U.S. patent application number 16/960500 was filed with the patent office on 2020-12-03 for wear resistant insert.
The applicant listed for this patent is Halliburton Energy Services, Inc.. Invention is credited to Philip Park-Hung Leung.
Application Number | 20200378195 16/960500 |
Document ID | / |
Family ID | 1000005088682 |
Filed Date | 2020-12-03 |
United States Patent
Application |
20200378195 |
Kind Code |
A1 |
Leung; Philip Park-Hung |
December 3, 2020 |
Wear Resistant Insert
Abstract
A wear resistant insert including a deposition substrate having
an exterior surface, and a wear resistant layer deposited on the
exterior surface of the deposition substrate. The wear resistant
insert may further include a structure interface layer deposited on
an exterior surface of the wear resistant layer. A method of
forming a wear resistant insert including providing a deposition
substrate having an exterior surface, and depositing a wear
resistant layer on the exterior surface of the deposition
substrate. The method may further include depositing a structure
interface layer on an exterior surface of the wear resistant layer.
The method may further include separating the wear resistant layer
from the deposition substrate intact.
Inventors: |
Leung; Philip Park-Hung;
(Edmonton, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Halliburton Energy Services, Inc. |
Houston |
TX |
US |
|
|
Family ID: |
1000005088682 |
Appl. No.: |
16/960500 |
Filed: |
February 27, 2018 |
PCT Filed: |
February 27, 2018 |
PCT NO: |
PCT/CA2018/050226 |
371 Date: |
July 7, 2020 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E21B 17/1007 20130101;
C23C 4/185 20130101; C23C 4/134 20160101; C23C 4/129 20160101; C23C
4/10 20130101; E21B 17/1078 20130101 |
International
Class: |
E21B 17/10 20060101
E21B017/10; C23C 4/10 20060101 C23C004/10; C23C 4/134 20060101
C23C004/134; C23C 4/129 20060101 C23C004/129; C23C 4/18 20060101
C23C004/18 |
Claims
1. A wear resistant insert, comprising: (a) a deposition substrate
having an exterior surface; and (b) a wear resistant layer
comprising a wear resistant material deposited on the exterior
surface of the deposition substrate.
2. The wear resistant insert as claimed in claim 1 wherein the wear
resistant layer has an interior surface which defines a wear
resistant bore of the wear resistant layer and wherein the wear
resistant layer is separable from the deposition substrate intact
in order to expose the wear resistant bore.
3. The wear resistant insert as claimed in claim 2 wherein the
deposition substrate is destroyable while leaving the wear
resistant layer intact so that the wear resistant layer is
separable intact from the deposition substrate by destroying the
deposition substrate.
4. The wear resistant insert as claimed in claim 3 wherein the
deposition substrate is less wear resistant than the wear resistant
layer so that the deposition substrate is destroyed by wearing of
the deposition substrate.
5. The wear resistant insert as claimed in claim 3 wherein the
deposition substrate is dissolvable without dissolving the wear
resistant layer so that the deposition substrate is destroyed by
dissolving the deposition substrate.
6. The wear resistant insert as claimed in claim 3 wherein the
deposition substrate is meltable without melting the wear resistant
layer so that the deposition substrate is destroyed by melting the
deposition substrate.
7. The wear resistant insert as claimed in claim 2 wherein the wear
resistant layer is deposited on the deposition substrate by
immersion, electrodeposition, electroless deposition, welding,
cladding, spraying, vapour deposition, additive manufacturing, or a
combination thereof
8. The wear resistant insert as claimed in claim 2 wherein the wear
resistant material is a non-metallic crystalline material, a
carbide, a nitride, an alloy, or a combination thereof
9. The wear resistant insert as claimed in claim 2 wherein the
deposition substrate is an elongated member and wherein the wear
resistant layer is deposited on the exterior surface of the
deposition substrate as an elongated tube.
10. The wear resistant insert as claimed in claim 9 wherein the
deposition substrate defines a substrate bore extending
longitudinally through the deposition substrate.
11. The wear resistant insert as claimed in claim 2 wherein the
wear resistant layer has an exterior surface, further comprising a
structure interface layer deposited on the exterior surface of the
wear resistant layer.
12. The wear resistant insert as claimed in claim 11 wherein the
structure interface layer is machinable.
13. The wear resistant insert as claimed in claim 11 wherein the
structure interface layer is non-porous.
14. A method of forming a wear resistant insert, comprising: (a)
providing a deposition substrate, wherein the deposition substrate
has an exterior surface; and (b) depositing a wear resistant layer
on the exterior surface of the deposition substrate, wherein the
wear resistant layer comprises a wear resistant material.
15. The method as claimed in claim 14 wherein depositing the wear
resistant layer on the exterior surface of the deposition substrate
comprises depositing the wear resistant layer by immersion,
electrodeposition, electroless deposition, welding, cladding,
spraying, vapour deposition, additive manufacturing, or a
combination thereof
16. The method as claimed in claim 14 wherein the wear resistant
material is a non-metallic crystalline material, a carbide, a
nitride, an alloy, or a combination thereof
17. The method as claimed in claim 14, further comprising
separating the wear resistant layer from the deposition substrate
intact.
18. The method as claimed in claim 14 wherein the wear resistant
layer has an exterior surface, further comprising depositing a
structure interface layer on the exterior surface of the wear
resistant layer.
19. The method as claimed in claim 18, further comprising providing
at least one hole, slot or groove in the structure interface
layer.
20. The method as claimed in claim 19 wherein providing at least
one hole, slot or groove in the structure interface layer comprises
machining the structure interface layer.
21. The method as claimed in claim 14, further comprising
installing the wear resistant insert in an interior space of a
structure.
22. The method as claimed in claim 21, further comprising
separating the wear resistant layer from the deposition substrate
intact after installing the wear resistant insert in the interior
space of the structure.
23. The method as claimed in claim 22 wherein separating the wear
resistant layer from the deposition substrate intact comprises
destroying the deposition substrate.
24. The method as claimed in claim 22 wherein the deposition
substrate is an elongated member, wherein the interior space of the
structure is a bore defined by the structure, and wherein
installing the wear resistant insert in the interior space of the
structure comprises inserting the wear resistant insert in the bore
of the structure.
25. The method as claimed in claim 24, further comprising fastening
the wear resistant insert to the structure after the wear resistant
insert has been inserted in the bore of the structure.
26. The method as claimed in claim 24 wherein the deposition
substrate defines a substrate bore extending longitudinally through
the deposition substrate and wherein separating the wear resistant
layer from the deposition substrate intact comprises passing a
fluid through the substrate bore in order to destroy the deposition
substrate.
27. The method as claimed in claim 24 wherein the structure is a
structure for use in a borehole.
28. The method as claimed in claim 24 wherein the structure is a
drilling motor for use in drilling a borehole.
Description
TECHNICAL FIELD
[0001] A wear resistant insert, a method of forming a wear
resistant insert, and a method of installing a wear resistant
insert in or on a structure.
BACKGROUND OF THE INVENTION
[0002] The surfaces of a tool or other structure may be susceptible
to wear during use. Such wear may have various causes, including
but not limited to friction, abrasion, erosion, corrosion, impacts,
and/or fatigue. Increasing the wear resistance of an interior
surface of a tool or other structure may be challenging due to line
of sight limitations, access limitations, space limitations due to
small component dimensions (including as a non-limiting example
within small bores), material incompatibilities, and/or other
limitations. In the oil and gas industry, the interior surfaces of
tools and other non-tubular or tubular structures may be
susceptible to wear as a result of the environments in which the
structures are used and the conditions to which the structures are
exposed.
BRIEF DESCRIPTION OF DRAWINGS
[0003] Embodiments of the invention will now be described with
reference to the accompanying drawings, in which:
[0004] FIG. 1 is a schematic view of portions of a drilling motor
for use in drilling a borehole.
[0005] FIG. 2 is a schematic pictorial view of a first non-limiting
embodiment of a wear resistant insert.
[0006] FIG. 3 is a schematic pictorial view of a second
non-limiting embodiment of a wear resistant insert.
