CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims benefit of U.S. provisional patent application Serial No. 62/794,218, filed January 18, 2019, and entitled“Composite Metal -to-Metal Progressive Cavity Pump,” which is hereby incorporated herein by reference in its entirety for all purposes.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002] Not applicable.

TECHNICAL FIELD

[0003] The present disclosure relates generally to positive-displacement devices that include rotors rotatably disposed in stators; still more particularly, the present disclosure relates to stators and rotors for progressive cavity pumps (PCP); still more particularly, the present disclosure relates to stators and rotors formed from a stack of laminates; still more particularly, the present disclosure relates to the method of assembling individual laminates or stacks of laminates together to form a rotor or a stator.

BACKGROUND

[0004] A progressive cavity pump (PC pump or PCP) transfers fluid by means of a sequence of discrete cavities that move through the pump as a rotor is turned within a stator. The transfer of fluid in this manner results in a volumetric flow rate proportional to the rotational speed of the rotor within the stator, as well as relatively low levels of shearing applied to the fluid. Consequently, progressive cavity pumps are typically used in fluid metering and pumping of viscous or shear sensitive fluids, particularly in downhole operations for the ultimate recovery of oil and gas. Progressive cavity pumps may also be referred to as PC pumps, progressing cavity pumps, "Moineau" pumps, eccentric screw pumps, or cavity pumps.

[0005] A PC pump may be used in reverse as a progressive cavity motor (PC motor) by passing fluid through the cavities between the rotor and stator to power the rotation of the rotor relative to the stator, thereby converting the hydraulic energy of a high pressure fluid into mechanical energy in the form of speed and torque output, which may be harnessed for a variety of applications, including downhole drilling. Progressive cavity motors may also be referred to as positive displacement motors (PD motors), eccentric screw motors, or cavity motors. PD motors, or simply mud motors, are used in the directional drilling of oil and gas wells.

[0006] Progressive cavity devices (e.g., progressive cavity pumps and motors) include a stator having a helical internal bore and a helical rotor rotatably disposed within the stator bore. Conventional stators often comprise a radially outer tubular housing and a radially inner component disposed within the housing. The inner component may include a cylindrical outer surface that is bonded to the cylindrical inner surface of the housing and a helical inner surface that defines the helical bore of the stator. Alternatively, the stator may comprise a single integral component. Conventional rotors often comprise a steel tube or rod having a helical- shaped outer surface, which may be chrome-plated or coated for wear and corrosion resistance. The helical internal bore defines lobes on the inner surface of the stator and the helical-shaped outer surface of the rotor defines at least one lobe on the outer surface of the rotor. In general, the rotor may have one or more lobes. To satisfy the fundamental gear tooth law, the stator will have one more lobe than the rotor.

[0007] When the rotor and stator are assembled, the rotor and stator lobes intermesh to form a series of cavities. More specifically, an interference fit between the helical outer surface of the rotor and the helical inner surface of the stator results in a plurality of circumferentially spaced hollow cavities in which fluid can travel. During rotation of the rotor, these hollow cavities advance from one end of the stator towards the other end of the stator. Each cavity is sealed from adjacent cavities by the interference fit creating a continuous contact line between the rotor and the stator by said interference. For example, during downhole drilling operations, drilling fluid or mud is pumped through the PD motor as the sealed cavities progressively open and close to accommodate the circulating mud. Pressure differentials across adjacent cavities exert forces on the rotor that causes the rotor to rotate within the stator. The centerline of the rotor is typically offset from the center of the stator so that the rotor rotates within the stator on an eccentric orbit. The amount of torque generated by the power section depends on the cavity volume, pressure differential, and fluid density.

BRIEF SUMMARY OF THE DISCLOSURE

[0008] Herein disclosed is a progressive cavity pump or motor, comprising: a stator comprising: a stator assembly having a radially outer surface and a radially inner surface defining a helical-shaped stator through-bore extending axially through the stator about a central axis; and a rotor disposed within the helical-shaped stator through-bore and configured for rotation in the stator through-bore; wherein: (a) the stator assembly comprises one or a plurality of stacks of laminates, wherein each stack of laminates comprises (i) a plurality of first laminates comprising a first material dispersed among a plurality of second laminates comprising a second material, wherein the second material has a higher wear resistance than the first material, (ii) a plurality of laminates comprising a composite matrix of a first material and a second material, wherein the second material is a filler having a higher wear resistance than the first material, (iii) a combination of (i) and (ii), or (iv) solely laminates comprising a second material, wherein the second material has a higher wear resistance than a first material, and wherein the first material comprises steel; (b) the rotor comprises a stack of laminates; or (c) both (a) and (b).

[0009] Also disclosed herein is a stator for a progressive cavity pump or motor, comprising: a stator assembly having a radially outer surface, and a radially inner surface defining a helical shaped through-bore extending axially through the stator about a central axis, wherein the stator assembly comprises one or a plurality of stacks of laminates, wherein each stack of laminates comprises: (i) a plurality of first laminates comprising a first material dispersed among a plurality of second laminates comprising a second material, wherein the second material has a higher wear resistance than the first material, (ii) a plurality of laminates comprising a composite matrix of a first material and a second material, wherein the second material is a filler having a higher wear resistance than the first material, (iii) a combination of (i) and (ii), or (iv) solely laminates comprising a second material, wherein the second material has a higher wear resistance than a first material, and wherein the first material comprises steel.

[0010] Further disclosed herein is a method of forming a stator or a rotor component of a progressive cavity pump, the method comprising: providing a plurality of laminates; stacking the plurality of laminates to form a stack of laminates; and binding the laminates together to form the stator or the rotor component, wherein the stack of laminates comprises (i) a plurality of first laminates comprising a first material dispersed among a plurality of second laminates comprising a second material, wherein the second material has a higher wear resistance than the first material (ii) a plurality of laminates comprising a composite matrix of a first material and a second material, wherein the second material is a filler having a higher wear resistance than the first material, (iii) a combination of (i) and (ii), or (iv) solely laminates comprising a second material, wherein the second material has a higher wear resistance than a first material, and wherein the first material comprises steel.

