BACKGROUND

Wear-resistant, superhard compacts are utilized in a variety of mechanical applications. For example, polycrystalline diamond compacts (“PDCs”) are used in drilling tools (e.g., cutting elements, gage trimmers, etc.), machining equipment, bearing apparatuses, wire-drawing machinery, and in other mechanical apparatuses.

PDCs and other superhard compacts have found particular utility as superhard bearing elements in thrust bearings within pumps, turbines, subterranean drilling systems, motors, compressors, generators, gearboxes, and other systems and apparatuses. For example, a PDC bearing element typically includes a superhard diamond layer that is commonly referred to as a diamond table. The diamond table is formed and bonded to a substrate using a high-pressure/high-temperature (“HPHT”) process.

Despite the availability of a number of different bearing apparatuses including such PDCs and/or other superhard materials, manufacturers and users of bearing apparatuses continue to seek bearing apparatuses that exhibit improved performance characteristics, lower cost, or both.

SUMMARY

Embodiments disclosed herein are directed to bearing assemblies, related bearing apparatuses, and related methods. In an embodiment, a bearing assembly is disclosed. The bearing assembly includes a support structure having a first end and a second end. The support structure defines a support structure conduit extending from the second end to the first end. The bearing assembly also includes a superhard bearing element secured to the support structure. The superhard bearing element includes a superhard sealing surface, a base surface, at least one lateral surface extending between the superhard sealing surface and the base surface, at least one interior surface extending between the superhard sealing surface to the base surface, and a plurality of fins. The at least one interior surface defines a bearing element conduit coupled to the support structure conduit. The plurality of fins are separated from each other by a plurality of grooves formed in at least one of the at least one lateral surface, the interior surface, or the support structure.

In an embodiment, a bearing assembly is disclosed. The bearing assembly includes a support structure having a first end and a second end. The support structure defines a support structure conduit extending from the second end to the first end. The bearing assembly also includes a superhard bearing element secured to the support structure. The superhard bearing element includes an at least partially leached polycrystalline diamond table defining a superhard sealing surface. The at least partially leached polycrystalline diamond table includes a leached region extending inwardly from the superhard sealing surface. The superhard bearing elements also includes a base surface, at least one lateral surface extending between the superhard sealing surface and the base surface, and at least one interior surface extending between the superhard sealing surface to the base surface. The at least one interior surface defines a bearing element conduit coupled to the support structure conduit.

In an embodiment, a bearing assembly is disclosed. The bearing assembly includes a support structure having a first end and a second end. The support structure defines a support structure conduit extending from the second end to the first end. The support structure defines a recess at the first end thereof. The bearing assembly also includes a superhard bearing element at least partially disposed in and press-fit or brazed in the recess. The superhard bearing element includes a superhard sealing surface, a base surface, at least one lateral surface extending between the superhard sealing surface and the base surface, and at least one interior surface extending between the superhard sealing surface to the base surface. The at least one interior surface defines a bearing element conduit coupled to the support structure conduit.

In an embodiment, a bearing assembly is disclosed. The bearing assembly includes a support structure having a first end and a second end. The support structure defines a support structure conduit extending from the second end to the first end. The bearing assembly also includes a superhard bearing element secured to the support structure. The superhard bearing element includes a superhard sealing surface exhibiting a surface roughness, in root mean square, of about 5 μm to about 40 μm, a base surface, at least one lateral surface extending between the superhard sealing surface and the base surface, and at least one interior surface extending between the superhard sealing surface to the base surface. The at least one interior surface defines a bearing element conduit coupled to the support structure conduit.

In an embodiment, a bearing apparatus is disclosed. The bearing apparatus includes a stator bearing assembly and a rotor bearing assembly that contacts and is configured to rotate relative to the stator bearing assembly. At least one of the stator bearing assembly or the rotor bearing assembly is any one of the bearing assemblies disclosed herein.

In an embodiment, a method of operating a bearing apparatus is disclosed. The method includes rotating a rotor bearing assembly relative to a stator bearing assembly. The rotor bearing assembly includes a rotor support structure and a rotor bearing element secured to the rotor support structure. The stator bearing assembly includes a stator support structure and a stator bearing element secured to the stator support structure. The rotor bearing element includes a first superhard sealing surface and the stator bearing element including a second superhard sealing surface. The first superhard sealing surface contacts and the second superhard sealing surface. The method also includes flowing a fluid through each of a stator support structure conduit defined by at least one inner support structure surface of the stator support structure, a stator bearing element conduit that is defined by at least one stator interior surface of the second superhard bearing element, a rotor support structure conduit defined by at least one inner support structure surface of the rotor support structure, and a rotor bearing element conduit that is defined by at least one rotor interior surface of the first superhard bearing element. The stator bearing element conduit extends between the second superhard sealing surface and the stator base surface and the rotor bearing element conduit extends between the first superhard sealing surface and the rotor base surface.

Features from any of the disclosed embodiments may be used in combination with one another, without limitation. In addition, other features and advantages of the present disclosure will become apparent to those of ordinary skill in the art through consideration of the following detailed description and the accompanying drawings.

