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.

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows: 
     
         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.