[0011] Also disclosed herein is a rotor for a progressive cavity pump or motor, comprising: a stack of laminates. [0012] Further disclosed herein is a method of forming a rotor of a progressive cavity pump, the method comprising: providing a plurality of laminates; stacking the plurality of laminates to form a stack of laminates; and binding the laminates together to form the rotor.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] For a detailed description of disclosed embodiments, reference will now be made to the accompanying drawings in which:

[0014] Figure 1 is a schematic partial cross-sectional view of a production system in accordance with principles disclosed herein;

[0015] Figure 2 is a perspective, partial cut-away view of an embodiment of a pump of the production system of Figure 1 in accordance with principles disclosed herein;

[0016] Figure 3 is a cross-sectional end view of the pump of Figure 2;

[0017] Figure 4A is a schematic of a composite stack of laminates in which a wear resistant material is incorporated at a macroscopic level via the interdispersion of laminates of dissimilar materials (e.g., a base material, a wear resistant material), according to an embodiment of this disclosure;

[0018] Figure 4B is a schematic of a composite stack 59 of laminates 101 of a composite material 62C in which a wear resistant material is incorporated at a microscopic level via alteration of the metallurgy of a base material via integration of the wear resistant material into the matrix of the base material at a microscopic level, according to an embodiment of this disclosure;

[0019] Figure 5 is a schematic of a bi-material composite laminate stack 59, according to an embodiment of this disclosure;

[0020] Figure 6 is a schematic of a composite stack 59 with binder material 61 on the edges 60 of the laminates or on an inner diameter (ID) of an outer tubular or casing 51 to support the binding of the laminate stack(s) 59 to the outer casing 51;

[0021] Figure 7 is a schematic of a stack 59 of laminates 101 having a fiberglass winding 51A therearound to bind the laminates together directly forming the outer casing to constrain the laminates with each other while ensuring the stack 59 can hold internally applied pressure (sealed volumes);

[0022] Figure 8A and Figure 8B are schematics of a stator 50, according to embodiments of this disclosure; and

[0023] Figure 9 is a block flow diagram of a method 200 of providing a rotor 80 or a stator 50 of a progressive cavity pump 40, according to an embodiment of this disclosure. DETAILED DESCRIPTION OF DISCLOSED EXEMPLARY EMBODIMENTS

[0024] The following discussion is directed to various embodiments. However, one skilled in the art will understand that the examples disclosed herein have broad application, and that the discussion of any embodiment is meant only to be exemplary of that embodiment, and not intended to suggest that the scope of the disclosure, including the claims, is limited to that embodiment. The drawing figures are not necessarily to scale. Certain features and components herein may be shown exaggerated in scale or in somewhat schematic form and some details of conventional elements may not be shown in interest of clarity and conciseness.

[0025] In the following discussion and in the claims, the terms "including" and "comprising" are used in an open-ended fashion, and thus should be interpreted to mean "including, but not limited to... ." Also, the term "couple" or "couples" is intended to mean either an indirect or direct connection. Thus, if a first device couples to a second device, that connection may be through a direct connection, or through an indirect connection as accomplished via other devices, components, and connections. In addition, as used herein, the terms "axial" and "axially" generally mean along or parallel to a central axis (e.g., central axis of a body or a port), while the terms "radial" and "radially" generally mean perpendicular to the central axis. For instance, an axial distance refers to a distance measured along or parallel to the central axis, and a radial distance means a distance measured perpendicular to the central axis. Any reference to up or down in the description and the claims is made for purposes of clarity, with “up”, “upper”, “upwardly”, “uphole”, or“upstream” meaning toward the surface of the borehole and with“down”,“lower”,“downwardly”,“downhole”, or“downstream” meaning toward the terminal end of the borehole, regardless of the borehole orientation.

[0026] As used herein, the word "unitary" means a component that is created as a single piece or unit. That is, a component that includes pieces that are created separately and then coupled together as a unit is not a "unitary" component or body.

[0027] As used herein, a "planar body" or "planar member" is generally a thin element including opposed, wide, generally parallel surfaces as well as a thinner edge surface extending between the wide parallel surfaces. The perimeter, and therefore the edge surface, may include generally straight portions, e.g., as on a rectangular planar member, or may be curved, as on a disk, or have any other shape. Further, a "unitary planar member" includes all of a construction generally disposed in a similar plane.

[0028] As used herein, "about" used in the context of "disposed about [an element or axis]" or "extend about [an element or axis]" means encircle or extend around. [0029] As used herein,“laminated” means formed from a plurality of thin layers (e.g., thin laminates as described hereinbelow).

Overview

[0030] Demanding thermal applications require the use of innovative technology similar to traditional PCPs but where the stators are fully built from a carbon or stainless steel alloy. This is known as a Metal-to-Metal (MTM) solution, and such a pump may be referred to herein as a MTM pump. As utilized herein, a“pump” refers to an apparatus comprising a paired stator and rotor.

[0031] Disclosed herein is a method of combining“laminates” to build a high temperature PCP stator, and a stator so formed. The herein disclosed method may also be utilized to provide a PCP rotor.

[0032] Traditional PCPs are based around an elastomer compound injected into a carbon steel tube and typically deployed in“low temperature” oil wells or wells which do not have a high concentration of aromatic oils. For higher temperature and/or stimulated wells and/or reservoirs producing high aromatic oils, Metal-to-Metal (MTM) PCP technology is a possible alternative.