[0007] FIG. 4 is a longitudinal cross-sectional view depicting a
third non-limiting embodiment of a wear resistant insert installed
in a drilling motor of the general type depicted in FIG. 1.
DETAILED DESCRIPTION
[0008] This description is directed, in part, to a wear resistant
insert, to a method of forming a wear resistant insert, and to a
method of installing a wear resistant insert in or on a
structure.
[0009] The wear resistant insert described herein may be used in
any environment and/or with any structure in which wear resistance
is desired. The wear resistance which is provided by the wear
resistant insert may be resistance to any cause of wear, including
as non-limiting examples, wear by friction, abrasion, erosion,
corrosion, impacts, and/or fatigue.
[0010] The wear resistant insert described herein may be
particularly suited for providing wear resistance to a structure in
which it may be difficult or impossible to apply or provide wear
resistance to the structure directly because of line of sight
limitations, access limitations, space limitations due to small
component dimensions (including as a non-limiting example within
small bores), material incompatibilities, and/or other limitations,
and/or where the heat required to apply or provide wear resistance
to the structure may degrade or otherwise adversely affect the
material properties of the material or materials from which the
structure is formed.
[0011] As a non-limiting example, the wear resistant insert
described herein may be used to provide wear resistance to an
interior space of a structure. A structure having an interior space
may be a non-tubular structure or a tubular structure, and may
fully or partially define and/or enclose the interior space. Both a
non-tubular structure and a tubular structure may have any shape
and may fully or partially define and/or enclose an interior space
having any shape. As a non-limiting example, a tubular structure
may define a longitudinal axis and/or may be elongated, a tubular
structure may have a round, oval, polygonal or any other suitable
cross-sectional shape, and a tubular structure may define and/or
enclose an interior space having a round, oval, polygonal or any
other suitable cross-sectional shape.
[0012] As a non-limiting example, the structure may be a
non-tubular or tubular housing having an interior space which
contains moving parts and which may therefore be particularly
susceptible to wear by friction, abrasion, erosion, corrosion,
impacts, and/or fatigue. As a non-limiting example, the structure
may be a tubular structure which contains or transports a fluid,
including but not limited to a pipe, a conduit, or a trough and
which may therefore be particularly susceptible to wear by
abrasion, erosion and/or corrosion.
[0013] As a non-limiting example, the wear resistant insert
described herein may be used with a structure which is suitable to
be inserted and used within a borehole. As a non-limiting example,
the structure may be a non-tubular or tubular tool or other
structure for use in drilling a borehole. As a non-limiting
example, such a tool or other structure may be a component of a
drilling string. As non-limiting examples, such a tool or other
structure may comprise, consist of, or consist essentially of a
drill pipe, a drill collar, a drilling tool, a logging tool, a
measuring tool, a communication tool, a reamer, a stabilizer,
and/or a drill bit. Non-limiting examples of a drilling tool
include a drilling motor, a rotary steerable drilling apparatus, a
turbine, a reciprocating hammer, or any other apparatus which is
suitable for use in drilling a borehole.
[0014] The wear resistant insert comprises a wear resistant layer.
The wear resistant layer comprises a wear resistant material. The
wear resistant insert may comprise a deposition substrate having an
exterior surface. The wear resistant layer may be deposited on the
exterior surface of the deposition substrate. Alternatively, the
wear resistant insert may not comprise a deposition substrate, and
the wear resistant layer may be deposited independently in a
desired shape.
[0015] The deposition substrate supports the wear resistant layer
during the deposition of the wear resistant layer. The deposition
substrate may also support the wear resistant layer during storage,
handling, and/or installation of the wear resistant insert. If such
support is not required, the deposition substrate may in some
circumstances be omitted from the wear resistant insert.
[0016] The deposition substrate may have any shape which is
suitable for the intended use of the wear resistant insert,
including the size, dimensions, and configuration of the structure
with which it is used. As non-limiting examples, the deposition
substrate may have essentially a two-dimensional (eg., planar)
shape or the deposition substrate may have a three-dimensional
shape.
[0017] If the deposition substrate has essentially a
two-dimensional shape, the two-dimensional shape may have two
opposing faces and a perimeter having any suitable perimeter shape,
including but not limited to round, oval, polygonal, or a
combination of such shapes. If the deposition substrate has a
two-dimensional shape, the exterior surface of the deposition
substrate may comprise one or both of the opposing faces and/or the
perimeter of the deposition substrate.
[0018] If the deposition substrate has a three-dimensional shape,
the three-dimensional shape may be any desired form. If the
deposition substrate has a three-dimensional shape, the exterior
surface of the deposition substrate may comprise the exterior of
the deposition substrate. As a non-limiting example of a
three-dimensional shape, the deposition substrate may comprise,
consist of, or consist essentially of an elongated member. If the
deposition substrate comprises, consists of, or consists
essentially of an elongated member, the exterior surface of the
elongated member may have any desired cross-sectional shape. As
non-limiting examples, the exterior surface of the elongated member
may be round, oval, polygonal, or a combination of such shapes.
[0019] The deposition substrate may define one or more holes,
notches, slots, grooves, and/or bores. As a non-limiting example,
the deposition substrate may define a substrate bore. The substrate
bore may extend through the deposition substrate. If the deposition
substrate comprises, consists of, or consists essentially of an
elongated member, the substrate bore may extend longitudinally
through the elongated member. Such holes, notches, slots, grooves,
and/or bores may be formed in the deposition substrate during
fabrication of the deposition substrate or after fabrication of the
deposition substrate by machining or by some other suitable
process.
[0020] The exterior surface of the deposition substrate may define
one or more discontinuities including, as non-limiting examples,
one or more protrusions, lugs, flanges, extensions, holes, notches,
slots, grooves, and/or bores. The one or more discontinuities may
define and/or influence the shape and/or configuration of the wear
resistant layer which is deposited on the exterior surface of the
deposition substrate, and/or may accommodate features of the
structure with which the wear resistant insert is to be used. Such
discontinuities may be formed in the deposition substrate during
fabrication of the deposition substrate or after fabrication of the
deposition substrate by machining or by some other suitable
process.
[0021] The wear resistant layer may be deposited either directly or
indirectly on the deposition substrate. The wear resistant layer is
deposited directly on the deposition substrate if the wear
resistant layer is in direct contact with the deposition substrate.
The wear resistant layer is deposited indirectly on the deposition
substrate if one or more intermediate materials or layers separate
the wear resistant layer from the deposition substrate.
[0022] The wear resistant layer may be deposited on all or a
portion of the exterior surface of the deposition substrate. The
wear resistant layer may be deposited on the exterior surface of
the deposition substrate in any suitable manner which is capable
essentially of applying a coating of the wear resistant layer on
all or a portion of the exterior surface of the deposition
substrate. As non-limiting examples, the wear resistant layer may
be deposited on the exterior surface of the deposition substrate by
immersion, electrodeposition, electroless deposition, welding,
cladding, spraying, vapour deposition, additive manufacturing, or a
combination of such processes.
[0023] As a non-limiting example, immersion may comprise, consist
of, or consist essentially of dipping and/or immersing the
deposition substrate in a fluid bath. As non-limiting examples,
electrodeposition may comprise, consist of, or consist essentially
of electroplating and/or electrodeposition. As non-limiting
examples, welding may comprise, consist of, or consist essentially
of oxyacetylene welding, tungsten inert gas (TIG) welding, metal
inert gas (MIG) welding, laser welding, and/or electron beam
welding. As a non-limiting example, cladding may comprise, consist
of, or consist essentially of laser cladding. As non-limiting
examples, spraying may comprise, consist of, or consist essentially
of plasma transferred arc (PTA) spraying, high velocity oxy-fuel
(HVOF) spraying, high velocity air fuel (HVAF) spraying, and/or
cold spraying. As non-limiting examples, vapour deposition may
comprise, consist of, or consist essentially of physical vapour
deposition (PVD) and/or chemical vapour deposition (CVD). As
non-limiting examples, additive manufacturing may comprise, consist
of, or consist essentially of binder jetting, directed energy
deposition, material extrusion, material jetting, powder bed
fusion, sheet lamination, vat polymerization, and/or 3D printing.
