stator to increase the lateral and axial support and lateral and axial load-accommodating capabilities of the bearing assembly.

[0130] As is apparent in light of Figures 8A-19B, some embodiments of the present disclosure include high performance radial bearings incorporating polycrystalline diamond elements in sliding engagement with curved or cylindrical surfaces formed of or including at least some diamond reactive material. Some such embodiments include high performance radial bearings in which the diamond reactive material including rotor is placed in sliding contact with preferably three or more polycrystalline diamond elements mounted on a stator. The polycrystalline diamond elements of the stator are preferably planar, but may be slightly concave, convex, or any combination of the three. The face contours of the polycrystalline diamond elements of the stator need not, and preferably do not, match the circumferential curvature of the stator. Although three or more polycrystalline diamond elements are preferred, the technology of this application may be practiced with as few as one or two polycrystalline diamond elements, such as when polycrystalline diamond elements are used to reduce wear and friction on the gravitationally low side of a stator in a horizontally oriented positive displacement pump or opposite the scraping side of a directional drilling assembly.

[0131] In certain applications, the bearing assemblies disclosed herein are configured to withstand thrust loads, and at least some embodiments of the bearing assemblies disclosed herein are capable of accommodating both radial and thrust load components simultaneously.

[0132] At least some embodiments of the bearing assemblies disclosed herein are commercially available with relatively large diameters.

[0133] Radial Bearings - PCD Element Shape, Size and Arrangement In some applications, the radial bearing has one or more convex profiled polycrystalline diamond elements mounted on a rotor (or stator) which are in sliding contact with the stator (or rotor).

[0134] In some applications, the polycrystalline diamond elements are arranged in an annular fashion along the bearing component. A non-limiting example is a ring of five planar polycrystalline diamond elements disposed on the distal portion of the stator and another ring of five planar polycrystalline diamond elements disposed on the proximal portion of the stator. Thus, a high performance polycrystalline diamond element bearing assembly can be arranged to ensure stable operation along the length of the stator / rotor interface while requiring fewer total polycrystalline diamond elements than those used in conventional existing assemblies.

[0135] The polycrystalline diamond elements may be arranged in any pattern, layout, spacing or staggered arrangement within the bearing assembly to provide the desired support without regard for the need for overlapping contact with the polycrystalline diamond element mating surfaces on the opposing bearing surfaces.

[0136] Radial bearing - contact area of ​​the mating surface The important performance criterion is that the polycrystalline diamond elements are constructed and arranged to eliminate any edge or point contact with the opposing engagement surface or component. With planar polycrystalline diamond elements placed on the stator, such polycrystalline diamond elements generally encounter incomplete surface contact with the rotor, i.e., the engagement surface contact area is less than the entire surface when the rotor rotates relative to the polycrystalline diamond element. With at least a slightly domed or convex polycrystalline diamond element mounted on either the rotor or the stator, such polycrystalline diamond elements exhibit a small, approximately circular engagement surface contact area. When a convex polycrystalline diamond element mounted on either the rotor or the stator is saddle-shaped, the polycrystalline diamond element exhibits a small linear surface engagement surface contact area. With slightly concave polycrystalline diamond elements placed on the stator, a somewhat narrower linear engagement surface contact area is seen on each polycrystalline diamond element.

[0137] Radial bearings - mounting of PCD elements The polycrystalline diamond elements can be mounted directly onto the bearing element (e.g., stator or rotor) by methods known in the art, including but not limited to brazing, gluing, press fitting, shrink fitting, or screwing. Additionally, the polycrystalline diamond elements can be mounted into a separate ring or rings. The ring or rings can then be placed onto the bearing element (rotor or stator) by methods known in the art, including but not limited to gluing, press fitting, screw fitting, or brazing. The flat or dome-shaped polycrystalline diamond elements can be mounted in a manner that allows them to rotate about their axis.

[0138] Radial bearing - Treatment of opposing mating surfaces In some embodiments, the opposing mating surface of the diamond reactive material is pre-saturated with carbon (e.g., before mating with the mating surface). Such pre-saturation reduces the ability of the diamond reactive material to attract carbon by graphitizing the surface of the polycrystalline diamond. Pre-saturation of the diamond reactive material surface contact area can be achieved by any method known in the art.

[0139] Radial Bearings - Source of Solid Lubricants In certain applications, a solid lubricant source, for example, a graphite or hexagonal boron nitride rod or inclusion, in either an energized or unenergized state, is in contact with a counter-engaging surface formed of or including at least some diamond reactive material.

[0140] Radial bearings - Applications The bearing assemblies disclosed herein may form part of a machine or other device or system. In some such aspects, the proximal end of the stator may be connected to another component, such as a drill string or a motor housing, by a threaded connection, welding, or other connection means known in the art. In some aspects, when the bearing assembly is used in downhole applications, the distal end of the rotor may be augmented with a thrust bearing, which may carry a threaded connection for attachment of a drill bit, or may be a drill bit formed and / or placed directly on the end of the rotor mandrel. These component connections are not limited to downhole applications and may be applied to other applications, for example, wind turbine energy generator or machine applications.

[0141] The particular forms of the bearing assemblies described herein can be used in a wide variety of other applications, including, but not limited to, heavy equipment, automobiles, turbines, drive trains, rail vehicles, computer hard drives, centrifuges, medical equipment, pumps, and motors.

[0142] In certain embodiments, the bearing assemblies disclosed herein are suitable for placement and use in harsh environments (e.g., downhole). In some such embodiments, the bearing assemblies are less susceptible to fracture than bearing assemblies in which a polycrystalline diamond engagement surface engages with another polycrystalline diamond engagement surface. In certain embodiments, radial bearings suitable for such harsh environments provide higher service value compared to bearing assemblies that include a polycrystalline diamond engagement surface engaged with another polycrystalline diamond engagement surface. Furthermore, the bearing assemblies disclosed herein may be spaced apart at a greater distance than is required when using a bearing assembly that includes a polycrystalline diamond engagement surface engaged with another polycrystalline diamond engagement surface.

[0143] In certain applications, such as downhole applications, the bearing assemblies disclosed herein can further function as rotor locks.

[0144] In a lubricated environment, a bearing assembly can benefit from the hydrodynamic effects of the lubricant, which creates clearances between its moving and fixed elements.

[0145] Thrust bearing Certain embodiments of the present disclosure include thrust bearings and thrust bearing assemblies, and devices and systems including the same, as well as methods of manufacturing, assembling and using the same, in which one thrust face is formed of or includes at least a portion of polycrystalline diamond and the other, opposing thrust face is formed of or includes at least some diamond reactive material.

[0146] Thrust bearings - Polycrystalline diamond and diamond reactive material interface In some aspects, the present disclosure allows the engagement between the thrust surface and the opposing thrust surface to be interfaced using a polycrystalline diamond element in contact with the diamond reactive material. For example, the polycrystalline diamond element can be positioned and arranged on one thrust surface for contact with the other opposing thrust surface, where the other opposing thrust surface is formed of or includes at least some diamond reactive material. The polycrystalline diamond element can have an engagement surface for engagement with the opposing engagement surface of the diamond reactive material.

[0147] In some embodiments, the opposing engagement surface comprises or consists of at least 2% diamond reactive material by weight, or 2% to 100%, 5% to 95%, 10% to 90%, 15% to 85%, 20% to 80%, 25% to 75%, 25% to 70%, 30% to 65%, 35% to 60%, 40% to 55%, or 45% to 50% diamond reactive material by weight.

[0148] In certain applications, the polycrystalline diamond elements, or at least their mating surfaces, are lapped or polished, and optionally highly lapped or highly 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.

[0149] Exemplary Thrust Bearing Turning now to the figures, exemplary non-limiting embodiments of thrust bearings will now be described. Like reference numbers refer to like elements throughout the figures. For example, in Figures 21A and 21B, reference number 2102 refers to the mating surface of a polycrystalline diamond element, and in Figures 22A and 22B, reference number 2202 refers to the mating surface of a polycrystalline diamond element.