[0033] Due to the elastomer compound on traditional PCPs, this technology typically has a high resistance to wear, erosion and abrasion, because the elastomer deforms to accept solids or compression. Due to the limited elasticity of MTM stators, due to both the manufacturing process and the selection of materials, wear by erosion and abrasion is a concern as such wear can affect pump performance and run life.

[0034] Herein disclosed is a stator or rotor comprising thin (e.g., 20-25 thousandths or‘thou’ thickness) laminates joined together individually or in stacks. Dissimilar materials are utilized to build laminate stacks, and individual laminate pairs and/or laminate stacks are bound together with or without an outside casing.

[0035] In embodiments, the use of thin wall laminates makes economical the incorporation of wear resistant materials (e.g., interlocked ceramic or non-metal material laminates, which may be sintered, stamped or machined). As described hereinbelow, the use of such high wear resistant materials can provide strength, durability and wear resistance to the stator and/or the rotor of a progressive cavity pump. In embodiments, utilizing the wear resistant materials in a composite matrix at laminate level (e.g., 1 out of every 4 laminates comprises the wear resistant material) limits the effects of thermal expansion on the assembly during heat cycles, which may provide improved cohesion of the assembly and homogeneity of the performance regardless of temperature. In embodiments, each (or at least a portion) of the laminates comprises a composite material (e.g., which can be anisotropic or isotropic) comprising both the wear resistant material and a base or matrix material. In some such embodiments, all the laminates are substantially identical. In such embodiments, a wear resistant laminate (i.e., a laminate comprising a wear resistant material) is not interleaved between two base material (e.g., steel) laminates, but the wear resistant material (e.g., ceramic) is integrated (e.g., as particles or atoms) directly into the base material (e.g., steel) matrix.

[0036] Referring to Figure 1, a well or production system 10 is shown. Production system 10 is generally configured for extracting hydrocarbon bearing reservoir fluid (indicated by arrow 12 in Figure 1) from a subsurface reservoir 3 via a wellbore 5 that extends through the subsurface reservoir 3 from the surface 7. Though shown as vertical in Figure 1, in general, wellbore 5 may have generally vertical portions or generally horizontal portions and may have curved portions between various portions. In the embodiment of Figure 1, production system 10 includes a tubular casing 14, which may be a metal pipe for example, is positioned and cemented in wellbore 5. Casing 14 has a set of perforations 16 at a location corresponding to subsurface reservoir 3 to provide for fluid communication between subsurface reservoir 3 and a central passage 18 of casing 14.

[0037] In this embodiment, production system 10 additionally includes production tubing 20 that extends into casing 14 from the surface 7, an extension shaft 25 that extends into and through production tubing 20 from a set of exterior surface equipment 30 positioned at the surface 7, and a positive displacement device or pump 40. Although in this embodiment positive displacement device 40 comprises a pump, in other embodiments, device 40 may comprise a fluid motor (e.g., a downhole motor used in drilling systems) or other types of positive displacement devices. Pump 40 is coupled to the lower ends of production tubing 20 and extension shaft 25 and is positioned within casing 14 and wellbore 5 at a selected depth below the surface 7. Production tubing 20 includes a lower end 21 within casing 14 and wellbore 5, and an upper end 23 opposite to the lower end 21 that may extend above the surface 7, where upper end 23 terminates at a discharge port 24. The discharge port 24 of production tubing 20 is routed to a convenient location to release an outlet stream 15 of fluid produced from subsurface reservoir 3.

[0038] Surface equipment 30 of production system 10 includes a source of rotational power, which is motor 32 in this embodiment, a shaft bearing 34, and other equipment known in the art. Shaft 25 may also be called a rod string and is coupled between pump 40 and motor 32 to transmit rotational power from motor 32 to pump 40. In this embodiment, motor 32 is positioned outside the production tubing 20 and outside the wellbore 5, and the fluid-tight shaft bearing 34 allows shaft 25 to extend into production tubing 20 without a loss of reservoir fluid 12. During operation of production system 10, fluid 12 from subsurface reservoir 3 enters casing 14 through perforations 12, where the reservoir fluid 12 enters pump 40 suspended within casing 14. Pump 40 discharges the reservoir fluid 12 into the lower end 21 of production tubing 20, through which the reservoir fluid 12 flows to the surface 7 and is discharged from the upper end 23 of production tubing 20 at discharge port 24 as outlet stream 15.

[0039] Figure 2 is a perspective, partial cut-away view of an embodiment of a pump 40 of the production system of Figure 1 in accordance with principles disclosed herein, and Figure 3 is a cross-sectional end view of the pump of Figure 2. Pump 40 of production system 10 includes a generally cylindrical housing or stator 50 and a helical shaped rotor 80 rotatably disposed in stator 50. Pump 40 comprises a progressive cavity pump (PCP) 40. Additionally, in the embodiment of Figures 1-3, pump 40 comprises a metal-to-metal (MTM) PCP 40 in which stator 50 of pump 40 does not include an elastomeric liner, which may be susceptible to degradation and failure in at least some applications, including high temperature applications and applications where reservoir fluid 12 includes chemicals that may corrode or otherwise inhibit the performance of an elastomeric liner. In embodiments, stator 50 comprises a radially outer surface 57, a radially inner surface 54 and a plurality of stator sections 50A- 50C each having a pair of opposing axial ends 52. Helical-shaped rotor 80 of pump 40 includes an outer surface 82 that defines a set of rotor lobes or helical profiles 84 that intermesh with a set of stator lobes or helical profiles 56 defined by the radially inner surface 54 of stator 50. Although in this embodiment pump 40 comprises a MTM PCP 40, in other embodiments, pump 40 may comprise an elastomeric PCP 40 including a stator 50 with an elastomeric liner.