As non-limiting examples, 3D printing may comprise, consist of, or
consist essentially of laser melting, metal laser sintering, laser
sintering, fused deposition modeling, fused filament fabrication,
stereolithography, and/or laminated object manufacturing.
[0024] The wear resistant layer may comprise, consist of, or
consist essentially of a wear resistant material. The wear
resistant material may comprise, consist of, or consist essentially
of any material which is capable of improving the wear resistance
of the structure with which the wear resistant insert is to be
used. The wear resistant material may be a single material or may
be a combination of materials. As non-limiting examples, the wear
resistant material may comprise, consist of, or consist essentially
of a non-metallic crystalline material, a carbide, a nitride, a
metallic or non-metallic alloy, a ceramic, or a combination of such
materials. As non-limiting examples, the wear resistant material
may be provided as a continuous material or may be provided as
particles. Particles of the wear resistant material may be provided
in any shape, including as non-limiting examples, spherical
particles and/or angular particles. Particles of the wear resistant
material may be formed in any suitable manner.
[0025] As non-limiting examples, a non-metallic crystalline
material as a wear resistant material may comprise, consist of, or
consist essentially of polycrystalline diamond and/or
polycrystalline cubic boron nitride. As non-limiting examples, a
carbide as a wear resistant material may comprise, consist of, or
consist essentially of tungsten carbide, chromium carbide, boron
carbide, and/or silicon carbide. As non-limiting examples, a
nitride as a wear resistant material may comprise, consist of, or
consist essentially of titanium nitride and/or cubic boron nitride.
As non-limiting examples, a metallic alloy as a wear resistant
material may comprise, consist of, or consist essentially of a
nickel alloy, a cobalt alloy, and/or a cobalt/nickel chromium
alloy. As non-limiting examples, a ceramic as a wear resistant
material may be provided individually or as a ceramic/metal
(cermet) composite material. Non-limiting examples of cermet
materials which may be suitable for use as the wear resistant
material include blends of tungsten carbide, cobalt, and chrome
(listed in decreasing order of proportion, such as an 86/10/4
blend) and/or blends of tungsten carbide and nickel (listed in
decreasing order of proportion, such as a 90/10 blend).
[0026] The wear resistant layer may comprise one or more materials
in addition to the wear resistant material. As non-limiting
examples, the wear resistant layer may comprise one or more
materials as a binder, matrix, and/or carrier for particles of the
wear resistant material. A binder, matrix, and/or carrier may
comprise, consist of, or consist essentially of any suitable
material or combination of materials which is compatible with the
wear resistant material and the deposition substrate. As
non-limiting examples, a binder, matrix and/or carrier may
comprise, consist of, or consist essentially of nickel, cobalt, an
alloy such as a braze alloy and/or a Stellite.TM. alloy comprised
of various amounts of cobalt, nickel, iron, aluminum, boron,
carbon, chromium, manganese, molybdenum, phosphorous, sulfur,
silicon and/or titanium, a carbide such as tungsten carbide and/or
silicon carbide, or a combination of such materials.
[0027] The wear resistant layer may be separable from the
deposition substrate intact. The wear resistant layer is separable
from the deposition substrate intact if the wear resistant layer
can be separated from the deposition substrate without significant
damage occurring to the wear resistant layer. The wear resistant
layer may be separable from the deposition substrate intact in any
manner. The wear resistant layer may be separable from the
deposition substrate intact in a manner which is non-destructive to
the deposition substrate or in a manner which is destructive to the
deposition substrate. If the wear resistant layer is separable from
the deposition substrate in a manner which is destructive to the
deposition substrate, the deposition substrate may be considered as
a "sacrificial" deposition substrate.
[0028] As a non-limiting example, the wear resistant layer may be
separable from the deposition substrate intact by moving the
deposition substrate relative to the wear resistant layer in a
manner which is either non-destructive or destructive to the
deposition substrate. The deposition substrate may be movable
either non-destructively or destructively relative to the wear
resistant layer while leaving the wear resistant layer intact if
the physical or chemical connection or bond between the deposition
substrate and the wear resistant layer can be overcome without
significantly damaging the wear resistant layer and if the shape of
the deposition substrate facilitates the movement relative to the
wear resistant layer which is necessary in order to separate the
wear resistant layer from the deposition substrate intact.
[0029] The exterior surface of the deposition substrate may be
treated prior to depositing the wear resistant layer on the
exterior surface of the deposition substrate. The exterior surface
of the deposition substrate may be treated for any purpose or
combination of purposes. As a non-limiting example, the exterior
surface of the deposition substrate may be treated in order to
reduce the magnitude of the physical or chemical connection or bond
between the deposition substrate and the wear resistant layer. The
exterior surface of the deposition substrate may be treated in any
suitable manner, including as non-limiting examples, by coating the
exterior surface of the deposition substrate with a suitable
material and/or by surface treating the exterior surface of the
deposition substrate in a suitable manner.
[0030] The wear resistant layer may be separable from the
deposition substrate in a manner which is destructive to the
deposition substrate by providing that the deposition substrate is
partially or fully destroyable while leaving the wear resistant
layer intact. As a non-limiting example, the deposition substrate
may be partially or fully destroyed by passing a fluid or other
material through a substrate bore which extends through the
deposition substrate. As a non-limiting example, the deposition
substrate may be less wear resistant than the wear resistant layer
so that the deposition substrate is destroyed by wearing of the
deposition substrate. As a non-limiting example, the deposition
substrate may be dissolvable without dissolving the wear resistant
layer so that the deposition substrate is destroyed by dissolving
the deposition substrate. As a non-limiting example, the deposition
substrate may be meltable without melting the wear resistant layer
so that the deposition substrate is destroyed by melting the
deposition substrate.
[0031] The deposition substrate may be constructed of any material
or combination of materials which is compatible with the wear
resistant material, the wear resistant layer, and with the manner
in which the wear resistant layer is to be separable from the
deposition substrate, including as non-limiting examples, metal,
wood, plastic, glass, ceramic, composite material, or a combination
of such materials. As non-limiting examples, the deposition
substrate may comprise a non-stick material or exterior surface or
a deformable material to facilitate movement of the deposition
substrate relative to the wear resistant layer in order to separate
the wear resistant layer from the deposition substrate, and/or the
deposition substrate may comprise a relatively wearable material, a
relatively dissolvable material, or a relatively meltable material
in comparison with the wear resistant layer to facilitate
separation of the wear resistant layer from the deposition
substrate in a manner which is destructive to the deposition
substrate.
[0032] As particular non-limiting examples, the deposition
substrate may comprise, consist of, or consist essentially of one
or more metal materials such as carbon steels, alloy steels,
stainless steels, and/or metallic alloys. In circumstances in which
the wear resistant insert is intended to be used with a structure
for insertion and use in a borehole, non-limiting examples of metal
materials which may be suitable for use in the deposition substrate
include 4140 steel, 4145 steel, 4330V steel, 17-4 PH stainless
steel, 718 nickel alloy, 625 nickel alloy, and non-magnetic
austenitic steels.
[0033] The deposition substrate may be fabricated using any
suitable process or combination of processes and using any suitable
tooling or combination of tooling which are compatible with the
material from which the deposition substrate is constructed and the
desired shape of the deposition substrate. As non-limiting
examples, the deposition substrate may be fabricated by molding,
casting, forging, extruding, welding, soldering, machining, 3-D
printing, lathing, cutting, or combination of these and/or other
processes, and using any tooling which is suitable for performing
such processes, including as non-limiting examples, lathes, welding
and cutting equipment, and computer numerical control (CNC)
equipment.
[0034] The wear resistance of the wear resistant insert is provided
by the wear resistant layer. The wear resistant layer has an
interior surface, an exterior surface, and a thickness. Since the
wear resistant layer is deposited on the exterior surface of the
deposition substrate, the interior surface of the wear resistant
layer is adjacent to the exterior surface of the deposition
substrate upon formation of the wear resistant insert.