[0150] FIG. 21A shows a top view of a thrust ring 2120 having a thrust face 2101 according to an embodiment of the technology of this application. The thrust face 2120 (also referred to as a polycrystalline diamond thrust face) includes polycrystalline diamond elements 2102 embedded therein, attached thereto, bonded and / or engaged therewith. The polycrystalline diamond elements 2102 may be directly attached to the thrust face 2120 by methods known in the art, including but not limited to brazing, gluing, press fitting, shrink fitting, or screwing. Although the thrust face 2120 is shown and described as having three polycrystalline diamond elements 2102, one skilled in the art will understand that the thrust face 2120 can include more or less than three polycrystalline diamond elements 2102. Similarly, although shown evenly spaced, one skilled in the art will understand that the spacing between the polycrystalline diamond elements 2102 can be even or uneven. Furthermore, one skilled in the art will appreciate that the spacing between the polycrystalline diamond elements 2102 may be greater or less than that shown in Figure 21A.

[0151] Each polycrystalline diamond element 2102 includes an engagement surface 2122. The engagement surface 2122 may be a lapped, polished, highly lapped, or highly polished surface of polycrystalline diamond. In some embodiments, the engagement surface 2122 may be flat or convex.

[0152] 21B shows a thrust bearing assembly 2100 including a thrust face 2101 of a thrust ring 2120 in sliding contact with an opposing thrust face 2104 of an opposing thrust ring 2103. The thrust ring 2103 and the opposing thrust face 2104 are formed of or include at least some diamond reactive material. Thus, during operation, when the thrust bearing assembly 2100 is carrying a load, the engagement surface 2122 is in sliding contact with the opposing thrust face 2104 (also referred to as the opposing engagement surface).

[0153] Although both thrust rings 2120 and 2103 are shown having a ring shape, it will be understood by those skilled in the art that the thrust surfaces disclosed herein can be formed on thrust components of other shapes suitable for thrust bearings depending on the particular application.

[0154] 22A shows a top view of a thrust ring 2220 having a thrust face 2201 with bonded polycrystalline diamond elements 2202 according to an embodiment of the present application. In this embodiment, the thrust face 2201 is fitted with twelve polycrystalline diamond elements 2202, each having an engagement surface 2222.

[0155] FIG. 22B shows a side view of thrust bearing assembly 2200 including the thrust face 2201 of FIG. 22A in sliding contact with an opposing thrust face 2204 such that the engagement surface 2222 is in sliding contact with the opposing thrust face 2204 formed of or including at least some diamond reactive material.

[0156] Thrust bearing - Polycrystalline diamond layer with radiused edges 23 shows a side view of an exemplary polycrystalline diamond element 2302 of an embodiment of the technology of this application. In this example, the polycrystalline diamond element 2302 includes a polycrystalline diamond layer 2324 supported by a tungsten carbide substrate 2326. The diamond-to-substrate interface line is shown at 2305.

[0157] An engagement surface 2322 is formed on the polycrystalline diamond layer 2324 opposite the interface between it and the tungsten carbide substrate 2326 (i.e. opposite the diamond-to-substrate interface line 2305). The engagement surface 2322 may be a lapped, polished, highly lapped or highly polished top surface of the polycrystalline diamond layer 2324. As shown, the polycrystalline diamond layer 2324 has a relatively significant edge radius 2306 along an edge 2328 from the diamond-to-substrate interface line 2305 to the engagement surface 2322. 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 or at all supported on tungsten carbide.

[0158] Thrust bearings - Polycrystalline diamond layer with arcuate edges FIG. 24 shows a side view of an exemplary polycrystalline diamond element 2402 of an embodiment of the technology of this application. In this example, a polycrystalline diamond layer 2424 is supported by a tungsten carbide substrate 2426 and interfaces with the tungsten carbide substrate 2426 at a diamond-to-substrate interface line 2405. The polycrystalline diamond element 2402 is substantially similar to the polycrystalline diamond element 2402, except that the polycrystalline diamond layer 2424 has a more arcuate edge 2407 compared to the edge radius 2406. The arcuate edge 2407 of the polycrystalline diamond layer 2424 can be provided by an arcuate edge treatment known in the art. Side edges 2428 are also shown.

[0159] Thrust bearings - Polycrystalline diamond layer with large edge radius 25 shows a side view of an exemplary polycrystalline diamond element 2502 of an embodiment of the technology of this application. In this example, polycrystalline diamond layer 2524 is supported by a tungsten carbide substrate 2526, with diamond-to-substrate interface lines shown at 2505. Polycrystalline diamond element 2502 is substantially similar to polycrystalline diamond element 2502, except that polycrystalline diamond layer 2524 has large radius edges 2507. Large radius edges 2507 can be provided by large radius edge treatments known in the art. Side edges 2528 are also shown.

[0160] Thrust bearings - Polycrystalline diamond layer with larger edge radius FIG. 26 shows a side view of an exemplary polycrystalline diamond element 2602 of an embodiment of the technology of this application. In this example, the polycrystalline diamond layer 2624 is supported by a tungsten carbide substrate 2626, with a diamond-to-substrate interface line shown at 2605. The polycrystalline diamond element 2602 is substantially similar to the polycrystalline diamond element 2502, except that the polycrystalline diamond layer 2624 has a larger radius edge 2609, which can be provided by a large radius edge treatment known in the art. In this example, the edge radius begins at a contact point 2610 in the tungsten carbide substrate 2626, rather than on the polycrystalline diamond layer 2624 as in the case of the polycrystalline diamond element 2502. Side edges 2628 are also shown.

[0161] Thrust bearings - Polycrystalline diamond layer with multi-component edges 27 shows a side view of an exemplary polycrystalline diamond element 2702 of an embodiment of the technology of this application. In this example, a polycrystalline diamond layer 2724 is supported by a tungsten carbide substrate 2726, with diamond-to-substrate interface lines shown at 2705. The polycrystalline diamond layer 2724 has been processed with a multi-component edge process including an edge radius 2711 connected to a chamfered bevel 2712 which is connected to an additional edge radius 2713.

[0162] Thus, in some embodiments, the bearing of this application is a high performance thrust bearing in which the diamond reactive material of the opposing thrust surface is placed in sliding contact with at least one polycrystalline diamond element mounted on another thrust surface. The polycrystalline diamond element of the thrust surface is preferably planar, but can be convex. Although three or four or more polycrystalline diamond elements are preferred, the technology of this application can be implemented with as few as one or two polycrystalline diamond elements. Even the use of a single polycrystalline diamond element in sliding contact with the opposing diamond reactive material surface can provide a reduced coefficient of friction between thrust bearing surfaces (thrust surfaces) and can function to eliminate or reduce wear between the surfaces.

[0163] 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 thrust bearings with polycrystalline diamond to polycrystalline diamond engagement.Therefore, the thrust bearing achieved by the technology of this application is a harsh environment compatible thrust bearing that provides high service value compared to thrust bearings with polycrystalline diamond to polycrystalline diamond engagement.

[0164] Thrust bearings - Elimination of edge contact An important performance criterion of at least some embodiments of the thrust bearing of the present disclosure is that the polycrystalline diamond bearing element is configured (i.e., positioned, arranged) to eliminate any edge contact between itself and the opposing component (i.e., opposing thrust surface) formed or containing at least some diamond reaction material. A preferred method of achieving this important performance criterion is to use polycrystalline diamond elements with relatively significant edge radii. The edge radii of the polycrystalline diamond element are such that in the event of tilting or misalignment of one or both of the thrust surfaces, the edge radii of the polycrystalline diamond element will present an obtuse surface to the opposing thrust surface formed or containing at least some diamond reaction material, rather than presenting a sharp edge that may result in machining, cutting, or scraping of the surface of the diamond reaction material. Without limiting the present disclosure, in certain embodiments, conventional chamfered polycrystalline diamond edge treatment is not preferred.

[0165] The polycrystalline diamond edge treatment shown and described with reference to Figures 23-27 provides a non-limiting method of blunting the otherwise planar faces (engagement faces 2322, 2422, 2522, 2622, 2722) of the respective polycrystalline diamond elements. Such blunting of the planar edges avoids machining or cutting occurring between the opposing thrust faces, such as when either of the polycrystalline diamond thrust face (engagement face) and the opposing thrust face of the diamond reactive material are subject to tilt or mask inspection system alignment. If such tilt or misalignment occurs and the polycrystalline diamond layer of the polycrystalline diamond element has a sharp edge 2830 as shown in Figure 28 rather than a treated edge, the sharp edge 2830 may be machined, cut, or otherwise inappropriately engage the opposing thrust face. Also shown within the depiction of polycrystalline diamond element 2802 in FIG. 28 are engagement surface 2822, side edge 2828, polycrystalline diamond layer 2824, diamond-to-substrate interface line 2805, and tungsten carbide substrate 2826.