[0040] As best shown in Figure 3, the rotor 80 has one fewer lobe 84 than the stator 50. When the rotor 80 and the stator 50 are assembled, a series of cavities 90 are formed between the outer surface 82 of the rotor 80 and the radially inner surface 54 of the stator 50. Each cavity

90 is sealed from adjacent cavities 90 by the interference fit formed along the contact line between the rotor 80 and the stator 50. Additionally, a central or longitudinal axis 85 of the rotor 80 is radially offset from a central or longitudinal axis 55 of the stator 50 by a fixed value known as the“eccentricity” of the rotor-stator assembly. Consequently, rotor 80 may be described as rotating eccentrically within stator 50. During operation of pump 40, rotor 80 is rotated by motor 32 via extension shaft 25 to force reservoir fluid 12 through a first set of open cavities 90. As the rotor 80 rotates inside the stator 50, adjacent cavities 90 are opened and filled with reservoir fluid 12. As this rotation and filling process repeats in a continuous manner, the fluid flows progressively down the length of pump 40 until the pressurized reservoir fluid 12 is discharged into the lower end 21 of production tubing 20.

[0041] In at least some applications, the capacity of pump 40 to generate sufficient discharge pressure to flow or“lift” reservoir fluid 12 upwards through production tubing 20 to discharge port 24 is dependent on the axial and angular alignment between the sections 50A- 50C of stator 50. In other words, axial and/or angular misalignment between the sections 50A-50C of stator 50 may inhibit the performance of pump 40. For example, axial and/or angular misalignment between sections 50A-50C of stator 50 during the assembly of pump 40 may produce discontinuities in the radially inner surface 54 of stator 50 that increase the wear of pump 40 and reduce the lift capacity of pump 40, thereby inhibiting the performance of the production system 10. Thus, it may advantageous in at least some applications to maintain as much axial and angular alignment as possible between adjoining sections 50A- 50C of stator 50 to thereby maximize the performance of pump 40 and production system 10. Accordingly, such sections may be aligned using teaching provided in U.S. Patent No. 62/713370, the disclosure of which is hereby incorporated herein by reference in its entirety for purposes not contrary to this disclosure.

[0042] With reference to Figures 2, 3, 4A and 8A, a stator 50 according to embodiments of this disclosure comprises a stator assembly 53 having a radially outer surface 57, and a radially inner surface 54 defining a helical-shaped through-bore 104 extending axially through the stator about a central axis 55. In embodiments, the stator 50 further comprises an outer casing 51 in which the stator assembly 53 is coaxially disposed, the stator assembly 53 is attached to the stator outer casing 51.

[0043] In embodiments, the stator assembly 53 comprises a laminated stack 59 of laminates

101, as depicted and further described hereinbelow with reference to Figures 4-7. Laminates may also be referred to herein as‘elements’, ‘planar elements’, or‘laminate bodies’. In embodiments, the laminates 101 are disk-shaped, and may thus be referred to as laminate disks. When present in a stator 50, a laminated stack 59 can comprise: (i) a plurality of first laminates comprising a first material dispersed among a plurality of second laminates comprising a second material, wherein the second material has a higher wear resistance than the first material, (ii) a plurality of laminates comprising a composite matrix of a first material and a second materials as filler, wherein the second material has a higher wear resistance than the first material, (iii) a combination of (i) and (ii), or (iv) solely laminates comprising a second material, wherein the second material has a higher wear resistance than a first material, and wherein the first material comprises steel. Although the word“comprising” will be utilized for brevity, it is to be understood that“comprising” includes the narrower terms“consisting essentially” or, and“consisting of.” For example, the previous sentence should be understood to include: When present in a stator 50, a laminated stack 59 can comprise, consist essentially of, or consist of: (i) a plurality of first laminates comprising, consisting essentially of, or consisting of a first material dispersed among a plurality of second laminates comprising, consisting essentially of, or consisting of a second material, wherein the second material has a higher wear resistance than the first material, (ii) a plurality of laminates comprising, consisting essentially of, or consisting of a composite matrix of a first material and a second material, wherein the second material has a higher wear resistance than the first material, (iii) a combination of (i) and (ii), or (iv) solely laminates comprising, consisting essentially of, or consisting of a second material, wherein the second material has a higher wear resistance than a first material, and wherein the first material comprises steel.

[0044] Also disclosed herein is a progressive cavity pump or motor 40 comprising a stator 50 and a rotor 80 disposed within the helical-shaped through-bore 104 and configured for rotation in the through-bore. In embodiments, the rotor 80 is a‘laminated’ or composite rotor 80 as described herein comprising a stack 59 of laminates 101, the stator is a“laminated’ or composite stator 50 as described herein comprising a stack 59 of laminates 101, or both the stator and the rotor comprise a stack 59 of laminates 101 as described herein. When present in rotor 80, a laminated stack 59 can comprise: (i) a plurality of first laminates 101 comprising a first material dispersed among a plurality of second laminates comprising a second material, wherein the second material has a higher wear resistance than the first material, (ii) a plurality of laminates comprising a composite matrix of the first material and the second material, (iii) a combination of (i) and (ii), or (iv) solely laminates comprising the first material or laminates comprising the second material. In embodiments, the rotor 80 is a non-laminated or conventional rotor, and the stator is a laminated stator as described herein comprising a stack 59 of laminates 101. In embodiments, the rotor is a carbon steel rotor.

[0045] In embodiments, the stator is a laminated stator according to this disclosure comprising a stack 59 of laminates 101 as described herein, and the rotor is a laminated rotor comprising a stack 59 of laminates as described herein. In other embodiments, the stator is a non-laminated or conventional stator, and the rotor 80 is a laminated rotor comprising a stack 59 of laminates as described herein.