[0035] The wear resistant insert may be installed in or on a
structure so that the interior surface and/or the exterior surface
of the wear resistant layer is exposed to one or more causes of
wear. The wear resistant layer essentially provides a coating of a
wear resistant material which is applied to a surface of the
structure by installing the wear resistant insert in or on the
structure, without coating the structure directly. The wear
resistant layer may therefore essentially provide a wear resistant
"sleeve" for the structure.
[0036] If the exterior surface of the wear resistant layer is to be
exposed to wear, the wear resistant insert may be installed in or
on a structure so that the interior surface of the wear resistant
layer is adjacent to a surface of the structure. In such
circumstances, the wear resistant layer may if required be
separated from the deposition substrate before the wear resistant
insert is installed in or on the structure so that the interior
surface of the wear resistant layer can be positioned adjacent to
the surface of the structure.
[0037] If the interior surface of the wear resistant layer is to be
exposed to wear, the wear resistant insert may be installed in or
on a structure so that the exterior surface of the wear resistant
layer is adjacent to a surface of the structure. In such
circumstances, the wear resistant layer may be separated from the
deposition substrate either before or after the wear resistant
insert is installed in or on the structure.
[0038] Since the wear resistant layer is deposited on the exterior
surface of the deposition substrate, the interior surface of the
wear resistant layer may have a similar or identical shape as the
exterior surface of the deposition substrate.
[0039] If the deposition substrate has essentially a
two-dimensional shape, the wear resistant layer may essentially be
two-dimensional. As a non-limiting example, if the deposition
substrate is essentially planar, the wear resistant layer may be
essentially planar.
[0040] If the deposition substrate has a three-dimensional shape,
the wear resistant layer may be three-dimensional. As a
non-limiting example, if the deposition substrate has a
three-dimensional shape, the wear resistant layer may be a shell or
a portion of a shell surrounding the deposition substrate, so that
when the wear resistant layer is separated from the deposition
substrate, the wear resistant layer may define a wear resistant
cavity which is exposed by separation of the wear resistant layer
from the deposition substrate.
[0041] As a more particular non-limiting example, if the deposition
substrate comprises, consists of, or consists essentially of an
elongated member, the wear resistant layer may be deposited on the
deposition substrate as an elongated tube, so that when the wear
resistant layer is separated from the deposition substrate, the
wear resistant layer may define a wear resistant bore having a
cross-sectional shape which is similar or identical to the exterior
surface of the deposition substrate, and which may be exposed by
separation of the wear resistant layer from the deposition
substrate.
[0042] The wear resistant insert may optionally comprise a
structure interface layer deposited on the exterior surface of the
wear resistant layer. The structure interface layer has an exterior
surface. The structure interface layer may be deposited on the
exterior surface of the wear resistant layer for any purpose or
combination of purposes. As a non-limiting example, the structure
interface layer may protect the wear resistant layer during
storage, handling, installation, and/or use of the wear resistant
insert. As a non-limiting example, the structure interface layer
may provide a suitable machinable layer for providing additional
features on the wear resistant insert, including but not limited to
holes, slots, and/or grooves, which may be configured to receive
fastening devices for connecting the wear resistant insert with a
structure, to accommodate features of the structure with which the
wear resistant insert is to be used, and/or for receiving and/or
accommodating one or more seals for providing a seal between the
wear resistant insert and the structure. As a non-limiting example,
the structure interface layer may provide material compatibility
with the structure. As a non-limiting example, the structure
interface layer may provide support for the wear resistant layer in
addition to the support provided by the deposition substrate, which
support may possibly reduce the likelihood of disintegration of a
worn or damaged (i.e., cracked or broken) wear resistant layer and
may prevent pieces of the wear resistant layer from becoming loose
and/or becoming separated from the wear resistant layer. As a
non-limiting example, the structure interface layer may provide a
substantially non-porous layer or surface to inhibit fluids or
other substances from passing through the wear resistant layer and
contacting the structure with which the wear resistant insert is
used. As a non-limiting example, the exterior surface of the
structure interface layer may provide a surface having a relatively
low coefficient of friction or comprising a lubricant to facilitate
the installation of the wear resistant insert in or on a structure.
As a non-limiting example, the structure interface layer may
provide a layer which is more suitable for interfacing with the
structure than is the wear resistant layer. As a non-limiting
example, the structure interface layer may provide a suitable layer
for attachment or connection of the wear resistant insert with the
structure by welding, brazing, soldering and/or with a suitable
adhesive.
[0043] The structure interface layer may be deposited either
directly or indirectly on the wear resistant layer. The structure
interface layer is deposited directly on the wear resistant layer
if the structure interface layer is in direct contact with the wear
resistant layer. The structure interface layer is deposited
indirectly on the wear resistant layer if one or more materials
separate the structure interface layer from the wear resistant
layer.
[0044] The structure interface layer may be deposited on all or a
portion of the exterior surface of the wear resistant layer. The
structure interface layer may be deposited on the exterior surface
of the wear resistant layer in any suitable manner which is capable
essentially of applying a coating on all or a portion of the
exterior surface of the wear resistant layer. As non-limiting
examples, the structure interface layer may be deposited on the
exterior surface of the wear resistant layer by immersion,
electrodeposition, electroless deposition, welding, cladding,
spraying or vapour deposition, additive manufacturing, or a
combination of such processes.
[0045] The structure interface layer may comprise, consist of, or
consist essentially of any material or combination of materials
which is suitable for the intended purpose or purposes of the
structure interface layer including as non-limiting examples,
metal, plastic, ceramic, composite material, or a combination of
such materials.
[0046] As particular non-limiting examples, the structure interface
layer may comprise, consist of, or consist essentially of one or
more metal materials such as carbon steels, alloy steels, stainless
steels, and/or metallic alloys. In circumstances in which the wear
resistant insert is intended to be used with a structure for
insertion and use in a borehole, non-limiting examples of metal
materials which may be suitable for use in the structure interface
layer include 625 nickel alloy and 630, 304, 316, 410 and 420
stainless steel.
[0047] The wear resistant layer and/or the structure interface
layer may define one or more additional features, including but not
limited to holes, slots, and/or grooves. As non-limiting examples,
such holes, slots, and/or grooves may be defined in the exterior
surface of the wear resistant layer and/or in the exterior surface
of the structure interface layer. Such holes, slots, and/or grooves
may be provided for any purpose, including as non-limiting
examples, for receiving one or more fastening devices for
connecting the wear resistant insert with a structure, for
accommodating features of the structure with which the wear
resistant insert is to be used, and/or for receiving and/or
accommodating one or more seals for providing a seal between the
wear resistant insert and the structure. As non-limiting examples,
such fastening devices may comprise, consist of, or consist
essentially of pins, lugs, set screws, keys, rivets, and/or
splines, which may interact with such holes, slots and/or grooves
to inhibit the wear resistant insert from rotating and/or moving
relative to the structure. As non-limiting examples, such seals may
comprise, consist of, or consist essentially of one or more 0-ring
seals and/or any other suitable type of seal. As non-limiting
examples, such features of the structure to be accommodated may
comprise, consist of, or consist essentially of ports, recesses,
protrusions, and/or other discontinuities in the structure. Such
additional features may be formed in the wear resistant layer
and/or the structure interface layer during deposition thereof,
and/or may be formed in the wear resistant layer and/or the
structure interface layer after deposition by machining or by some
other suitable process.
[0048] The wear resistant layer may optionally be separable from
the structure interface layer intact. In such circumstances, the
considerations and techniques regarding separating the wear
resistant layer from the deposition substrate intact may also apply
to separating the wear resistant layer from the structure interface
layer intact.
[0049] The wear resistant insert as described above may be formed
separately from a structure and may be installed in the structure
during or after fabrication of the structure.
[0050] A method of forming the wear resistant insert may comprise
providing the deposition substrate, and depositing a wear resistant
layer comprising a wear resistant material on the exterior surface
of the deposition substrate.
[0051] In some circumstances, the deposition substrate may be
omitted, and the wear resistant layer may be deposited
independently in a desired shape without the use of a deposition
substrate. As a non-limiting example, the wear resistant layer may
be deposited independently in a desired shape without the use of a
deposition substrate using a suitable additive manufacturing
process. As a non-limiting example, a suitable additive
manufacturing process may comprise, consist of, or consist
essentially of a 3D printing process.