[0166] Figures 29A and 29B show the use of edged and unedged polycrystalline diamond elements, respectively. Figure 29A shows a portion of a thrust bearing assembly 2900a, showing polycrystalline diamond element 2902a in sliding contact with thrust ring 2903a (only a portion of which is shown). In Figure 29A, thrust ring 2903a is tilted or misaligned with polycrystalline diamond element 2902a, such that the plane defined by thrust surface 2904a is at an angle to the plane defined by engagement surface 2922a. Thus, thrust surface 2904a engages edge 2950 of polycrystalline diamond element 2902a.

[0167] Similar to FIG. 29A, FIG. 29B shows a portion of a thrust bearing assembly 2900b, showing polycrystalline diamond element 2902b in sliding contact with thrust ring 2903b (only a portion of which is shown). In FIG. 29B, thrust ring 2903b is tilted or misaligned with polycrystalline diamond element 2902b, such that the plane defined by thrust surface 2904b is at an angle to the plane defined by engagement surface 2922b. Thus, thrust surface 2904b engages edge 2930 of polycrystalline diamond element 2902b. However, because polycrystalline diamond element 2902a has an edge treatment, edge 2950 is obtuse compared to edge 2930, which is acute. Because edge 2930 is acute, it may be possible to machine, cut, or otherwise improperly engage thrust surface 2904b. However, in the embodiment depicted in FIG. 29A, the edges 2950 are obtuse, thereby reducing or eliminating the occurrence of such machining or cutting.

[0168] In certain embodiments, the thrust bearings disclosed herein comprise a polycrystalline diamond layer having an edge radius of at least 0.050'' radius. In certain embodiments, the thrust bearings disclosed herein comprise a polycrystalline diamond layer having an edge radius that is at least 0.060'' radius, at least 0.070'' radius, at least 0.080'' radius, or at least 0.090'' radius.

[0169] Thrust bearings - Polycrystalline diamond elements - shape, size and arrangement In some aspects, the polycrystalline diamond elements are arranged in a ring (i.e., thrust ring) along the bearing component. The polycrystalline diamond bearing elements of the present technology can be arranged in a ring around the disposed thrust surface. A non-limiting example is a ring consisting of five planar polycrystalline diamond bearing elements for engagement with an opposing thrust surface formed of or including at least some diamond reaction material. Without being bound by theory, a comparable thrust bearing having a polycrystalline diamond thrust surface vs. a polycrystalline diamond thrust surface (rather than a polycrystalline diamond thrust surface vs. a diamond reaction material thrust surface) may require a total of 20 or even 30 polycrystalline diamond elements to carry the axial load. Thus, some embodiments of the technology of this application result in a polycrystalline diamond thrust bearing with an individual polycrystalline diamond element spacing greater than that achievable in a thrust bearing having a polycrystalline diamond thrust surface vs. polycrystalline diamond thrust surface contact. Using the technology of this application, the polycrystalline diamond elements can be arranged in any pattern, layout, spacing, or staggered arrangement that provides the desired support without concern for the need for overlapping contact with the polycrystalline diamond surface on the opposing bearing surface.

[0170] Thrust bearings - mounting of PCD elements As mentioned above, the polycrystalline diamond elements can be mounted directly onto the bearing element (e.g., thrust ring) by methods known in the art, including but not limited to brazing, gluing, press fitting, shrink fitting, or screwing. The polycrystalline diamond elements can be mounted into a separate ring or rings. The ring or rings can then be placed onto the bearing element by methods known in the art, including but not limited to gluing, press fitting, screw fitting, or brazing.

[0171] The flat faced or dome shaped polycrystalline diamond element may be mounted in a manner that allows it to rotate about its own axis.

[0172] Thrust bearing - Treatment of opposing mating surfaces In some embodiments, the opposing mating surface of the diamond reactive material is pre-saturated with carbon (e.g., before mating with the mating surface). Such pre-saturation reduces the ability of the diamond reactive material to attract carbon by graphitizing the surface of the polycrystalline diamond. Pre-saturation of the diamond reactive material surface contact area can be achieved by any method known in the art.

[0173] In certain applications, a solid lubricant source, for example, a graphite or hexagonal boron nitride rod or inclusion, in either an energized or unenergized state, contacts an opposing mating surface formed of or including at least some diamond reactive material.

[0174] In a lubricated environment, a bearing assembly can benefit from the hydrodynamic effects of the lubricant, which creates clearances between its moving and fixed elements.

[0175] Material Processing Certain embodiments of the present disclosure include process steps for the treatment of materials or surfaces, including those of devices having engagement and counter-engagement surfaces in moving contact with one another, and further relate to devices having materials or surfaces treated by such process steps. The process steps disclosed herein can be used to treat the counter-engagement surfaces disclosed herein, including diamond reactive materials. The process steps disclosed herein can be applied to any of the devices shown and described herein, including the cam follower assembly (and portions thereof) of Figures 1-6, the radial bearing assembly (and portions thereof) of Figures 8A-19B, and the thrust bearing assembly (and portions thereof) of Figures 21A-29B. For example, with reference to FIGS. 1-29B, some of the exemplary materials and surfaces that can be treated using the process steps disclosed herein include opposing engagement surface 211 (FIGS. 2A and 2B), opposing engagement surface 311 (FIGS. 3 and 6), opposing engagement surface 411 (FIG. 4), opposing engagement surface 511 (FIG. 5), opposing engagement surface 815 (FIGS. 8A and 8B), opposing engagement surface 915 (FIGS. 9A and 9B), opposing engagement surface 1015 (FIGS. 10A and 10B), opposing engagement surface 1115 (FIGS. 11A and 11B), opposing engagement surface 1215 (FIGS. 12A and 12B), opposing engagement surface 1315 (FIGS. 13A and 13B), opposing engagement surface 1415 (FIGS. 14A and 14B), opposing engagement surface 1515 (FIGS. 15A and 15B), opposing engagement surface 1615 (FIGS. 16A and 16B), opposing engagement surface 1715 (FIGS. 17A and 17B), opposing engagement surface 1815 (FIGS. 18A and 18B), opposing engagement surface 1915 (FIGS. 19A and 19B), opposing engagement surface 2015 (FIGS. 20A and 20B), opposing engagement surface 211 (FIGS. 20A and 20B), opposing engagement surface 2215 (FIGS. 20A and 20B), opposing engagement surface 2315 (FIGS. 20A and 20B), opposing engagement surface 2415 (FIGS. 20A and 20B), opposing engagement surface 2515 (FIGS. 20A and 20B), opposing engagement surface 2615 (FIGS. 20A and 20B), opposing engagement surface 2 These are mating surface 1315 (Figures 13A and 13B), opposing engagement surface 1415 (Figures 14A and 14B), opposing engagement surface 1515 (Figures 15A and 15B), opposing engagement surface 1615 (Figures 16A and 16B), opposing engagement surface 1715 (Figures 17A and 17B), opposing engagement surface 1815 (Figures 18A and 18B), opposing engagement surface 1915 (Figures 19A and 19B), opposing engagement surface 2104 (Figures 21A and 21B), opposing engagement surface 2204 (Figures 22A and 22B), and opposing engagement surfaces 2904a and 2904b (Figures 29A and 29B).

[0176] In some specific embodiments, the opposing mating surface to which the material treatments disclosed herein are applied is or includes steel or another diamond-reactive material, and the mating surface is or includes polycrystalline diamond.

[0177] Certain material treatments that can be used to treat the diamond reactive material or at least its opposing bearing surface include those described in incorporated U.S. patent application Ser. Nos. 16 / 049,588, 16 / 049,608, and 16 / 049,617, including the application of a solid lubricant such as graphite or hexagonal boron nitride on the opposing bearing surface, pre-saturating the opposing bearing surface with carbon, and boriding, nitriding, or otherwise case-hardening the opposing bearing surface. The application of graphite or another form of carbon to the opposing bearing surface can provide a carbon sacrificial layer, which is described in more detail below.

