Corrosion resistant bearing elements, bearing assemblies, bearing apparatuses, and motor assemblies using the same
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.
1 . A bearing assembly, comprising:
a support ring;
a plurality of bearing elements mounted to and distributed circumferentially about an axis of the support ring, at least one bearing element of the plurality of bearing elements including:
a polycrystalline diamond table having a bearing surface, the polycrystalline diamond table including a plurality of bonded diamond grains defining a plurality of interstitial regions at least partially occupied by a metal-solvent catalyst; and
a substrate disposed at least partially in the support ring and bonded to the polycrystalline diamond table; and
one or more sacrificial anodes that extend from a first surface of the polycrystalline diamond table of a first bearing element of the plurality of bearing elements to a second surface of the polycrystalline diamond table of a second bearing element of the plurality of bearing elements, the one or more sacrificial anodes being configured to prevent corrosion of at least some of the metal-solvent catalyst when the bearing assembly is exposed to lubricant or cooling fluid.
2 . The bearing assembly of claim 1 , further comprising one or more corrosion resistant regions positioned between the one or more sacrificial anodes and at least one of the first bearing element or the second bearing element.
3 . The bearing assembly of claim 2 , wherein the one or more corrosion resistant regions cover at least a portion of a first lateral surface of the polycrystalline diamond table of the first bearing element, at least a portion of a second lateral surface of the polycrystalline diamond table of the second bearing element, and a portion of the substrate each of the first bearing element and the second bearing element of the plurality of bearing elements.
4 . The bearing assembly of claim 3 , wherein the one or more corrosion resistant regions cover any of the first lateral surface, any of the second lateral surface, and any lateral surface the substrate positioned outside the support ring.
5 . The bearing assembly of claim 3 , wherein the one or more corrosion resistant regions cover at least a portion of the bearing surface of each of the first bearing element and the second bearing element of the plurality of bearing elements.
6 . The bearing assembly of claim 1 , wherein the polycrystalline diamond table of each of the plurality of bearing elements includes an edge chamfer and the one or more sacrificial anodes at least partially cover the edge chamfer of each of the at least one of the plurality of bearing elements and the at least another bearing element of the plurality of bearing elements.
7 . The bearing assembly of claim 1 , wherein the one or more sacrificial anodes include one or more of a zinc anode, an aluminum anode, or a magnesium anode.
8 . The bearing assembly of claim 1 , further comprising:
one or more corrosion resistant regions that cover a portion of the first bearing element and the second bearing element of the plurality of bearing elements; and
wherein the one or more sacrificial anodes cover at least a portion of the one or more corrosion resistant regions.
9 . The bearing assembly of claim 8 , wherein the one or more corrosion resistant regions cover any of a first lateral surface of the polycrystalline diamond table of first bearing element, any of a second lateral surface of the polycrystalline diamond table of the second bearing element, and any lateral surface the substrate positioned outside the support ring.
10 . The bearing assembly of claim 8 , wherein the one or more corrosion resistant regions cover at least a portion of the bearing surface of each of the at least one of the plurality of bearing elements and the at least another bearing element of the plurality of bearing elements.
11 . The bearing assembly of claim 8 , wherein the polycrystalline diamond table of each of the plurality of bearing elements includes an edge chamfer and the one or more corrosion resistant regions at least partially cover the edge chamfer of each of the first bearing element and the second bearing element of the plurality of bearing elements.
12 . A method for manufacturing a bearing assembly, the method comprising:
providing a plurality of bearing elements, each bearing element of the plurality of bearing elements including:
a polycrystalline diamond table having a bearing surface, the polycrystalline diamond table including a plurality of bonded diamond grains defining a plurality of interstitial regions at least partially occupied by a metal-solvent catalyst; and
a substrate bonded to the polycrystalline diamond table;
securing the plurality of bearing elements to a support ring such that the substrate is at least partially disposed in the support ring; and
forming one or more sacrificial anodes on the support ring that extend from a first surface of the polycrystalline diamond table of a first bearing element of the plurality of bearing elements to a second surface of the polycrystalline diamond table of a second bearing element of the plurality of bearing elements, the one or more sacrificial anodes being configured to prevent corrosion of at least some of the metal-solvent catalyst when the bearing assembly is exposed to lubricant or cooling fluid.