[0052] The method may comprise depositing the wear resistant layer
on the exterior surface of the deposition substrate in a suitable
manner. As non-limiting examples, the method may comprise
depositing the wear resistant layer on the exterior surface of the
deposition substrate by immersion, electrodeposition, electroless
deposition, welding, cladding, spraying, vapour deposition,
additive manufacturing, or a combination of such processes.
[0053] The method may optionally comprise depositing a structure
interface layer on an exterior surface of the wear resistant layer
in a suitable manner. As non-limiting examples, the method may
comprise depositing the structure interface layer on the exterior
surface of the wear resistant layer by immersion,
electrodeposition, electroless deposition, welding, cladding,
spraying, vapour deposition, additive manufacturing, or a
combination of such processes.
[0054] The method may comprise providing the wear resistant layer
and/or the structure interface layer with one or more additional
features, including but not limited to holes, slots, and/or
grooves. Such holes, slots, and/or grooves may be provided for any
purpose, including as non-limiting examples, for receiving one or
more fastening devices for connecting the wear resistant insert
with a structure, for accommodating features of the structure with
which the wear resistant insert is to be used, and/or for receiving
and/or accommodating one or more seals for providing a seal between
the wear resistant insert and the structure. As non-limiting
examples, such fastening devices may comprise, consist of, or
consist essentially of pins, lugs, set screws, keys, rivets, and/or
splines, which may interact with such holes, slots, and/or grooves
to inhibit the wear resistant insert from rotating and/or moving
relative to the structure. As non-limiting examples, such features
of the structure may comprise, consist of, or consist essentially
of ports, recesses, protrusions, and/or other discontinuities in
the structure. The method may comprise forming such additional
features in the wear resistant layer and/or the structure interface
layer during deposition thereof, and/or the method may comprise
forming such additional features in the wear resistant layer and/or
the structure interface layer after deposition by machining or by
some other suitable process.
[0055] The method may comprise installing the wear resistant insert
in or on a structure. As a non-limiting example, the method may
comprise installing the wear resistant insert in an interior space
of a structure. As a non-limiting example, the method may comprise
installing the wear resistant insert in an interior space of a
structure by inserting the wear resistant insert into the interior
space of the structure.
[0056] As a non-limiting example, the deposition substrate may
comprise, consist of, or consist essentially of an elongated
member, the interior space of the structure may comprise, consist
of, or consist essentially of a bore defined by the structure, and
installing the insert in the interior space of the structure may
comprise inserting the wear resistant insert in the bore of the
structure.
[0057] The method may comprise fastening the wear resistant insert
to the structure in a suitable manner after the wear resistant
insert has been installed in or on the structure. As a non-limiting
example, the method may comprise fastening the wear resistant
insert to the structure after the wear resistant insert has been
inserted in a bore defined by the structure. As non-limiting
examples, the wear resistant insert may be fastened to the
structure by welding, soldering, gluing, by providing an
interference fit, with one or more fastening devices, or with a
combination of suitable fastening techniques. As a non-limiting
example, the method may comprise fastening the wear resistant
insert to the structure by engaging one or more suitable fastening
devices such as screws, bolts, plugs, or rivets, or a combination
of such fastening devices with one or more holes, slots, or grooves
provided in the structure interface layer and/or the wear resistant
layer of the wear resistant insert in order to inhibit the wear
resistant insert from rotating and/or moving relative to the
structure.
[0058] The method may comprise separating the wear resistant layer
from the deposition substrate intact in a suitable manner before,
during, or after the wear resistant layer is installed in or on the
structure. As a non-limiting example, the method may comprise
separating the wear resistant layer from the deposition substrate
intact after installing the wear resistant insert in or on a
structure. As a more particular non-limiting example, the method
may comprise separating the wear resistant layer from the
deposition substrate intact after installing the wear resistant
insert in an interior space of a structure.
[0059] The method may comprise separating the wear resistant layer
from the deposition substrate intact in a manner which is
non-destructive to the deposition substrate or in a manner which is
destructive to the deposition substrate.
[0060] As a non-limiting example, the method may comprise
separating the wear resistant layer from the deposition substrate
intact by moving the deposition substrate non-destructively or
destructively relative to the wear resistant layer.
[0061] As a non-limiting example, the method may comprise
separating the wear resistant layer from the deposition substrate
intact by partially or fully destroying the deposition substrate.
As a non-limiting example, the method may comprise separating the
wear resistant layer from the deposition substrate intact by
passing a fluid or other material through a substrate bore which
extends through the deposition substrate. As a non-limiting
example, the method may comprise separating the wear resistant
layer from the deposition substrate intact by causing,
facilitating, or allowing wearing of the deposition substrate. As a
non-limiting example, the method may comprise separating the wear
resistant layer from the deposition substrate intact by dissolving
the deposition substrate without dissolving the wear resistant
layer. As a non-limiting example, the method may comprise
separating the wear resistant layer from the deposition substrate
intact by melting the deposition substrate without melting the wear
resistant layer.
[0062] As a more particular non-limiting example, the deposition
substrate may define a substrate bore extending longitudinally
through the deposition substrate, the deposition substrate may be
less wear resistant than the wear resistant layer, and the method
may comprise separating the wear resistant layer from the
deposition substrate intact may comprise passing a fluid through
the substrate bore to wear the deposition substrate, thereby
exposing an wear resistant bore defined by an interior surface of
the wear resistant layer.
[0063] The method may optionally comprise separating the wear
resistant layer from the structure interface layer intact. In such
circumstances, the considerations and techniques regarding
separating the wear resistant layer from the deposition substrate
intact may also apply to separating the wear resistant layer from
the structure interface layer intact.
[0064] FIGS. 1-4 are exemplary only. The wear resistant insert
described herein may be used with any suitable structure and may be
configured in any suitable manner in order to provide wear
resistance to the structure.
[0065] In the description of non-limiting embodiments which
follows, features which are identical or equivalent in the
non-limiting embodiments may be identified with the same reference
numbers.
[0066] Referring to FIG. 1, an exemplary drilling motor (20) for
drilling a borehole (21) comprises a plurality of sections, only
some of which are depicted in FIG. 1. Depicted in FIG. 1 are a
power section (22), a transmission section (24) and a bearing
section (26). The sections of the drilling motor (20) constitute
components of a powertrain which utilizes fluid energy to rotate a
drill bit (28) connected with the distal end of the drilling motor
(20).
[0067] The sections of the drilling motor (20) are contained within
a housing (30). The housing (30) may comprise a single piece
tubular housing, or may comprise a plurality of housing sections
connected together in a suitable manner. In the exemplary drilling
motor (20) depicted in FIG. 1, the housing (30) has a generally
round cross-sectional shape.
[0068] As depicted in FIG. 1, the housing (30) comprises a
plurality of housing sections connected together end-to-end with
threaded connections, including a power section housing (32), a
transmission section housing (34), and a bearing section housing
(36). A proximal end of the power section housing (32) is connected
directly or indirectly with a drilling string (38), which extends
from a surface end (not shown) of the borehole (21) and may
comprise lengths of tubular pipe connected together or a continuous
tubular pipe. As depicted in FIG. 1, the drilling string (38) has a
generally round cross-sectional shape.
[0069] The power section (22) of the drilling motor (20) comprises
a stator (40) and a rotor (42). The stator (40) is fixedly
connected with the power section housing (32), and the rotor (42)
is rotatable within the stator (40) in response to a fluid passing
through the power section (22) between the interior surface of the
stator (40) and the exterior surface of the rotor (42).
[0070] As depicted in FIG. 1, the power section (22) is a
Moineau-type power section in which the stator (40) and the rotor
(42) are lobed. The rotor (42) has one fewer lobe than the stator
(40), and rotates within the stator (40) eccentrically relative to
the axis of the drilling motor (20).
[0071] The transmission section (24) accommodates and converts the
eccentric movement of the rotor (42) to concentric rotation of a
driveshaft (44) within the bearing section housing (34). A distal
end of the driveshaft (44) extends from a distal end of the bearing
section housing (34) and the drill bit (28) is connected directly
or indirectly with the distal end of the driveshaft (44) so that
rotation of the rotor (42) causes rotation of the drill bit
(28).