[0178] In some embodiments, diamond reactive material or its surface is hardened or treated to enhance corrosion resistance through one or more material treatments, or a combination thereof.For example, diamond reactive material can be hardened, plated, coated, clad, or a combination thereof.Some exemplary material treatments that can be used to treat diamond reactive material and its surface include, but are not limited to, cold working or work hardening, such as burnishing and shot peening; heat treatment, such as through hardening, case hardening, or low temperature treatment; plating or coating, such as physical vapor deposition (PVD), chemical vapor deposition (CVD), chrome plating, phosphating, or anodizing; and clad.

[0179] Cold work / work hardening In some embodiments, the diamond reaction material or at least its mating opposing surface is subjected to plastic deformation to harden the diamond reaction material and smooth its surface. Some exemplary plastic deformation processes that can be used include work hardening, which includes cold working.

[0180] "Work hardening" (sometimes called strain hardening) is the process of plastically deforming a material, thereby strengthening the material as a result of dislocations in the material's crystal structure. Some work hardening processes are cold working or forming processes in which a material is treated at a temperature below the recrystallization temperature of the material (e.g., ambient temperature). Work hardening of metals increases the hardness, yield strength, and tensile strength of the metal, and also increases the fatigue life (fatigue resistance) of the metal.

[0181] In some embodiments, when the diamond engagement surface and the counter engagement surface of the diamond reaction material engage with each other and move relative to each other, such movable engagement between these surfaces causes work hardening of the counter engagement surface. That is, the thermal and mechanical forces involved in such movable engagement of these surfaces cause plastic deformation of at least that surface of the diamond reaction material. As a result of such plastic deformation, dislocations are generated in the crystal structure of the diamond reaction material at least at the counter engagement surface. Therefore, the operation of the component that includes such engagement surface and counter engagement surface causes work hardening of at least the counter engagement surface.

[0182] Work hardening - burnishing One particular type of work hardening is "burnishing." To burnish a surface, the surface is placed into sliding contact with another surface. The engagement and interfacing of the two surfaces (e.g., an engaging surface and an opposing engaging surface as disclosed herein) results in plastic deformation of at least one of the surfaces during such sliding contact, smoothing and polishing the burnished surface, and hardening it. Plastic deformation occurs when the contact stress on the surface exceeds the yield strength of the material at the surface. Burnished surfaces can exhibit high resistance to fatigue failure, corrosion, and stress corrosion, reduced visual defects and porosity, and surface compressive residual stresses.

[0183] In some embodiments, burnishing of the opposing engagement surface occurs as a result of the sliding movement of the engagement surface when engaged with the opposing engagement surface (e.g., when a cam follower slides on a cam-actuated rotor or a radial bearing element slides against a bearing surface).

[0184] In some embodiments, the mating surfaces comprising diamond reactive material are burnished. The burnished mating surfaces exhibit higher hardness as determined according to Brinell, Rockwell, Knoop, and / or Vickers hardness compared to the mating surfaces before burnishing, and also exhibit improved surface finish (e.g., smoother surface) compared to the mating surfaces before burnishing. Burnishing methods are known to those skilled in the art and will not be described in more detail.

[0185] Work hardening - shot peening Another type of work hardening is "shot peening," which provides a compressive residual stress layer on a material surface. To shot peen a surface, the surface is bombarded with "shot" (particles), which may be composed of metal, glass, or ceramic. The shot strikes the surface with sufficient force to cause plastic deformation of the material at least at the surface of the material. In some embodiments, the opposing mating surface is shot peened prior to engagement with the mating surface.

[0186] Thus, in some embodiments, the opposing mating surfaces of the diamond reactive material are hardened and / or surface smoothed by a non-abrasive process as opposed to an abrasive process such as polishing. Methods of shot peening are known to those skilled in the art and will not be described in greater detail.

[0187] Heat Treatment In some embodiments, the diamond reactive material or at least its mating opposing surface is subjected to a heat treatment to harden the diamond reactive material. Some exemplary heat treatment processes that can be used include through hardening, case hardening, and low temperature treatment.

[0188] Heat treatment - through hardening "Through hardening" involves hardening a material to result in an increase in the hardness of the material. Through hardening results in a generally uniform hardening of the material throughout the bulk of the material as opposed to only at the surface of the material. To through harden a material, the material is heated and then quenched, and then reheated or tempered.

[0189] Thus, in some embodiments, the diamond reactive material is hardened throughout the material (e.g., by through-hardening) as opposed to being hardened only at its opposing mating surfaces (e.g., by case hardening). Methods of through-hardening are known to those skilled in the art and will not be described in greater detail.

[0190] Heat treatment - case hardening "Case hardening" results in hardening of a face of the device without substantial hardening occurring below that face of the device. Case hardening as disclosed herein can include carburizing, nitriding, cyaniding, carbonitriding, and boriding. In some embodiments, case hardening as disclosed herein includes flame hardening, induction hardening, or laser hardening. In some embodiments, case hardening includes the introduction of a substance onto the face of the diamond reaction material and heating so that the substance migrates into the diamond reaction material. For example, carburizing, nitriding, and boriding may include dissolving an external element into the face of the steel (e.g., relatively low carbon steel of 0.3% C or less) to result in face hardening. This results in hardening of the diamond reaction material at the face where the substance migrates into the diamond reaction material. For example, carbon or a carbon-containing substance can be introduced onto the opposing mating face of the diamond reaction material and heated so that the carbon content is increased at the surface layer of the diamond reaction material, thereby hardening the surface layer. Case hardening can therefore include the step of adding a material to the diamond reaction material (adding carbon). In some embodiments, case hardening includes flame hardening, induction hardening, and laser hardening, where the surface of the metal is hardened without the introduction of external carbon or other elements. For example, steels containing a sufficient amount of carbon (e.g., relatively high carbon steels, such as 0.3% C or more) can be hardened by flame hardening, induction hardening, or laser hardening.

[0191] In some embodiments, the mating surface is case hardened prior to engagement with the mating surface, the method of case hardening being known to those skilled in the art and will not be described in more detail.

[0192] Heat Treatment - Low Temperature Treatment In some embodiments, diamond reaction material is subjected to cold treatment or low temperature treatment, such as cryogenic freezing, to harden diamond reaction material or at least its mating surface.For example, diamond reaction material can be cooled (for example, with liquid or gaseous nitrogen) to a temperature ranging from -100°F to -300°F.In addition to high hardness, such treatment can provide diamond reaction material or at least its mating surface with high wear resistance.The method of low temperature treatment is known to those skilled in the art and will not be described in more detail.

[0193] Outer Layers - Plating, Coatings, and Cladding As mentioned above, work hardening and heat treatment are processes that process diamond reactant material to change the physical properties (e.g., hardness) that diamond reactant material itself exhibits. However, in some embodiments, additive material is added on or over diamond reactant material to provide certain properties. Additive material can be added on diamond reactant material in the form of, for example, plating, coating, or cladding. For example, additive material can provide diamond reactant material with high corrosion resistance compared to the corrosion resistance of diamond reactant material that does not have additive material on it.

[0194] Outer layer: chrome plating One exemplary plating process can include electrolytically plating, for example chromium alloy plating or chrome plating, the mating surface of diamond reactive material by electrolytically plating a relatively thin chrome layer on the mating surface of diamond reactive material, to provide the mating surface with high corrosion resistance and / or surface hardness compared to the corrosion resistance and / or surface hardness before chrome alloy plating or chrome plating.The plating method is known to those skilled in the art and will not be described in detail.

[0195] Outer layer - phosphate treatment Another exemplary process for providing an outer layer on the mating surface of diamond reactive material is phosphating.In phosphating, an acid-metal reaction on the mating surface of diamond reactive material forms a metal-phosphate layer that adds at least temporary corrosion protection.The method of phosphating is known to those skilled in the art and will not be described in detail.

[0196] Outer layer - vapor deposition In some embodiments, the outer layer is provided on the opposing mating surface of the diamond reactive material through vapor deposition. In some embodiments, a plasma is used during the CVD process, which is sometimes referred to as plasma deposition.

