Corrosion-Resistant Bearing Elements for Fluid-Cooled Thrust Bearings
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Solution Overview
Problem
Subterranean drilling systems face challenges with the operational lifetime of thrust-bearing apparatuses due to corrosion from drilling fluids, which affects the longevity and efficiency of the drilling process.
Innovation Solution
The implementation of bearing assemblies with corrosion-resistant properties, featuring polycrystalline diamond tables and substrates, along with corrosion-resistant regions and sacrificial anodes, to protect the bearing elements from galvanic and electrochemical corrosion when exposed to lubrication or cooling fluids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If drilling fluid is circulated through the bearing elements to cool and lubricate them, then the bearing elements are cooled and lubricated, but the metal-solvent catalyst in the bearing elements undergoes corrosion
Solution Approach 1:
A corrosion-resistant coating is applied as an intermediary layer between the metal-solvent catalyst and the drilling fluid. This coating allows the drilling fluid to continue cooling and lubricating the bearing elements while preventing direct contact between the fluid and the catalyst, thereby eliminating corrosion
Solution Approach 2:
The bearing element is constructed as a composite structure with a metal-solvent catalyst core and a corrosion-resistant outer layer. This composite design combines the beneficial properties of both materials: the metal-solvent catalyst provides bonding and structural integrity, while the outer layer provides corrosion resistance, allowing the bearing to withstand exposure to drilling fluids
2Strength
If the bearing elements are made with metal-solvent catalyst to bond diamond grains, then the bearing elements have strong bonding, but the catalyst is susceptible to corrosion from drilling fluid
Solution Approach 1:
The bearing element uses a composite structure where the metal-solvent catalyst is combined with a corrosion-resistant material. The catalyst maintains its bonding function for diamond grains while the corrosion-resistant material protects it from fluid degradation
Solution Approach 2:
A protective coating serves as an intermediary barrier between the metal-solvent catalyst and the corrosive drilling fluid. This coating allows the catalyst to maintain strong bonding of diamond grains internally while being protected from external corrosion
3Ease of operation
If drilling fluid is diverted to cool and lubricate bearing elements, then bearing performance is improved, but the operational lifetime is reduced due to corrosion
Solution Approach 1:
The bearing element employs a composite construction with corrosion-resistant materials that allow continuous exposure to drilling fluid for cooling and lubrication without degradation. This enables the bearing to maintain improved operational performance throughout its extended service life
Solution Approach 2:
A corrosion-resistant coating acts as a mediator that permits the drilling fluid to continuously cool and lubricate the bearing elements while preventing the fluid from causing corrosion. This resolves the contradiction by allowing the beneficial cooling/lubrication function to continue without the harmful corrosion effect
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution significantly extends the operational lifetime of thrust-bearing apparatuses by preventing corrosion, thereby enhancing the durability and reliability of subterranean drilling systems.
Implementation Method 1
protect the bearing elements from leaching, galvanic, or electrochemical corrosion that may occur when the bearing assembly comes in contact with lubrication or cooling fluid
Implementation Method 2
protect the bearing elements from leaching, galvanic, or electrochemical corrosion that may occur when the bearing assembly comes in contact with lubrication or cooling fluid
Implementation Method 3
The bearing assembly includes a support ring and a plurality of bearing elements... configured to protect the bearing elements from leaching, galvanic, or electrochemical corrosion
Data Source
AI summary
Embodiments disclosed herein relate to bearing assemblies and methods of manufacturing. In an embodiment, a bearing assembly includes a support ring and bearing elements. The bearing elements are mounted to and distributed circumferentially about an axis of the support ring. At least one of the bearing elements includes a polycrystalline diamond table, a substrate bonded to the polycrystalline diamond table, bonding region defined by the substrate and the polycrystalline diamond table, and a corrosion resistant region. The corrosion resistant region includes a corrosion resistant material that covers at least a portion of at least one lateral surface of the bonding region. The corrosion resistant region prevents corrosion of at least some material in the bonding region covered by the corrosion resistant region (e.g., during use). Other embodiments employ one or more sacrificial anodes as an alternative to or in combination with the corrosion resistant region.