13 . The method of claim 12 , further comprising disposing one or more corrosion resistant regions at least proximate to the first bearing element and the second bearing element of the plurality of bearing elements before forming the one or more sacrificial anodes.
14 . The method of claim 13 , wherein disposing the one or more corrosion resistant regions includes disposing the one or more corrosion resistant regions to cover at least a portion of a first lateral surface of a polycrystalline diamond table of the first bearing element, at least a portion of a second lateral surface of a polycrystalline diamond table of the second bearing element, and a portion of the substrate each of the first bearing element and the second bearing element of the plurality of bearing elements.
15 . The method of claim 13 , wherein disposing the one or more corrosion resistant regions includes disposing the one or more corrosion resistant regions to cover any of the first lateral surface, any of the second lateral surface, and any lateral surface the substrate positioned outside the support ring.
16 . The method of claim 13 , wherein disposing the one or more corrosion resistant regions includes disposing the one or more corrosion resistant regions to cover at least a portion of the bearing surface of each of the at least one of the plurality of bearing elements and the at least another bearing element of the plurality of bearing elements.
17 . The method of claim 13 , wherein disposing the one or more corrosion resistant regions includes disposing the one or more corrosion resistant regions to at least partially cover an edge chamfer of each of the at least one of the plurality of bearing elements and the at least another bearing element of the plurality of bearing elements.
18 . The method of claim 12 , wherein the one or more sacrificial anodes include one or more of a zinc anode, an aluminum anode, or a magnesium anode.
19 . The method of claim 12 , further comprising:
disposing one or more corrosion resistant regions to cover a first lateral surface of a polycrystalline diamond table of the first bearing element, the second lateral surface of a polycrystalline diamond table of the second bearing element, and a portion of the substrate each of the first bearing element and the second bearing element of the plurality of bearing elements; and
wherein forming one or more sacrificial anodes on the support ring includes disposing the one or more sacrificial anodes to cover at least a portion of the one or more corrosion resistant regions.
20 . The method of claim 19 , wherein disposing the one or more corrosion resistant regions includes disposing the one or more corrosion resistant regions to cover any of the first lateral surface, any of the second lateral surface, and any lateral surface the substrate positioned outside the support ring.
21 . The method of claim 19 , wherein disposing the one or more corrosion resistant regions includes disposing the one or more corrosion resistant regions to cover at least a portion of the bearing surface of each of the at least one of the plurality of bearing elements and the at least another bearing element of the plurality of bearing elements.
22 . The method of claim 19 , wherein disposing the one or more corrosion resistant regions includes disposing the one or more corrosion resistant regions to at least partially cover an edge chamfer of each of the at least one of the plurality of bearing elements and the at least another bearing element of the plurality of bearing elements.
23 . A bearing assembly, comprising:
a support ring; and
a plurality of bearing elements mounted to and distributed circumferentially about an axis of the support ring, at least one bearing element of the plurality of bearing elements including:
a polycrystalline diamond table having a bearing surface, the polycrystalline diamond table including a plurality of bonded diamond grains defining a plurality of interstitial regions at least partially occupied by a metal-solvent catalyst; and
a substrate disposed at least partially in the support ring and bonded to the polycrystalline diamond table; and
a sacrificial anode that extends across the support ring from a first bearing element of the plurality of bearing elements to a second bearing element of the plurality of bearing elements, the sacrificial anode being configured to prevent corrosion of at least some of the metal-solvent catalyst when the bearing assembly is exposed to lubricant or cooling fluid.