[0197] Vapor deposition involves depositing one component from a gaseous state onto the surface of another solid component to form a deposition layer on the surface. In some embodiments, the deposition is applied to the opposing engagement surface prior to engagement with the engagement surface. One exemplary component that can be deposited on the opposing engagement surface to form a deposition layer on the opposing engagement surface is carbon. The method of vapor deposition is known to those skilled in the art and will not be described in more detail.

[0198] Carbon sacrificial layer For example, a carbon sacrificial layer can be deposited on the opposing engagement surface. As used herein, "carbon sacrificial layer" means a carbon layer disposed between the opposing engagement surface and the diamond of the engagement surface such that when the opposing engagement surface and the engagement surface are movably engaged at or above the graphitization temperature of diamond (i.e., about 700°C), the reaction between the diamond reactive material and the carbon sacrificial layer occurs prior to or at least before the graphitization of the diamond of the engagement surface. That is, the carbon sacrificial layer is disposed between the engagement surface of the diamond and the opposing engagement surface of the diamond reactive material, so that the carbon sacrificial layer is closer to the diamond reactive material than the diamond of the engagement surface and is therefore more likely to react with the diamond reactive material. The carbon sacrificial layer can be provided by vapor deposition or another method such as the addition of a solid lubricant or pre-saturation with carbon as described elsewhere herein. Thus, the opposing engagement surface of the diamond reactive material can have a carbon sacrificial layer thereon. The carbon sacrificial layer can include carbon or carbon-containing molecules or carbon-containing compositions. In one embodiment, the opposing mating surface of the diamond reactive material may be pre-saturated with carbon to form a sacrificial carbon layer (e.g., prior to engagement with the mating surface), such that graphitization of the face of the polycrystalline diamond reduces the ability of the diamond reactive material to attract carbon.

[0199] Outer layer - Cladding In some embodiments, the outer layer is provided on the opposing engagement surface by cladding the opposing engagement surface. The opposing engagement surface can be clad with any of many materials, including materials that are not diamond reaction materials. For example, the opposing engagement surface can be clad with materials that have higher corrosion resistance than diamond reaction materials. Cladding methods are known to those skilled in the art and will not be described in more detail.

[0200] Outer layer - anodized In some embodiments, the opposing mating surface of the diamond reactive material is anodized to increase the corrosion resistance, wear resistance and / or hardness of the opposing mating surface.The method of anodization is known to those skilled in the art and will not be described in detail.

[0201] Although various material processing steps have been described that involve the addition of material to the diamond reactive material (outer layer and case hardening) with no or little material removal from the diamond reactive material (burnishing and shot peening), material processing is not limited to such steps. In some embodiments, the diamond reactive material is processed in a manner that results in the removal of material from the diamond reactive material, such as by applying a polishing or leaching process thereto.

[0202] Material Processing Method In some embodiments, a method is provided for treating the diamond reactive material or at least its mating surface with one or more of the material treatment steps disclosed herein, including work hardening / cold working, heat treatment, and outer layer addition (e.g. plating, coating, cladding). For example, the diamond reactive material (or mating surface) can be treated to give it (or mating surface) high hardness, high corrosion resistance, or a combination thereof. Although the various material treatment steps disclosed herein are described individually, one or more of these material treatment steps can be combined. For example, the mating surface can be case hardened, then burnished and through hardened, and then shot peened, or any other combination of material treatment steps.

[0203] In some embodiments, the opposing engagement surface is subjected to a material treatment process prior to engagement with the engagement surface. For example, the opposing engagement surface may be through hardened and / or shot peened prior to engagement with the engagement surface. In other embodiments, the opposing engagement surface is subjected to a material treatment process during or subsequent to engagement with the engagement surface. For example, moving (e.g., sliding) engagement of the engagement surface with the opposing engagement surface results in burnishing of the opposing engagement surface. That is, the engagement surface may move (e.g., sliding) in engagement with the opposing engagement surface to generate sufficient mechanical and / or thermal forces to burnish the opposing engagement surface in some applications.

[0204] In some embodiments, the method includes plastically deforming the mating surfaces to harden the mating surfaces, smooth the surfaces (i.e., improve the surface finish) of the mating surfaces, or a combination thereof. Such methods may include burnishing or shot peening the mating surfaces, or another work-hardening or cold working step.

[0205] In some embodiments, the method includes heat treating the diamond reactive material to increase its hardness and / or corrosion resistance.

[0206] In some embodiments, the method includes adding one or more outer layers on or above the opposing mating surface to impart additional properties to the opposing mating surface, such as increased hardness and / or corrosion resistance.

[0207] In some embodiments, the method does not include a material removal step such as polishing or leaching.

[0208] In some embodiments, the diamond reactant material is treated to produce a property change (e.g., increased hardness) that is exhibited throughout the diamond reactant material. In some such embodiments, the property change is exhibited uniformly (or nearly uniformly) throughout the diamond reactant material. For example, through-hardening produces a nearly uniform increase in hardness throughout the diamond reactant material. An example of such a property change exhibited throughout the diamond reactant material is shown in FIG. 31B.

[0209] In other embodiments, diamond reactant material is treated to produce a property change (e.g., hardness increase) that is only exhibited at its surface and at a separate depth that is less than the total depth of diamond reactant material below its surface. That is, in such embodiments, at a certain depth below diamond reactant material, the property change produced by material treatment is not exhibited. For example, case hardening produces a separate hardening of diamond reactant material at its surface and at a separate depth below it. An example of such property change that is exhibited at the surface of diamond reactant material is shown in FIG. 30B.

[0210] Pre-burnished surface Certain embodiments provide pre-burnished counterengagement surfaces. As used herein, a "pre-burnished" counterengagement surface is a counterengagement surface that has been burnished prior to operational use, such as prior to deployment to the field (e.g., downhole deployment for operational use). The counterengagement surface may be pre-burnished a sufficient amount such that the counterengagement surface maintains a substantially constant coefficient of friction (CoF) when movably engaged with the engagement surface. By pre-burnishing the bearing surface, a device including the bearing surface may have a longer operational life since there are no longer surface portions (e.g., irregularities) that are relatively easily deformed due to plastic deformation. Due to the lower CoF provided by such pre-burnishing and the elimination of the surface portions that are relatively easily deformed, a part or device including the engagement surface and the counterengagement surface will exhibit less "disconnect" between these surfaces.

[0211] Material Processing Equipment Some embodiments of the present disclosure include a device that includes an engagement surface of diamond and an opposing engagement surface of diamond reaction material, the engagement surface and the opposing engagement surface being in moving (e.g., sliding) contact with each other (i.e., at least one of the engagement surface and the opposing engagement surface moves relative to the other while remaining in contact with the other surface). In some such embodiments, the engagement surface and the opposing engagement surface are surfaces of a bearing assembly, such as a cam follower assembly, a radial bearing assembly, or a thrust bearing assembly. In some such embodiments, the diamond reaction material (or at least the opposing engagement surface) is work-hardened, heat-treated, or treated to have an outer layer thereon.

[0212] 30A and 30B show an exemplary mating surface before and after material treatment, respectively. With reference to FIG. 30A, component 3000a includes material 3002, such as steel or another diamond-reactive material. Component 3000 includes mating surface 3004a, which is a bearing surface. With reference to FIG. 30B, component 3000 has been subjected to one or more material treatments disclosed herein (e.g., work hardening / cold work, heat treatment, and addition of an outer layer) to form treated surface 3004b including treated layer 3006. In some embodiments, treated layer 3006 is of a different material composition than material 3002. In other embodiments, treated layer 3006 is of the same or substantially the same composition as material 3002. For example, treated layer 3006 can be a layer of material 3002 that has been work hardened (e.g., burnished or shot peened). In some embodiments, the treated layer 3006 is a layer of a second material that is different from the material 3002 and that has been deposited on the material 3002, such as by coating, plating, cladding, or deposition. In some embodiments, the treated layer 3006 is a portion of the material 3002 that has been modified by a material treatment process to differ in at least one property from the remainder of the material 3002 (e.g., higher hardness). In some such embodiments, the treated layer 3006 is a layer of the material 3002 that has been subjected to a case hardening process, such as carburizing, nitriding, cyaniding, or carbonitriding. The treated layer 3006 can be a layer of a hardened diamond reactive material. For example, the treated layer 3006 can be a layer of a work-hardened diamond reactive material, such as a burnished or shot peened diamond reactive material, or a heat-treated diamond reactive material, such as a case hardened diamond reactive material. The treated layer 3006 can be an outer layer of an additional material, such as a plated, coated, phosphating, anodized layer, cladding, or deposition layer.As used herein, a material or surface is "work hardened" if it has been work hardened, "heat treated" if it has been heat treated, "case hardened" if it has been case hardened, "through hardened" if it has been through hardened, and "low temperature treated" if it has been low temperature treated. Treated layer 3006 can be a carbon sacrificial layer.

