Corrosion-Resistant Bearing Elements for Subterranean Drilling

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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 affect the overall efficiency and longevity of the drilling process.

Innovation Solution

The use of bearing assemblies with corrosion-resistant properties, featuring polycrystalline diamond tables and substrates with bonded diamond grains, along with corrosion-resistant materials and sacrificial anodes, to protect the bearing elements from corrosion when exposed to lubrication or cooling fluids.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If drilling fluid is used to cool and lubricate bearing elements, then lubrication and cooling effectiveness is improved, but corrosion of metal-solvent catalysts in the bearing elements occurs

Engineering Contradiction:

Improvelubrication and cooling effectivenessVSAvoidcorrosion resistance of bearing elements

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent applies the disposable principle by providing sacrificial anodes that are intentionally designed to corrode preferentially rather than the bearing elements. These anodes are consumable components that sacrifice themselves to protect the more valuable bearing elements, effectively trading a cheap, replaceable component (anode) to preserve the expensive, critical component (bearing element with metal-solvent catalyst).

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent applies the intermediary principle by introducing sacrificial anodes as a mediating element between the corrosive drilling fluid and the bearing elements. The anodes act as a buffer that intercepts the corrosion attack, creating a protective electrochemical environment that shields the bearing elements from direct contact with corrosive agents in the drilling fluid.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If bearing elements are made with metal-solvent catalysts to enable polycrystalline diamond formation, then bearing element performance is improved, but susceptibility to corrosion from drilling fluid increases

Engineering Contradiction:

Improvebearing element performanceVSAvoidcorrosion susceptibility

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies preliminary anti-action by pre-installing sacrificial anodes that create a protective electrochemical environment before corrosion can damage the bearing elements. The anodes are positioned and activated in advance to establish a protective potential field that prevents corrosion attacks on the metal-solvent catalysts before they can occur.

Inventive Principle:

Principle #9Preliminary anti-action

Solution Approach 2:

The patent uses disposable sacrificial anodes that are intentionally designed to be consumed rather than protect the bearing elements. These anodes are replaceable components that sacrifice their material integrity to prevent corrosion of the critical bearing elements containing metal-solvent catalysts.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Productivity

If thrust-bearing apparatuses operate continuously in corrosive drilling fluid environments, then drilling productivity is improved, but operational lifetime of bearing apparatuses decreases

Engineering Contradiction:

Improvedrilling productivityVSAvoidoperational lifetime of bearing apparatuses

Core Design Contradiction:

ProductivityVSDuration of action of stationary object

Solution Approach 1:

The patent applies the disposable principle by using sacrificial anodes as consumable protective elements that extend the operational lifetime of the thrust-bearing apparatus. These anodes are intentionally designed to be replaced periodically, allowing the main bearing apparatus to operate continuously for extended periods without corrosion damage.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent applies self-service by implementing a self-protecting system where the sacrificial anodes automatically corrode in preference to the bearing elements through galvanic action. The system self-regulates the corrosion process, requiring no active control or intervention to protect the bearing elements from corrosion during continuous operation.

Inventive Principle:

Principle #25Self-service

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

Enhances the operational lifetime of thrust-bearing apparatuses by preventing corrosion, thereby extending the useful life of subterranean drilling systems and improving drilling efficiency.

Implementation Method 1

The corrosion resistant region includes a corrosion resistant material that covers at least a portion of the at least one lateral surface of the bonding region. The corrosion resistant region is configured to prevent corrosion of at least some material covered by the corrosion resistant region.

Methodology Applied

Scientific EffectCorrosion resistance:

Implementation Method 2

bearing assemblies, bearing apparatuses, motors, pumps, or other mechanical assemblies that include bearing elements or support rings having corrosion resistant properties configured to protect the bearing elements from leaching, galvanic, or electrochemical corrosion

Methodology Applied

Scientific EffectGalvanic corrosion protection:

Data Source

PatentUS20250020164A1Corrosion resistant bearing elements, bearing assemblies, bearing apparatuses, and motor assemblies using the same

Publication Date: 2025.01.16 US SYNTHETIC CORP

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.