[0046] Thus, according to this disclosure, at least one of the stator assembly 53 and the rotor 80 of a progressive cavity pump 40 comprises a stack 59 of laminates (also referred to herein as a ‘laminated stack’). In embodiments, the stator assembly 53 comprises a stack of laminates 101, wherein the stack 59 of laminates 101 comprises (i) a plurality of first laminates comprising a first material dispersed among a plurality of second laminates comprising a second material, wherein the second material has a higher wear resistance than the first material, (ii) a plurality of laminates comprising a composite matrix of a first material and a second material, wherein the second material has a higher wear resistance than the first material, (iii) a combination of (i) and (ii), or (iv) solely laminates comprising a second material, wherein the second material has a higher wear resistance than a first material, and wherein the first material comprises steel. In embodiments, (b) the rotor comprises a stack of laminates. In embodiments, both the stator assembly 53 and the rotor 80 comprise a stack of laminates. In embodiments, the stack of laminates of the rotor in (b) comprises: comprises (i) a plurality of first laminates comprising a first material dispersed among a plurality of second laminates comprising a second material, wherein the second material has a higher wear resistance than the first material, (ii) a plurality of laminates comprising a composite matrix of the first material and the second material, (iii) a combination of (i) and (ii), or (iv) solely laminates comprising the first material or solely laminates comprising the second material.

[0047] As will be discussed with reference to Figures 4-7, in an exemplary embodiment, stator assembly 53 comprises a stack 59 of laminates 101. In other exemplary embodiments, not shown but discussed below, stator assembly 53 is created by traditional methods and the rotor 80 comprises a stack 59 of laminates 101.

[0048] As depicted in Figures 4-7, a stator assembly 53 comprising a "laminate stack" 59 comprises a plurality of laminate bodies or laminates 101. Each laminate 101 can include a unitary body. As used herein, a "laminate body" or "laminate" is a generally planar body, and in an exemplary embodiment a unitary planar body, having a laminate thickness T _L . AS detailed further hereinbelow, the laminate thickness T _L can be, for example, in a range of from about 0.010 in. to about 0.100 in. (in a range of from about 10 thousandths (thou) to about 100 thou). As used herein, a "laminate stack" or a "stacked body" or a“stack of laminates” 59 includes a plurality of laminates 101 disposed with a planar surface 64 of one laminate body 101 against a planar surface 64 of an adjacent laminate body 101. Thus, with the exception of the first and last laminate body in the laminate stack 59, each laminate 101 is disposed between two adjacent laminates 101. Further, a stator laminate 101 can include a generally circular outer perimeter 112. As noted above, the inner passage of the stator 50 or stator assembly 53 defines a“helical passage” or through-bore 104. In an embodiment, the helical passage 104 has one more lobe than the rotor 80. As described further hereinbelow with reference to Figure 9, in embodiments, the laminates 101 are coupled by any suitable known method including, but not limited to, stacking the laminates 101, applying a binder to the exterior surface of the laminates 101 (as described further hereinbelow), brazing each laminate 101 to an adjacent laminate 101 to bind them together by heating and/or mechanically compressing the stator laminates 101. Each laminate 101 has an edge 60 along perimeter 112 that extends generally parallel to the axis of rotation 55 of the stator 50, i.e., the plane of the laminate edge 60 extends generally parallel to the axis of rotation 55 of the stator 50. As used herein, and with respect to a laminate, an "edge" 60 includes a surface extending between two generally parallel planar surfaces. In embodiments, the cross- sectional area of the laminate stack 59 may be generally constant, narrowing, or broadening in a direction along axis 55 from an inlet to an outlet.

[0049] In an exemplary embodiment, each laminate 101 has a first thickness. That is, each laminate 101 has a substantially similar thickness. In an alternate embodiment, not shown, laminates 101 have a thickness that may be different from a thickness of another laminate 101. For example, in an embodiment, each laminate 101 in a first set of laminates 101 has a first thickness and each laminate 101 in a second set of laminates 101 has a second thickness. The sets of laminates 101 may be disposed so that the first set of laminates is upstream of the second set of laminates 101. Alternatively, the first set of laminates 101 may be interleaved with the second set of laminates 101. In embodiments, the first set of laminates comprises laminates of the first or base material 62A, and the second set of laminates comprises laminates of the second or wear resistant material 62B. In embodiments, the laminates of the wear resistant material 62B have a thickness that is less than or equal to the thickness of the laminates of the first or base material 62A. It is noted that there may be additional sets of laminates 101 with different thicknesses, and each set of laminates may include any number of laminates 101.

[0050] In embodiments, the laminates 101 may become progressively thicker or thinner. In such embodiments, the laminates 101 may include "thick laminates" which, as used herein, includes a generally planar body, and in an exemplary embodiment a unitary planar body, having a thickness of greater than about 0.010 in (10 thou). In this embodiment, the laminates 101 may be thicker (or thinner) at the downstream end of the PCP 40. That is, the thickness T _L of the laminates 101 of a resulting laminated stator (or a resulting laminated rotor) may be greater at the downstream end thereof.

[0051] In embodiments, the stack of laminates (e.g., of the stator assembly 53 or the rotor 80) comprises (i) a plurality of first laminates comprising a first material dispersed among a plurality of second laminates comprising a second material. Such an embodiment is depicted in Figure 4A, which is a schematic of a composite stack 59 of laminates 101 in which a wear resistant material 62B is incorporated at a macroscopic level via the interdispersion of laminates 101 of dissimilar materials (e.g., laminates of a base material 62A and laminates of a wear resistant material 62B), according to an embodiment of this disclosure. In this embodiment, laminate stack 59 comprises a composite of laminates of dissimilar materials including a plurality of laminates of the first or‘base’ material 62A dispersed with a plurality of laminates 101 of the second or wear resistant material 62B. Such a composite may thus be considered a macroscopic composite of the base or first material 62A and the second or wear resistant material 62B.