[0213] 30A and 30B, in some embodiments, only the outer layer (treated layer 3006) is treated to exhibit desirable properties such as high hardness, while the remainder of the material 3002 remains unchanged compared to before the material treatment. Some exemplary material treatments that can provide a separate treated layer 3006 include burnishing, shot peening, case hardening, chrome plating, anodizing, phosphating, CVD, PVD, and cladding.

[0214] In other embodiments, the entirety of the material 3002 exhibits modified properties (e.g., increased hardness) compared to before the treatment, as shown in Figures 31A and 31B. An exemplary material treatment that can provide the treated material 3106 includes through-hardening. In some such embodiments, the treated material 3106 exhibits uniform properties (e.g., uniform hardness) and in other embodiments does not exhibit uniform properties.

[0215] In some embodiments, the opposing mating surfaces are processed to have a surface finish of 16 μin or less, 12 μin or less, or 8 μin or less.

[0216] Material Processing Selection The selection of which of one or more material treatments is applied to the diamond reactive material can be made based on a specific application. Some requirements that can be factors in the selection of material treatments include, but are not limited to, the financial cost of the material treatment, the severity of the application (e.g., the expected load on the opposing bearing surface during operation or the corrosiveness of the operating environment), or a combination thereof. For example, in some applications, cold work / work hardening may be less expensive to implement than plating / coating, which may be less expensive to implement than heat treatment. In more severe applications, heat treatment may provide the bearing surface with higher wear resistance than cold work / work hardening, which may provide the bearing surface with higher wear resistance than plating / coating. Such requirements are not limiting to the disclosure of the present invention, and are for illustrative purposes only, since different treatments have different functions to deal with wear under different operating and environmental conditions.

[0217] Working Example The following examples illustrate certain embodiments of the present disclosure, it being understood that these examples are provided by way of illustration and are not intended to limit the scope of the specification or claims. EXAMPLES

[0218] Example 1 - Cam Follower In order to develop and evaluate robust cam followers for use in various applications, such as for use in or with the "Drilling Machine" technology disclosed in the '254 application, applicants designed and constructed a modern test stand. The test stand used 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 actuating cylinder midway along its length. The rotor / stator assembly was pumped with circulating fluid using a positive displacement pump. Candidate cam follower mechanisms were placed in sealing contact with and under load from the cam actuating cylinder of the rotor mandrel. The test stand was used to test candidate cam follower mechanisms for residual performance and wear under loads ranging from 500 lbf to 3000 lbf in either clean water or sandy drilling fluid.

[0219] Tests performed included testing of a curved iron surface in high load linear surface contact with a rotating planar polycrystalline diamond. This test produced a slightly discolored Hertzian contact zone line on the face of the polycrystalline diamond approximately 0.250'' wide along the entirety of its 1 / 2'' wide face. Without being bound by theory, the width of the contact zone may be the result of vibrations in the system and possibly slight deformation of the iron metal under load. By calculation, the total contact area on the 1 / 2'' polycrystalline diamond element face at any given time is approximately 7% of the total area of ​​the polycrystalline diamond element face. The configuration used in this test demonstrated that even a small area on the face of the polycrystalline diamond element can handle significant loads. Thus, an effective polycrystalline diamond element cam follower can be designed and manufactured without the need for full surface contact between the polycrystalline diamond element and the cam surface of the target material.

[0220] Tests were performed on various configurations of the sliding interface. Table 3 below summarizes some of the tests performed and their results.

[0221] (Table 3) TIFF0007612611000003.tif205157 TIFF0007612611000004.tif70157

[0222] 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 somewhat successful test of a steel ball supported by a single polished polycrystalline diamond element in a steel cup. Test 4 summarizes the very successful testing of a single steel ball supported by an array of three polished polycrystalline diamond elements in a steel cup. Tests 5 through 9 summarize increasingly severe testing of each of the single polished polycrystalline diamond elements in sliding contact with a rotating iron cam surface. Test 10 summarizes a comparative test of a single polished polycrystalline diamond element versus a single polished raw polycrystalline diamond element, each in sliding contact with a rotating iron cam surface. These tests demonstrate the significant coefficient of friction increase when using polished raw polycrystalline diamond elements. Without being bound by theory, the conditions and results presented in Table 3 are believed to be representative of the potential use of polycrystalline diamond on diamond reactive materials, and should not be considered as limiting or exhaustive of the methods, systems, and apparatus disclosed herein.

[0223] Numerous and extensive tests have been conducted that have demonstrated the ability to operate an iron cam actuating cylinder in sliding contact with a polished polycrystalline diamond surface without adverse effects or apparent chemical interaction. Iron materials are attractive for bearing applications due to their ready availability, ease of forming and machining, higher elasticity than so-called carbide materials, and lower cost.

[0224] The applicant's test has demonstrated that even at relatively high loads and high RPM speeds, successful cam follower interface or load interface between polycrystalline diamond and diamond reactive material cam can be performed.The important finding of this test is that polycrystalline diamond element can be used in sliding contact with diamond reactive material at typical loads and speeds required in many commercial and industrial applications, as long as the polycrystalline diamond element is not placed in edge or point contact conditions that may lead to machining and chemical interaction.The unexpected success of this test has led to the development of new high-performance cam followers as disclosed herein.The unexpected and unexpected success of the applicant's test has also led to the development of new high-performance radial and thrust bearings.

[0225] Applicant has discovered that polycrystalline diamond, and particularly polished polycrystalline diamond, provides a cam follower engagement surface that has a sufficiently low coefficient of sliding friction for application over a wide range of cam actuating mechanisms while also avoiding the requirement for small moving parts and the need for sealing lubrication. These discoveries are surprising and unexpected in light of the previous aversion to using polycrystalline diamond in direct sliding engagement with diamond reactive materials.

[0226] Without being bound by theory, in operation, running the cam and cam follower in a liquid cooled, lubricated environment allows for higher speeds and loads to be achieved without thermo-chemical reactions setting in. Additionally, the polished polycrystalline diamond surface provides a lower thermo-chemical response.

[0227] Common cam materials are typically subjected to a PSI range of 58,000 PSI to 226,000 PSI. Without being bound by theory, it is believed that a cam actuated PDC assembly disclosed herein having a 1 / 2'' diameter PDC cam follower can apply a force of 10,000 lbs to 15,000 lbs during operation of the cam actuated PDC assembly, with a useful life of the assembly, in at least some embodiments, from about 1,000,000 cycles to cycles. When actuated with a force of 3000 lbs, which equates to 150,000 PSI, at least some embodiments of the assembly disclosed herein can operate over a cycle life of 1,000,000 cycles to 100,000,000 cycles.

[0228] From the descriptions and figures presented above, it can be readily appreciated that the face-to-face engagement technology of the present application can be used in a wide variety of applications, including the downhole environments discussed above. Additionally, the technology provided herein has broad application to other industrial applications.

[0229] Furthermore, although this example has been shown and described with respect to engagement between a cam follower surface and a cam surface, those skilled in the art will appreciate that the present disclosure is not limited to this particular application and that the concepts disclosed herein may be applied to engagement between any diamond reactive material surface engaging a diamond material surface. EXAMPLES

[0230] Example 2 - Further testing Continuing with Example 1, additional testing of a spherical iron ball under load and rotation against a planar polycrystalline diamond face produced a small, approximately 0.030 diameter discolored Hertzian contact area in the center of the polycrystalline diamond element. As with the contact description in Example 1, without being bound by theory, it is believed that the diameter of the discoloration is the result of slight vibrations due to slight deformation of the iron metal under load in the test apparatus.