[0072] As depicted in FIG. 1, the transmission section (24)
comprises a transmission shaft (50) which is coupled between the
rotor (42) and the driveshaft (44) so that rotation of the rotor
(42) causes rotation of the transmission shaft (50), and rotation
of the transmission shaft (50) causes rotation of the driveshaft
(44). The transmission shaft (50) may be directly or indirectly
coupled with the rotor (42) and the driveshaft (44).
[0073] The transmission shaft (50) may comprise any structure,
device or apparatus which is capable of accommodating the eccentric
rotation of the rotor (42) and converting the eccentric rotation of
the rotor (42) to concentric rotation of the driveshaft (44). As
non-limiting examples, the transmission shaft (50) may comprise a
relatively rigid shaft directly or indirectly coupled with the
rotor (42) and the driveshaft (44) with articulating couplings such
as constant velocity joints or universal joints, or may comprise a
flex shaft.
[0074] As depicted in FIG. 1, the transmission shaft (50) is a
relatively rigid shaft. A proximal end (72) of the transmission
shaft (50) is connected with the rotor (42) by a proximal
articulating coupling (80), and a distal end (74) of the
transmission shaft (50) is connected with the driveshaft (44) by a
distal articulating coupling (90).
[0075] Referring to FIG. 1, the drilling motor (20) may be operated
by passing a fluid such as a drilling fluid from the surface end
(not shown) of the borehole (21) sequentially through the drilling
string (38), through the power section (22), through the
transmission section (24), through the bearing section (26), and
through the drill bit (28), following which the fluid exits the
drill bit (28) and circulates back toward the surface end (not
shown) of the borehole (21) through the annular space between the
interior surface of the borehole (21) and the exterior surface of
the drilling motor (20) and the drill string (38).
[0076] As depicted in FIG. 1, the driveshaft (44) defines a
driveshaft bore (100) and a plurality of driveshaft ports (102)
which extend between the exterior of the driveshaft (44) and the
driveshaft bore (100). The driveshaft ports (102) enable all or a
portion of the fluid passing through the bearing section (26) to
pass through the driveshaft bore (100) instead of between the
interior surface of the bearing section housing (36) and the
exterior surface of the driveshaft (44), thereby enabling the fluid
to pass through the drill bit (28) in order to lubricate the
cutting surface and flush cuttings from the cutting surface. As
depicted in FIG. 1, the driveshaft bore (100) has a generally round
cross-sectional shape.
[0077] The fluid which passes through the driveshaft bore (100) via
the driveshaft ports (102) may do so under turbulent flow
conditions because of the geometry and configuration of the
driveshaft ports (102). As a result of these turbulent flow
conditions and the composition of the fluid which passes through
the driveshaft bore (100), the driveshaft bore (100) may be
susceptible to wear due to erosion or other sources. This wear may
result in premature failure of the driveshaft (44). Because the
driveshaft bore (100) is an interior space of the driveshaft (44),
it may be difficult to provide wear resistance to the driveshaft
bore (100) directly by applying a wear resistant coating to the
driveshaft bore (100) or by surface treating the driveshaft bore
(100).
[0078] FIGS. 2-4 depict non-limiting embodiments of wear resistant
inserts (110) relating to this description.
[0079] Referring to FIG. 2, a first non-limiting embodiment of a
wear resistant insert (110) comprises a deposition substrate (112),
a wear resistant layer (114), and an optional structure interface
layer (116). The first non-limiting embodiment of the wear
resistant insert (110) also comprises additional features for
receiving and/or accommodating a seal (not shown in FIG. 2) for
providing a seal between the wear resistant insert (110) and the
structure (not shown in FIG. 2) with which the wear resistant
insert (110) is to be used.
[0080] In the first non-limiting embodiment, the deposition
substrate (112) has a three-dimensional shape. More particularly,
in the first non-limiting embodiment, the deposition substrate
(112) is an elongated member having a substantially round
cross-sectional shape and defining a substrate bore (120) which
extends longitudinally through the deposition substrate (112). The
deposition substrate (112) therefore has a substantially
cylindrical exterior surface (122) and a substantially cylindrical
interior surface (124).
[0081] In the first non-limiting embodiment, the deposition
substrate (112) is formed from a metal which is less wear resistant
from abrasion and/or erosion than the wear resistant layer (114),
but which is sufficiently dimensionally stable to avoid significant
deformation during formation of the wear resistant insert
(110).
[0082] In the first non-limiting embodiment, the deposition
substrate (112) is more particularly an elongated tube constructed
from 4140 steel and/or 4145 steel.
[0083] In the first non-limiting embodiment, the wear resistant
layer (114) is deposited directly on the exterior surface (122) of
the deposition substrate (112) by laser cladding or by a suitable
alternate process or combination of suitable processes such as
plasma transferred arc (PTA) spraying, high velocity oxy-fuel
(HVOF) spraying, or high velocity air fuel (HVAF) spraying.
[0084] In the first non-limiting embodiment, the wear resistant
layer (114) comprises tungsten carbide, chromium carbide, boron
carbide, a nickel or cobalt based alloy matrix, and/or a
cobalt/nickel chromium alloy as a wear resistant material.
[0085] In the first non-limiting embodiment, the wear resistant
layer (114) has a three-dimensional shape as a result of being
deposited on the substantially cylindrical exterior surface (122)
of the deposition substrate (112). More particularly, in the first
non-limiting embodiment, the wear resistant layer (114) is an
elongated tube having a generally round interior surface (130)
which defines a wear resistant bore (132), a generally round
exterior surface (134) and a thickness (136).
[0086] In the first non-limiting embodiment, the optional structure
interface layer (116) is deposited directly on the exterior surface
(134) of the wear resistant layer (114) by a suitable process or
combination of processes such as cladding or spraying.
[0087] In the first non-limiting embodiment, the structure
interface layer (116) has a three-dimensional shape as a result of
being deposited on the substantially cylindrical exterior surface
(134) of the wear resistant layer (114). More particularly, in the
first non-limiting embodiment, the structure interface layer (116)
is an elongated tube having a generally round interior surface
(140) which defines a wear resistant bore (142), a generally round
exterior surface (144) and a thickness (146).
[0088] In the first non-limiting embodiment, the structure
interface layer (116) is constructed of a metal such as 625 nickel
alloy. The 625 nickel alloy of the structure interface layer (116)
provides structural support to the tungsten carbide based wear
resistant layer (114) as the 4140 steel and/or the 4145 steel of
the deposition substrate (112) erodes or as the wear resistant
layer (114) is otherwise separated from the deposition substrate
(112).
[0089] In more general terms, the specific materials, fabrication
processes, dimensions, and configuration of the wear resistant
insert (110) and of the deposition substrate (112), the wear
resistant layer (114), and the structure interface layer (116) may
all be selected to be compatible with the structure with which the
wear resistant insert (110) is to be used.
[0090] As a non-limiting example, the thickness (136) of the wear
resistant layer (114) may be selected to provide a desired duration
of wear resistance. As a non-limiting example, the structure
interface layer (116) may be deposited on the exterior surface
(134) of the wear resistant layer (114) so that the exterior
surface (144) of the structure interface layer (116) has a desired
fit within the structure with which the wear resistant insert (110)
is to be used. As a non-limiting example, the material from which
the structure interface layer (116) is constructed may be selected
based upon the intended purpose or combination of purposes of the
structure interface layer (116), and/or based upon the materials
from which the intended structure is constructed.
[0091] In the first non-limiting embodiment, the structure (not
shown in FIG. 2) with which the wear resistant insert (110) is used
may define an interior space (not shown in FIG. 2) comprising a
bore (not shown in FIG. 2), and the wear resistant insert (110) may
be configured to be inserted within the bore (not shown in FIG. 2)
of the structure (not shown in FIG. 2).