[0052] In embodiments, each laminate 101 of the plurality of laminates of laminate stack 59 has a laminate thickness T _L of less than or equal to about 200, 150, 100, 90, 80, 70, 60, 50, 45, 40, 35, 30, 25, 20, or 15 thousandths of an inch (thou), or in a range of from about 15 to about 200, from about 10 to about 100, or from about 10 to about 50 thou. In embodiments, (i) each laminate of the plurality of first (e.g., base material) laminates has a thickness of less than or equal to about 200, 150, 100, 90, 80, 70, 60, 50, 45, 40, 35, 30, 25, 20, or 15 thousandths of an inch (thou) or in a range of from about 15 to about 200, from about 10 to about 100, or from about 10 to about 50 thou (ii) each laminate of the plurality of second (e.g., wear resistant) laminates has a thickness of less than or equal to about 200, 150, 100, 90, 80, 70, 60, 50, 45, 40, 35, 30, 25, 20, or 15 thousandths of an inch (thou) or in a range of from about 15 to about 200, from about 10 to about 100, or from about 10 to about 50 thou; or (iii) both (i) and (ii).

[0053] In embodiments, both the stator assembly 53 and the rotor 80 comprise a stack 59 of laminates 101. In such embodiments, a laminate thickness T _L for the laminates of the stator can be substantially the same or different from a laminate thickness of the laminates of the rotor.

[0054] In embodiments, the plurality of first laminates comprising the first or base material

62A are dispersed among the plurality of second laminates comprising the second or more wear resistant material 62B such that a second laminate is positioned regularly throughout the laminate stack 59 (and thus along a length of the resulting rotor or the stator) or in an increasing frequency from one end of the stack 59 to another (e.g., increasing a wear resistance at a discharge end of the pump 40). For example, a laminate stack 59 can comprise a laminate of the second material 62B interleaved after every 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 30, 40, 50, or more laminates of the first or base material 62A. In embodiments, from a discharge end to a suction end of the laminate stack (and thus from an outlet to an inlet of the resulting rotor or stator), a density of laminates of the second or wear resistant material 62B increases from about 10% to about 100%, from about 20% to about 100% or from about 5% to about 100%.

[0055] In embodiments, the stack of laminates 59 comprises (ii) a plurality of laminates comprising a composite matrix 62C of the first material and the second material. Such an embodiment is depicted in Figure 4B, which is a schematic of a composite stack 59 of laminates 101 in which a wear resistant material is incorporated at a microscopic level via alteration of the metallurgy of a base material via integration of a wear resistant material into the matrix of the base material at a microscopic level to form a composite material 62C. In this embodiment, laminate stack 59 comprises a plurality of laminates 101 comprising a composite material comprising both the first or base material and the second or wear resistant (e.g., filler) material. Such a composite material 62C may thus be considered a microscopic composite of the first or base material 62A and the second or wear resistant material 62B. In the embodiment of Figure 4B, the plurality of laminates 101 comprise a composite material 62C in which the metallurgy of the first or base material 62A is altered and/or combined with the wear resistant material 62B to integrate the wear resistant material 62B into each laminate at the microstructural level. As indicated in Figures 4A and 4B, the inner surface 54 of stator 50 defined by stator assembly 53 has a helical internal profile 58.

[0056] In embodiments, the first or base material 62A is metallic. For example, the first material can comprise a durable material, such as a hard metal, ceramic, alloy or other composition having characteristics similar to a hard metal including, but not limited to, steel, carbon steel, tool steel, A2 tool steel, 17-4 PH stainless steel, crucible steel, 4150 steel, 4140 steel or 1018 steel, polished stainless steel or nearly any stainless, carbon or alloy steels.

[0057] The base materials would be considered ductile compared to the more brittle but hard second or wear resistant material 62B. In embodiments, the second material can be any material that is more wear resistant than the first or base material. In embodiments, the wear resistant or second material is non-metallic. By way of non-limiting example, in embodiments, the wear resistant material comprises a ceramic, a non-metal, or a harder, more wear resistant metal than a metal of the first or base material.

[0058] As depicted in Figure 9, a method 200 of forming a rotor or a stator component according to this disclosure can comprise providing laminates (as described hereinabove) at

201, stacking the laminates at 202, and binding the laminates to each other and/or with an outer casing or support tubular to form the rotor component or the stator component.

[0059] In embodiments, providing the laminates 101 at 201 comprises machining. In embodiments, the laminates 101 (e.g., laminates of the first or base material) can be provided at 201 by punching or stamping, for example, from stainless steel. A binder (e.g., brazing material) may be applied to the laminate prior to stamping, in embodiments. In embodiments, providing laminates at 201 comprises forming laminates comprising second or wear resistant material 62B. Such laminates comprising second material 62B can be formed, in embodiments, by providing a powder of the second material (e.g., a ceramic powder), and sintering. In embodiments, providing laminates at 201 comprises forming laminates comprising composite matrix 62C. Such laminates comprising composite 62C can be formed, in embodiments, by combining a powder of the second material (e.g., a ceramic powder) with a powder of the first material (e.g., stainless steel or carbon steel), and sintering. A desired wear resistance of the laminate comprising the composite matrix material 62C can be provided by adjusting an amount of the powder of the second material 62B mixed with the powder of the first material 62A.

[0060] The binding at 202 can be performed via any means known in the art. In embodiments, the rotor or the stator is produced via a single laminate stack 59. In other embodiments, multiple laminate stacks 59 are produced and bound together sequentially.

[0061] In embodiments, binding of the laminates at 202 comprises binding pairs of laminates 101 or stacks 59 of laminates together by applying heat and/or pressure. Following heating, the pairs of laminates or the laminated stack 59 can be immediately cooled. For example, in embodiments, binding pairs of laminates 101 or stacks 59 of laminates together is effected by melting a binder (e.g. silver), into the matrix material 62 (e.g., copper) of another laminate to create a strong bond. This process can comprise sheet metal preparation of dissimilar materials or the addition of an outside sleeve or outer casing 51 (e.g., as depicted in the embodiment of Figure 6, described hereinbelow), prior, during or post stamping at 201 to provide the laminates.