[0231] It has been found that the application of polycrystalline diamond elements in radial bearings can still accept significant loads using only much less than the entire surface of these elements.This discovery means that it is possible to design and manufacture effective polycrystalline diamond element-containing radial bearings without the need for full surface contact between polycrystalline diamond elements and opposing surfaces.By using this discovery in the technology of this application, radial bearings can be manufactured with much less processing of the polycrystalline diamond elements used, and the risk of edge collision or machining of diamond reactive material opposing surfaces can be significantly reduced. EXAMPLES

[0232] Example 3 - Burnishing In Example 3, a bearing surface made of diamond reactive material (steel) was subjected to a force (radial load) of 20 klbs for a period of 80 hours as shown in the graph of FIG. 32 under moving engagement with a polished diamond bearing surface. The coefficient of friction for the bearing surface was determined during the testing of the bearing surface and is also plotted in the graph of FIG. 32, where the load is the upper line in the graph and the CoF is the lower line in the graph. As is evident from FIG. 32, there is an initial period of about 20 hours during which the coefficient of friction decreases. After about the first 20 hours of load bearing, the coefficient of friction reaches a relatively stable state and the coefficient of friction of the bearing surface does not decrease significantly further and remains substantially constant for the final 60 hours of testing.

[0233] It has been found that such burnishing improves the bearing surface. Without being bound by theory, it is believed that during such burnishing, asperities on the metal bearing surface are cold worked or plastically deformed to provide a relatively smooth surface finish compared to that prior to burnishing. Similarly, it has also been found that as the surface finish of the bearing surface becomes smoother (fine surface finish), the coefficient of friction between the diamond and the diamond reactant material decreases. An increase in Rockwell C (HRC) from 32 to 38 has been observed. Similarly, the surface finish was about 16 μin or less.

[0234] Figures 33A and 33B show images of the burnished races during this test. As is evident from these images, the burnished races, indicated by the arrows, are significantly more polished in appearance than the base material. Prior to this test, the entire shaft shown in Figure 33A was covered with black phosphate, but the black phosphate is no longer present on the burnished races. Without being bound by theory, it is believed that the black phosphate coating wore off relatively early during this test. Table 4 shows the average hardness of the base material and the bearing races obtained during this test, and it is evident that the bearing races increased in hardness by 6 HRC at 80 hours of testing. The dimensional change along the bearing races relative to the base material is shown. The base material was a raw burnished surface.

[0235] (Table 4-Average hardness) TIFF0007612611000005.tif23152

[0236] Figure 33C is an image of a shaft that has been re-machined to pre-burnish the bearing area. The bearing area of ​​the shaft was pre-burnished to a surface finish of 8 μin. The unburnished side is also indicated by the arrow.

[0237] Figure 33D is a construction diagram of the shaft of Figure 33C showing four radial locations: A, B, C, and D. Locations B and C are burnished, while locations A and D are unburnished. Table 5 shows the average HRC for each region.

[0238] (Table 5-Average hardness) TIFF0007612611000006.tif34152

[0239] As can be seen from Table 5, the burnished areas have a higher hardness compared to the unburnished areas.

[0240] Figure 33E shows a re-machined shaft having the pre-burnished areas of Figures 33C and 33D after application of a radial load of 34 klbs for 10 hours. No measurable change is found along the bearing races compared to the remainder of the pre-burnished bearing area. Thus, pre-burnishing the bearing surface provides a bearing surface that is functional for operation without dimensional change along the bearing races, or at least without substantial dimensional change along the bearing races.

[0241] Although the above embodiments and advantages have been described in detail, it should be understood that various changes, substitutions, and modifications can be made without departing from the spirit and scope of the present disclosure. Moreover, the scope of the present disclosure is not intended to be limited to the particular embodiments of the processes, machines, manufacture, compositions of matter, means, methods, and steps described herein. As will be readily understood from the present disclosure by those skilled in the art, existing or future developed processes, machines, manufacture, compositions of matter, means, methods, or steps that perform substantially the same function or produce substantially the same result as the corresponding embodiments described herein can be utilized in accordance with the present disclosure. Accordingly, the claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps. Other embodiments of the invention are described below. [Embodiment 1] 1. A method of carrying a load in an apparatus, comprising: engaging the bearing surface with an opposing bearing surface; Including, the bearing surface comprises polished polycrystalline diamond; the opposing bearing surface comprises a diamond reactive material which is hardened; A method comprising: [Embodiment 2] 2. The method of claim 1, wherein the diamond reactive material is hardened at the opposing bearing surface. [Embodiment 3] 2. The method of embodiment 1, wherein the diamond reactant material is hardened throughout the diamond reactant material. [Embodiment 4] 2. The method of claim 1, wherein the diamond react material is hardened after engaging the bearing surface with the opposing bearing surface. [Embodiment 5] 2. The method of claim 1, wherein the diamond react material is hardened prior to engaging the bearing surface with the opposing bearing surface. [Embodiment 6] 2. The method of claim 1, wherein the opposing bearing surfaces have a surface finish of 16 μin or less. [Embodiment 7] the diamond reactant material is hardened by plastically deforming asperities on the opposing bearing surface; plastically deforming the asperities reduces the surface finish of the opposing bearing surfaces; 2. The method of embodiment 1, [Embodiment 8] 2. The method of claim 1, wherein the diamond reactive material is hardened by work hardening the opposing bearing surface. [Embodiment 9] 9. The method of claim 8, wherein the work hardening comprises burnishing the opposing bearing surface. [Embodiment 10] 10. The method of claim 9, wherein the burnishing comprises engaging the bearing surface and the opposing bearing surface in sliding contact. [Embodiment 11] 11. The method of claim 10, wherein the opposing bearing surface is burnished through sliding contact with the bearing surface at least until a coefficient of friction between the bearing surface and the opposing bearing surface reaches a steady state condition. [Embodiment 12] 9. The method of claim 8, wherein the work hardening comprises shot peening the opposing bearing surface. [Embodiment 13] 2. The method of embodiment 1, wherein the diamond reacting material is hardened by heat treating the diamond reacting material. [Embodiment 14] 14. The method of claim 13, wherein the heat treating comprises through hardening, case hardening, or low temperature treatment. [Embodiment 15] 2. The method of claim 1, further comprising providing an outer layer of material over the opposing bearing surface. [Embodiment 16] 16. The method of claim 15, wherein providing the outer layer of material comprises plating or coating the outer layer of material onto the opposing bearing surface. [Embodiment 17] providing an outer layer of material includes plating; said plating step including chrome plating a layer of chromium onto said opposing bearing surface; 17. The method of embodiment 16, [Embodiment 18] 16. The method of claim 15, wherein providing the outer layer of material comprises phosphatizing the opposing bearing surface to form a metal-phosphate layer on the opposing bearing surface. [Embodiment 19] 16. The method of embodiment 15, wherein providing the outer layer of material comprises depositing the outer layer onto the opposing bearing surface via vapor deposition. [Embodiment 20] 20. The method of claim 19, wherein the vapor deposition comprises chemical vapor deposition or physical vapor deposition. [Embodiment 21] 16. The method of claim 15, wherein providing an outer layer of material comprises cladding the opposing bearing surface. [Embodiment 22] 16. The method of claim 15, wherein providing the outer layer of material comprises anodizing the opposing bearing surface. [Embodiment 23] 2. The method of claim 1, further comprising providing a sacrificial layer of carbon on the opposing bearing surface. [Embodiment 24] the apparatus includes a bearing assembly including the bearing surface and the opposing bearing surface; The bearing assembly is a cam assembly, a radial bearing assembly, or a thrust bearing assembly. 2. The method of embodiment 1, [Embodiment 25] deploying the bearing assembly in a downhole environment; the opposing bearing surfaces are pre-burnished prior to deployment of the bearing assembly; 2. The method of embodiment 1, [Embodiment 26] 1. An apparatus comprising: a bearing surface comprising polished polycrystalline diamond; an opposing bearing surface including a diamond reactive material to be hardened; Including, the bearing surface and the opposing bearing surface are in movably engaged; An apparatus comprising: [Embodiment 27] 27. The apparatus of embodiment 26, wherein the diamond reactive material comprises a hardened layer on the opposing bearing surface. [Embodiment 28] 27. The apparatus of embodiment 26, wherein the diamond reacting material is hardened throughout the diamond reacting material. [Embodiment 29] 27. The apparatus of embodiment 26, wherein the opposing bearing surfaces have a surface finish of 16 μin or less. [Embodiment 30] 27. The apparatus of embodiment 26, wherein the opposing bearing surfaces are work hardened. [Embodiment 31] 31. The apparatus of embodiment 30, wherein the opposing bearing surfaces are burnished. [Embodiment 32] 31. The apparatus of embodiment 30, wherein the opposing bearing surfaces are shot peened. [Embodiment 33] 27. The apparatus of embodiment 26, wherein the diamond reactive material is heat treated. [Embodiment 34] 34. The apparatus of embodiment 33, wherein the diamond reactive material is through-hardened, case-hardened, or cryogenically treated. [Embodiment 35] 27. The apparatus of embodiment 26, further comprising an outer layer of material on the opposing bearing surface. [Embodiment 36] 36. The device of embodiment 35, wherein the outer layer of material comprises a plating or coating. [Embodiment 37] the outer layer of material comprises the plating; The plating includes chrome plating. 37. The apparatus of embodiment 36, [Embodiment 38] 36. The device of embodiment 35, wherein the outer layer of material comprises a metal-phosphate layer. [Embodiment 39] 36. The device of embodiment 35, wherein the outer layer of material comprises a vapor deposition layer. [Embodiment 40] 36. The apparatus of embodiment 35, wherein the outer layer of material comprises a cladding. [Embodiment 41] 37. The device of embodiment 36, wherein the outer layer of material comprises an anodized layer. [Embodiment 42] 27. The apparatus of embodiment 26, further comprising providing a sacrificial layer of carbon on the opposing bearing surface. [Embodiment 43] the apparatus includes a bearing assembly including the bearing surface and the opposing bearing surface; The bearing assembly is a cam assembly, a radial bearing assembly, or a thrust bearing assembly. 27. The apparatus of embodiment 26, [Embodiment 44] 27. The apparatus of embodiment 26, wherein the opposing engagement surfaces are pre-burnished. [Explanation of symbols]