[0092] In the first non-limiting embodiment, the additional
features of the wear resistant insert (110) comprise a groove (148)
for receiving an 0-ring seal (not shown in FIG. 2) for providing a
seal between the wear resistant insert (110) and the structure (not
shown in FIG. 2) with which the wear resistant insert (110) is to
be used.
[0093] In the first non-limiting embodiment, the groove (148) may
be provided only in the structure interface layer (116), the groove
(148) may be provided in both the structure interface layer (116)
and the wear resistant layer (112), or the groove (148) may be
provided in all of the structure interface layer (116), the wear
resistant layer (114), and the deposition substrate (112). The
groove (148) may be defined in the deposition substrate (112)
before the wear resistant layer (114) and the structure interface
layer (116) are deposited, or the groove (148) may be formed in the
deposition substrate (112), the wear resistant layer (114) and/or
the structure interface layer (116) by machining or some other
suitable process after the wear resistant layer (114) and the
structure interface layer (116) are deposited.
[0094] Referring to FIG. 3, a second non-limiting embodiment of a
wear resistant insert (110) comprises a deposition substrate (112),
a wear resistant layer (114), and an optional structure interface
layer (116). The second non-limiting embodiment of the wear
resistant insert (110) also comprises additional features for
receiving fastening devices and for accommodating features of the
structure (not shown in FIG. 3) with which the wear resistant
insert (110) is used.
[0095] The description of the second non-limiting embodiment of the
wear resistant insert (110) is limited to the differences between
the second non-limiting embodiment and the first non-limiting
embodiment, as described above.
[0096] In the second non-limiting embodiment, the additional
features of the wear resistant insert (110) comprise a slot (150)
for receiving a key (not shown) as a fastening device for
inhibiting rotation of the wear resistant insert (110) relative to
the structure (not shown in FIG. 3) with which the wear resistant
insert (110) is used, and a plurality of circumferentially spaced
ports (152) extending radially through the wear resistant insert
(110) to accommodate features of the structure (not shown in FIG.
3) with which the wear resistant insert (110) is to be used.
[0097] In the second non-limiting embodiment, the slot (150) may be
provided only in the structure interface layer (116), the slot
(150) may be provided in both the structure interface layer (116)
and the wear resistant layer (112), or the slot (150) may be
provided in all of the structure interface layer (116), the wear
resistant layer (114), and the deposition substrate (112). The slot
(150) may be defined in the deposition substrate (112) before the
wear resistant layer (114) and the structure interface layer (116)
are deposited, or the slot (152) may be formed in the deposition
substrate (112), the wear resistant layer (114) and/or the
structure interface layer (116) by machining or some other suitable
process after the wear resistant layer (114) and the structure
interface layer (116) are deposited.
[0098] In the second non-limiting embodiment, the ports (152) may
be defined in the deposition substrate (112) before the wear
resistant layer (114) and the structure interface layer (116) are
deposited, or the ports (152) may be formed in the deposition
substrate (112), the wear resistant layer (114) and/or the
structure interface layer (116) by machining or some other suitable
process after the wear resistant layer (114) and the structure
interface layer (116) are deposited. In the second non-limiting
embodiment, the ports (152) are provided to accommodate similar
features which are provided on the structure (not shown in FIG. 3)
with which the wear resistant insert (110) is to be used.
[0099] Referring to FIG. 4, a third non-limiting embodiment of a
wear resistant insert (110) comprises a deposition substrate (112),
a wear resistant layer (114), and an optional structure interface
layer (116). The third non-limiting embodiment of the wear
resistant insert (110) also comprises an additional feature for
accommodating features of the structure with which the wear
resistant insert (110) is used. The third non-limiting embodiment
of the wear resistant insert (110) may optionally also comprise one
or more additional features (not shown in FIG. 4) for receiving
fastening devices (not shown in FIG. 4), and/or for receiving
and/or accommodating one or more seals (not shown in FIG. 4) for
providing a seal between the wear resistant insert (110) and the
structure with which the wear resistant insert (110) may be used.
As depicted in FIG. 4, the structure is a drilling motor (20) of
the general type depicted in FIG. 1, and the wear resistant insert
(110) is installed in an interior space of the drilling motor (20),
more particularly the driveshaft bore (100) of the driveshaft (44)
of the drilling motor (20).
[0100] The description of the third non-limiting embodiment of the
wear resistant insert (110) and the drilling motor (20) depicted in
FIG. 4 is limited to the differences between the wear resistant
insert (110) and the drilling motor (20) depicted in FIG. 4, and
the wear resistant inserts (110) and the drilling motor (20)
depicted in FIGS. 1-3.
[0101] In the third non-limiting embodiment, the wear resistant
insert (110) is formed before it is installed in the drilling motor
(20) by providing the deposition substrate (112), depositing the
wear resistant layer (114) on the exterior surface (122) of the
deposition substrate (112), and depositing the optional structure
interface layer (116) on the exterior surface (134) of the wear
resistant layer (114).
[0102] In the third non-limiting embodiment, the additional feature
of the wear resistant insert (110) for accommodating features of
the drilling motor (20) comprises a plurality of angled ports (160)
which extend from a proximal end (162) of the wear resistant insert
(110) obliquely toward a distal end (164) of the wear resistant
insert (110), which effectively provide angled "cutouts" in the
proximal end (162) of the wear resistant insert (110). The angled
ports (160) are configured to correspond with the driveshaft ports
(102) in the driveshaft (44) of the drilling motor (20) and to
provide a smooth transition between the driveshaft ports (102) and
the driveshaft bore (100) when the wear resistant insert (110) is
installed in the driveshaft bore (100).
[0103] In the third non-limiting embodiment, the angled ports (160)
may be defined in the deposition substrate (112) before the wear
resistant layer (114) and the structure interface layer (116) are
deposited, or the angled ports (160) may be formed in the
deposition substrate (112), the wear resistant layer (114) and the
structure interface layer (116) by machining or some other suitable
process after the wear resistant layer (114) and the structure
interface layer (116) are deposited. Since the angled ports (160)
comprise oblique sidewalls, forming the angled ports (160) after
the wear resistant layer (114) and the structure interface layer
(116) have been deposited may be preferred.
[0104] Referring again to FIG. 4, after the wear resistant insert
(110) has been formed, the wear resistant insert (110) may be
installed in the driveshaft bore (100) of the driveshaft (44) of
the drilling motor (20) by inserting the proximal end (162) of the
wear resistant insert (110) into a distal end (170) of the
driveshaft bore (100) and sliding the wear resistant insert (110)
into the driveshaft bore (100) until the angled ports (162) of the
wear resistant insert (110) align with the driveshaft ports (102)
in the driveshaft (44).
[0105] Alternatively and/or optionally, after the wear resistant
insert (110) has been formed, the wear resistant layer (114) may be
separated from the structure interface layer (116) intact before
the wear resistant insert (110) is installed in the driveshaft bore
(100) of the driveshaft (44).
[0106] After the wear resistant insert (110) has been inserted into
the driveshaft bore (100) so that the angled ports (162) align with
the driveshaft ports (102), the wear resistant insert (110) may be
fastened to the driveshaft (44) and thus the drilling motor
(20).
[0107] In this regard, in the third non-limiting embodiment, the
optional one or more additional features (not shown in FIG. 4) for
receiving fastening devices (not shown in FIG. 4), and/or for
receiving and/or accommodating one or more seals (not shown in FIG.
4) may comprise holes, slots and/or grooves or any other suitable
feature or combination of features. In the third non-limiting
embodiment, the optional one or more additional features (not shown
in FIG. 4) may correspond to complementary features (not shown in
FIG. 4) in or on the driveshaft (44) of the drilling motor (20)
which facilitate fastening of the wear resistant insert (110) to
the driveshaft (44).
[0108] The optional one or more additional features (not shown in
FIG. 4) for receiving fastening devices (not shown in FIG. 4),
and/or for receiving and/or accommodating one or more seals (not
shown in FIG. 4) may be provided only in the structure interface
layer (116), in both the structure interface layer (116) and the
wear resistant layer (112), or in all of the structure interface
layer (116), the wear resistant layer (114), and the deposition
substrate (112). The optional one or more additional features may
be defined in the deposition substrate (112) before the wear
resistant layer (114) and the structure interface layer (116) are
deposited, or the optional one or more additional features may be
formed in the deposition substrate (112), the wear resistant layer
(114) and/or the structure interface layer (116) by machining or
some other suitable process after the wear resistant layer (114)
and the structure interface layer (116) are deposited.