[0062] As discussed further hereinbelow with reference to Figures 5-7, in embodiments, the binder 61 comprises a brazing material, a resin, an epoxy, or a binder, which can be applied to one or both sides of each laminate 101. In embodiments, the binder is applied as a layer. In embodiments, the binder comprises silver, copper, tin, or a combination thereof. In embodiments, the application of the heat source to reach fusion of the binder 61 may be in the form of a standard existing process (e.g., a furnace), or via the use of induction heating.

[0063] Whether integrated at the laminate level (e.g., as in the embodiment of Figure 4A) or at the material level (e.g., as in the embodiment of Figure 4B) the use of the wear resistant material (e.g., ceramics) may impede any binding by welding. Accordingly, in embodiments, no welding is utilized at 203 for binding together the laminates 101 in laminate stack 59 or for binding multiple stacks 59.

[0064] As noted above, in embodiments, binding at 203 of each pair of adjacent laminates 101 and/or stacks 59 of laminates together and/or to a stator outer casing 51 is effected via brazing, epoxy, or other chemical methods. Welding methods generally occur at high temperatures (e.g., 2500 to 3000°F) and have the potential to distort assemblies of sheet metals. Low temperature brazing and/or gluing may be utilized. For example, in embodiments, each pair of adjacent laminates 101 of a laminate stack 59 and/or multiple stacks 59 of laminates are bound together and/or are bound to a stator outer casing 51 at temperatures in a range of from about 850 to about 1500°F.

[0065] In embodiments, binding at 203 of adjacent laminates 101 and/or laminate stacks 59 to each other, and/or binding of the laminate stack(s) 59 to the stator outer casing 51 comprises melting a lower melting temperature material (also referred to herein as a‘binder’) between the components being bound together. For example, as depicted in Figure 5, which is a schematic of a bi-material composite laminate stack 59, a laminated stack 59 according to an embodiment of this disclosure can comprise a binder 61 between each pair of adjacent laminates 101. As discussed hereinabove, the laminates 101 comprise a laminate material 62 which can comprise the first material 62A, the second material 62B, or a composite matrix 62C thereof. In this embodiment, individual laminates 101 can be prepared at sheet metal level (e.g., to a final sheet or laminate thickness T _L of from about 10 to about 100 thou) to adhere the binder material 61 onto the laminate material 62. In embodiments, the laminates 101 are subsequently stamped (e.g., at 201), assembled (e.g., at 202) and fused together using brazing techniques (e.g., at 203). Such brazing techniques will be apparent to those of skill in the art upon reading this disclosure. Binding of the individual laminates 101 on the faces 64 thereof can be utilized, in embodiments, to allow higher internal pressures to be applied on the stator 50 without producing leakages.

[0066] As noted hereinabove, in embodiments, stator 50 can further comprise a tubular housing or an outer casing 51 within which stator assembly 53 is coaxially disposed. In such embodiments, a binder 61 may be located between the radially outer surface 57 and the outer casing 51. Figure 6 is a schematic of a composite laminate stack 59 comprising binder material 61 on the edges 60 along the perimeter 112 of the laminates 101 (which edges together define the radially outer surface 57 of the stator) and/or on the inner diameter (ID) of the outer casing 51 to support the binding of the stack(s) 59 to the outer casing 51. [0067] Alternative methods of binding the laminates 101 together at 203 will be apparent to those of skill in the art upon reading this disclosure, and such alternative embodiments are intended to be within the scope of this disclosure. For example, in embodiments, laminates 101 are bound directly, e.g., mechanically; with the stator outer casing 51 to constrain the laminates with each other while ensuring the laminate stack 59 can hold internally applied pressure and thus provide sealed volumes. As depicted in Figure 7, which is a schematic of an alternative method of binding laminates 101 with the outer casing 51, a stator 50 of this disclosure can further comprise a fiberglass composite winding 51 A and/or insertion of the stator assembly 53 into a circular geometry (e.g., piping, tubing, outer casing, etc.) to manage higher operating or handling stresses. Additionally, the edges 60 along the laminate outside perimeters 112 or at least a portion thereof (e.g., a portion of each perimeter of one or more of the laminates 101 or the entirety of the perimeters 112 of a portion of the laminates 101) may be managed (e.g., patterned) to increase friction with the outside component (e.g., the winding 51A or outer casing 51). For example, friction may be increased by notches, tabs, ridges, or the like on the perimeter(s) of the laminate(s) or on the inside diameter (ID) of the aforementioned circular geometry.

[0068] In embodiments, the method further comprises adjusting a distribution along a length of the laminate stack, a percentage, or both the distribution and the percentage of the plurality of second laminates, the plurality of laminates comprising the composite matrix of the first material and the second material, a composition of the composite material 62C in a plurality of laminates 101 comprising the composite matrix of the first material and the second material, or a combination thereof in the laminate stack 59 to provide a desired wear resistance of a resulting stator component, a wear resistance of a resulting rotor component, or a relative wear resistance of a stator component of a PCP 40 relative to a rotor component of the PCP 40.

[0069] Figure 8A and Figure 8B are schematics of a stator 50, according to embodiments of this disclosure. Although described with reference to the Figures as a laminate stack for the stator assembly 53 of a stator 50, it is to be understood that, in embodiments, the rotor 80 includes a laminate stack 59 as described hereinabove.

EXAMPLES

[0070] The embodiments having been generally described, the following examples are given as particular embodiments of the disclosure and to demonstrate the practice and advantages thereof. It is understood that the examples are given by way of illustration and are not intended to limit the specification or the claims in any manner.

Example 1: Laminated Stators [0071] In an embodiment, a stator for a progressive cavity pump or motor comprises a stator assembly having a radially outer surface, and a radially inner surface defining a helical-shaped through-bore extending axially through the stator about a central axis, and the stator assembly comprises a stack of laminates including at least one ceramic laminate. In embodiments, at least 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 20, 30, 40, 50 % or more of the laminates are ceramic laminates. In embodiments, a stator of this disclosure is made entirely of ceramic laminates.