[0242] 101 Engagement surface 102 Polycrystalline Diamond Element 104 Cam follower body 105 Cam follower 106 First end

Claims

1. 1. A method of manufacturing a bearing, comprising the steps of: providing a separate polycrystalline diamond bearing element having a bearing surface comprising polycrystalline diamond; providing opposed bearing elements having opposed bearing surfaces, said opposed bearing surfaces comprising a diamond reaction material, said diamond reaction material being metal, said diamond reaction material comprising at least 2 weight percent diamond solvent or diamond catalyst based on a total weight of said diamond reaction material; hardening the diamond reactant material on the opposing bearing surface; slidingly engaging the bearing surface with the opposing bearing surface; Including, A method comprising:

2. The method of claim 1 , wherein the opposing bearing surface is hardened after the bearing surface is engaged with the opposing bearing surface.

3. The method of claim 1 , wherein the diamond reactant material is hardened only on the opposing bearing surface.

4. The method of claim 1 , wherein the hardening step comprises plastically deforming asperities on the opposing bearing surfaces.

5. The method of claim 1 , wherein the hardening step comprises work hardening the opposing bearing surface.

6. The method of claim 5 , wherein the work hardening step comprises grinding the opposing bearing surface.

7. The method of claim 6 , wherein the step of grinding includes engaging the bearing surface and the opposing bearing surface in sliding contact.

8. The method of claim 5 , wherein the work hardening step includes the step of shot peening the opposing bearing surface.

9. The method of claim 1 , wherein the hardening step comprises through hardening, case hardening, or cryogenic treatment of the opposing bearing surface.

10. The method of claim 1, wherein the polycrystalline diamond bearing element has an edge radius of at least 0.050'', and further comprising a step of edging the bearing surface so that contact between the opposing bearing surface and the edge of the bearing surface is eliminated.

11. 1. A method of using a bearing assembly, comprising: providing a bearing assembly, the bearing assembly comprising a separate polycrystalline diamond bearing element having a bearing surface comprising polycrystalline diamond, and an opposing bearing element having an opposing bearing surface comprising a diamond reaction material, the diamond reaction material being metal, the diamond reaction material comprising at least 2 weight percent diamond solvent or diamond catalyst based on the total weight of the diamond reaction material, the diamond reaction material of the opposing bearing surface being hardened, and the bearing surface being slidably engaged to the opposing bearing surface; deploying the bearing assembly in a downhole environment; Including, A method comprising:

12. 1. A bearing assembly comprising: a separate polycrystalline diamond bearing element having a bearing surface comprising polycrystalline diamond; an opposed bearing element having opposed bearing surfaces, the opposed bearing surfaces comprising a diamond reaction material, the diamond reaction material being metal, the diamond reaction material comprising at least 2 weight percent diamond solvent or diamond catalyst based on the total weight of the diamond reaction material; the diamond reactant material on the opposing bearing surface is hardened; the bearing surface is slidably engaged with the opposing bearing surface; A bearing assembly comprising:

13. The bearing assembly of claim 12 , wherein the diamond reactant material of the opposing bearing surface is work hardened.

14. The bearing assembly of claim 13 , wherein the diamond reactive material on the opposing bearing surface is shot peened.

15. The bearing assembly of claim 13 , wherein the diamond reactant material on the opposing bearing surface is polished.

16. 13. The bearing assembly of claim 12, wherein the diamond reacting material of the opposing bearing surface is through-hardened, case-hardened or cryogenically treated.

17. The bearing assembly of claim 12, wherein the opposing bearing surface includes a chrome plating, a metal-phosphate layer, a cladding, or a sacrificial layer of carbon, or the opposing bearing surface is anodized.

18. 13. The bearing assembly of claim 12, wherein the diamond solvent or diamond catalyst is iron, copper, cobalt, nickel or titanium.

19. The bearing assembly of claim 12 , wherein the metal is a metal alloy.

20. The bearing assembly of claim 12 wherein the metal is steel.

21. The bearing assembly of claim 12 , wherein the metal is softer than an ultra-hard material.

22. The bearing assembly of claim 12 , wherein the individual polycrystalline diamond bearing elements comprise sintered polycrystalline diamond bodies.

23. A bearing assembly as described in claim 22, wherein the polycrystalline diamond sintered body is supported by a tungsten carbide substrate.

24. A bearing assembly as described in claim 12, wherein the bearing surface is slidably engaged with the opposing bearing surface such that contact between the opposing bearing surface and an edge of the bearing surface is eliminated.

25. A bearing assembly as described in claim 12, comprising a plurality of spaced apart polycrystalline diamond bearing elements including the individual polycrystalline diamond bearing elements, each of the plurality of polycrystalline diamond bearing elements being an independent type polycrystalline diamond bearing element spaced apart from others of the plurality of polycrystalline diamond bearing elements, each of the polycrystalline diamond bearing elements having a polycrystalline diamond bearing surface, each of the bearing surfaces being slidably engaged with the opposing bearing surface.

26. 1. A system including a bearing element, comprising: a first component having a metal bearing surface, the metal bearing surface comprising at least 2 weight percent iron, copper, cobalt, nickel, titanium, or a combination thereof, based on a total weight of the metal; A second component; and a discrete polycrystalline diamond bearing element on said second component, said discrete polycrystalline diamond bearing element having a diamond bearing surface; the diamond bearing surface is slidably engaged with the metal bearing surface; the metal bearing surface is polished; A system characterized by:

27. 27. The system of claim 26, wherein the second component is a cam follower and the first component is a cam.

28. 28. The system of claim 27, wherein the cam is a rotor.

29. 28. The system of claim 27, wherein the cam and cam follower are components of an internal combustion engine, a drilling machine, or a machine tool.

30. 27. The system of claim 26, wherein the first component and the polycrystalline diamond bearing element form a radial bearing.

31. 31. The system of claim 30, wherein one of the first component and the second component is a rotor and the other of the first component and the second component is a stator.

32. 27. The system of claim 26, wherein the first component and the individual polycrystalline diamond bearing elements form a thrust bearing.

33. The system described in claim 26, wherein the individual polycrystalline diamond bearing elements are embedded or attached within the second component.

34. The system described in claim 26, wherein the individual polycrystalline diamond bearing elements are stand-alone elements directly mounted to the second component.

35. The system described in claim 26, wherein the individual polycrystalline diamond bearing elements are directly attached to the second component by brazing, glueing, pressing, shrink fitting, or screwing.

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