[0109] As a result, in the third non-limiting embodiment, fastening
the wear resistant insert (110) to the driveshaft (44) may comprise
fastening the wear resistant insert (110) to the driveshaft (44)
with one or more suitable fastening devices (not shown in FIG. 4),
which may be facilitated by one or more optional additional
features (not shown in FIG. 4) on the wear resistant insert (110)
and complementary features (not shown in FIG. 4) in or on the
driveshaft (44).
[0110] Alternatively, in the third non-limiting embodiment and as
depicted in FIG. 4, the wear resistant insert (110) may be fastened
to the driveshaft (44) of the drilling motor (20) by welding,
brazing, soldering, gluing, and/or by providing an interference fit
between the wear resistant insert (110) and the driveshaft
(44).
[0111] After the wear resistant insert (110) has been fastened to
the driveshaft (44) of the drilling motor (20), the wear resistant
layer (114) may be separated from the deposition substrate (112)
intact, in order to expose the wear resistant bore (132) of the
wear resistant layer (114) within the driveshaft bore (100).
[0112] In the third non-limiting embodiment, the wear resistant
layer (114) may be separated from the deposition substrate (112)
intact in a manner which is destructive to the deposition substrate
(112), by partially or fully destroying the deposition substrate
(112) while leaving the wear resistant layer (114) intact. More
particularly, in the third non-limiting embodiment, the deposition
substrate (112) is less wear resistant than the wear resistant
layer (114) so that the deposition substrate (112) may be destroyed
by wearing of the deposition substrate (112). Even more
particularly, in the third non-limiting embodiment, the deposition
substrate (112) may be partially or fully destroyed by passing a
fluid through the substrate bore (120) in order to wear, dissolve,
melt or otherwise destroy the deposition substrate (112) while
leaving the wear resistant layer (114) intact.
[0113] Additional Disclosures
[0114] The following are non-limiting, specific embodiments of the
wear resistant insert, the method of forming the wear resistant
insert, and the method of installing the wear resistant insert as
described herein:
Embodiment A
[0115] A wear resistant insert, comprising: [0116] (a) a deposition
substrate having an exterior surface; and [0117] (b) a wear
resistant layer comprising a wear resistant material deposited on
the exterior surface of the deposition substrate.
Embodiment B
[0118] The wear resistant insert of Embodiment A wherein the wear
resistant layer has an interior surface which defines a wear
resistant bore of the wear resistant layer and wherein the wear
resistant layer is separable from the deposition substrate intact
in order to expose the wear resistant bore.
Embodiment C
[0119] The wear resistant insert of Embodiment A or B wherein the
deposition substrate is destroyable while leaving the wear
resistant layer intact so that the wear resistant layer is
separable intact from the deposition substrate by destroying the
deposition substrate.
Embodiment D
[0120] The wear resistant insert of Embodiment C wherein the
deposition substrate is less wear resistant than the wear resistant
layer so that the deposition substrate is destroyed by wearing of
the deposition substrate.
Embodiment E
[0121] The wear resistant insert of Embodiment C or D wherein the
deposition substrate is dissolvable without dissolving the wear
resistant layer so that the deposition substrate is destroyed by
dissolving the deposition substrate.
Embodiment F
[0122] The wear resistant insert of any one of Embodiments C
through E wherein the deposition substrate is meltable without
melting the wear resistant layer so that the deposition substrate
is destroyed by melting the deposition substrate.
Embodiment G
[0123] The wear resistant insert of any one of Embodiments A
through F wherein the wear resistant layer is deposited on the
deposition substrate by immersion, electrodeposition, electroless
deposition, welding, cladding, spraying, vapour deposition,
additive manufacturing, or a combination thereof
Embodiment H
[0124] The wear resistant insert of any one of Embodiments A
through G wherein the wear resistant material is a non-metallic
crystalline material, a carbide, a nitride, an alloy, or a
combination thereof.
Embodiment I
[0125] The wear resistant insert of any one of Embodiments A
through H wherein the deposition substrate is an elongated member
and wherein the wear resistant layer is deposited on the exterior
surface of the deposition substrate as an elongated tube.
Embodiment J
[0126] The wear resistant insert of any one of Embodiments A
through I wherein the deposition substrate defines a substrate bore
extending longitudinally through the deposition substrate.
Embodiment K
[0127] The wear resistant insert of any one of Embodiments A
through J wherein the wear resistant layer has an exterior surface,
further comprising a structure interface layer deposited on the
exterior surface of the wear resistant layer.
Embodiment L
[0128] The wear resistant insert of Embodiment K wherein the
structure interface layer is machinable.
Embodiment M
[0129] The wear resistant insert of Embodiment K or L wherein the
structure interface layer is non-porous.
Embodiment N
[0130] A method of forming a wear resistant insert, comprising:
[0131] (a) providing a deposition substrate, wherein the deposition
substrate has an exterior surface; and [0132] (b) depositing a wear
resistant layer on the exterior surface of the deposition
substrate, wherein the wear resistant layer comprises a wear
resistant material.
Embodiment O
[0133] The method of Embodiment N wherein depositing the wear
resistant layer on the exterior surface of the deposition substrate
comprises depositing the wear resistant layer by immersion,
electrodeposition, electroless deposition, welding, cladding,
spraying, vapour deposition, additive manufacturing, or a
combination thereof
Embodiment P
[0134] The method of Embodiment N or 0 wherein the wear resistant
material is a non-metallic crystalline material, a carbide, a
nitride, an alloy, or a combination thereof.
Embodiment Q
[0135] The method of any one of Embodiments N through P, further
comprising separating the wear resistant layer from the deposition
substrate intact.
Embodiment R
[0136] The method of any one of Embodiments N through Q wherein the
wear resistant layer has an exterior surface, further comprising
depositing a structure interface layer on the exterior surface of
the wear resistant layer.
Embodiment S
[0137] The method of Embodiment R, further comprising providing at
least one hole, slot or groove in the structure interface
layer.
Embodiment T
[0138] The method of Embodiment S wherein providing at least one
hole, slot or groove in the structure interface layer comprises
machining the structure interface layer.
Embodiment U
[0139] The method of any one of Embodiments N through T, further
comprising installing the wear resistant insert in an interior
space of a structure.
Embodiment V
[0140] The method of Embodiment U, further comprising separating
the wear resistant layer from the deposition substrate intact after
installing the wear resistant insert in the interior space of the
structure.
Embodiment W
[0141] The method of Embodiment V wherein separating the wear
resistant layer from the deposition substrate intact comprises
destroying the deposition substrate.
Embodiment X
[0142] The method of any one of Embodiments U through W wherein the
deposition substrate is an elongated member, wherein the interior
space of the structure is a bore defined by the structure, and
wherein installing the wear resistant insert in the interior space
of the structure comprises inserting the wear resistant insert in
the bore of the structure.
Embodiment Y
[0143] The method of Embodiment X, further comprising fastening the
wear resistant insert to the structure after the wear resistant
insert has been inserted in the bore of the structure.
Embodiment Z
[0144] The method of any one of Embodiments V through Y wherein the
deposition substrate defines a substrate bore extending
longitudinally through the deposition substrate and wherein
separating the wear resistant layer from the deposition substrate
intact comprises passing a fluid through the substrate bore in
order to destroy the deposition substrate.
Embodiment AA
[0145] The method of any one of Embodiments N through Z wherein the
structure is a structure for use in a borehole.
Embodiment BB
[0146] The method of any one of Embodiments N through AA wherein
the structure is a drilling motor for use in drilling a
borehole.
[0147] In this document, the word "comprising" is used in its
non-limiting sense to mean that items following the word are
included, but items not specifically mentioned are not excluded. A
reference to an element by the indefinite article "a" does not
exclude the possibility that more than one of the elements is
present, unless the context clearly requires that there be one and
only one of the elements.
* * * * *