Process for manufacturing a bearing

A process for manufacturing a wear surface the process comprising the steps of:

• a) providing a structure having a first surface and a second surface, the second surface opposing the first surface;
• b) applying a hard facing material on the first surface of the structure so that the hard facing material is fixed to the first surface of the structure;
• c) applying a material layer over the hard facing material so that the material layer is fixed to the hard facing material;
• d) controlled cooling the hard facing material from a process temperature of about 3500 degrees Fahrenheit to a temperature of 200 degrees Fahrenheit in a material specific time period in the range of two to five minutes;
• e) machining the structure so that a portion of the material layer is removed;
• and
• f) machining the second surface of the structure to expose the hard facing material in order to form a wear surface.

A process for manufacturing a bearing comprising the steps of:

• a) providing a tubular sleeve having a first inner surface and a first outer surface;
• b) applying a hard facing material on the first outer surface of the tubular sleeve so that the hard facing material is fused onto the first outer surface of the tubular sleeve to form a second outer surface of the tubular sleeve;
• c) applying a material layer on the second outer surface of the tubular sleeve so that the material layer is fused onto the second outer surface to form a third outer surface of the tubular sleeve;
• d) controlled cooling the hard facing material from a process temperature of about 3500 degrees Fahrenheit to a temperature of 200 degrees Fahrenheit in a material specific time period in the range of two to five minutes;
• e) machining the third outer surface of the tubular sleeve so that a portion of the material layer is removed;
• and
• f) machining the first inner surface of the tubular sleeve to form a second inner surface, said second inner surface composed of the hard facing material.

A process for manufacturing a radial bearing for use in a down hole mud motor, the process comprising:

• a) providing a tubular sleeve having a first inner surface and a first outer surface;
• b) fusing a hard facing material on the first outer surface of the tubular sleeve to form a second outer surface of the tubular sleeve;
• c) fusing a material layer on the second outer surface of the tubular sleeve to form a third outer surface of the tubular sleeve;
• d) controlled cooling the hard facing material from a process temperature of about 3500 degrees Fahrenheit to a temperature of 200 degrees Fahrenheit in a material specific time period in the range of two to five minutes;
• e) machining the third outer surface of the tubular sleeve so that a portion of the material layer is removed;
• f) machining the first inner surface of the tubular sleeve to form a second inner surface of the tubular sleeve, said second inner surface composed of the hard facing material;
• g) cutting the length of the tubular sleeve;
• h) machining the third outer surface of the tubular sleeve;
• i) machining the second inner surface of the tubular sleeve in order to form the radial bearing;
• j) placing the radial bearing into a housing;
• and
• k) inserting a mandrel into the radial bearing, said mandrel having an outer surface, and wherein said outer surface has a hard coating so that the hard coating of the mandrel abuts the radial bearing.