[0072] In an embodiment, a stator for a progressive cavity pump or motor comprises a stator assembly having a radially outer surface, and a radially inner surface defining a helical-shaped through-bore extending axially through the stator about a central axis, and the stator assembly comprises a stack of laminates including at least one composite laminate made from a composite matrix of a first or base material and a ceramic, wherein the first or base material has lower wear resistance than the ceramic. In embodiments, at least 10, 20, 30, 40, 50, 60, 70, 80, 90% or all of the laminates are composite laminates made from the composite matrix of the first or base material and the ceramic.

Example 2: Laminated Rotors

[0073] In an embodiment, a rotor for a progressive cavity pump or motor comprises a stack of laminates, wherein the stack of laminates comprises (i) a plurality of first laminates comprising a first or base material dispersed among a plurality of second laminates comprising a ceramic, (ii) a plurality of laminates comprising a composite matrix of the first or base material and the ceramic, (iii) a combination of (i) and (ii), or (iv) solely laminates comprising the first or base material or the ceramic, wherein the first or base material has a lower wear resistance than the ceramic. In embodiments, the first material comprises steel, and the rotor is made entirely of steel laminates.

Example 3: MTMPCPs

[0074] In an embodiment, a MTM PCP pump 40 of this disclosure is formed with a conventional (e.g., non-laminated) rotor and a laminated stator of this disclosure as described in Example 1. In an embodiment, a MTM PCP pump 40 of this disclosure is formed with a conventional (e.g., non-laminated) stator and a laminated rotor of this disclosure as described in Example 2. In an embodiment, a MTM PCP pump 40 of this disclosure is formed with a laminated stator of this disclosure as described in Example 1 and a laminated rotor of this disclosure as described in Example 2.

[0075] While various embodiments have been shown and described, modifications thereof can be made by one skilled in the art without departing from the spirit and teachings of the disclosure. The embodiments described herein are exemplary only, and are not intended to be limiting. Many variations and modifications of the subject matter disclosed herein are possible and are within the scope of the disclosure. Where numerical ranges or limitations are expressly stated, such express ranges or limitations should be understood to include iterative ranges or limitations of like magnitude falling within the expressly stated ranges or limitations (e.g., from about 1 to about 10 includes, 2, 3, 4, etc.; greater than 0.10 includes 0.11, 0.12, 0.13, etc.). For example, whenever a numerical range with a lower limit, R _L and an upper limit, Ru is disclosed, any number falling within the range is specifically disclosed. In particular, the following numbers within the range are specifically disclosed: R=Ri+k*(Ru-R _L ), wherein k is a variable ranging from 1 percent to 100 percent with a 1 percent increment, /. e.. k is 1 percent, 2 percent, 3 percent, 4 percent, 5 percent, ... 50 percent, 51 percent, 52 percent, ... , 95 percent, 96 percent, 97 percent, 98 percent, 99 percent, or 100 percent. Moreover, any numerical range defined by two R numbers as defined in the above is also specifically disclosed. Use of the term "optionally" with respect to any element of a claim is intended to mean that the subject element is required, or alternatively, is not required. Both alternatives are intended to be within the scope of the claim. Use of broader terms such as comprises, includes, having, etc. should be understood to provide support for narrower terms such as consisting of, consisting essentially of, comprised substantially of, etc.

[0076] Accordingly, the scope of protection is not limited by the description set out above but is only limited by the claims which follow, that scope including all equivalents of the subject matter of the claims. Each and every claim is incorporated into the specification as an embodiment of the present disclosure. Thus, the claims are a further description and are an addition to the embodiments of the present disclosure. The discussion of a reference is not an admission that it is prior art to the present disclosure, especially any reference that may have a publication date after the priority date of this application. The disclosures of all patents, patent applications, and publications cited herein are hereby incorporated by reference, to the extent that they provide exemplary, procedural, or other details supplementary to those set forth herein.

[0077] Unless expressly stated otherwise, the steps in a method claim may be performed in any order. The recitation of identifiers such as (a), (b), (c) or (1), (2), (3) before steps in a method claim are not intended to and do not specify a particular order to the steps, but rather are used to simplify subsequent reference to such steps.

ADDITIONAL DESCRIPTION

[0078] The particular embodiments disclosed above are illustrative only, as the present disclosure may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular illustrative embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the present disclosure. Alternative embodiments that result from combining, integrating, and/or omitting features of the embodiment(s) are also within the scope of the disclosure. While compositions and methods are described in broader terms of "having”, “comprising," "containing," or "including" various components or steps, the compositions and methods can also "consist essentially of’ or "consist of’ the various components and steps. Use of the term“optionally” with respect to any element of a claim means that the element is required, or alternatively, the element is not required, both alternatives being within the scope of the claim.

[0079] Numbers and ranges disclosed above may vary by some amount. Whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range are specifically disclosed. In particular, every range of values (of the form, "from about a to about b," or, equivalently, "from approximately a to b," or, equivalently, "from approximately a-b") disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. Moreover, the indefinite articles "a" or "an", as used in the claims, are defined herein to mean one or more than one of the element that it introduces. If there is any conflict in the usages of a word or term in this specification and one or more patent or other documents, the definitions that are consistent with this specification should be adopted.

[0080] Embodiments disclosed herein include:

[0081] A: A progressive cavity pump or motor, comprising: a stator comprising: a stator assembly having a radially outer surface and a radially inner surface defining a helical-shaped stator through-bore extending axially through the stator about a central axis; and a rotor disposed within the helical-shaped stator through-bore and configured for rotation in the stator through-bore; wherein: (a) the stator assembly comprises one or a plurality of stacks of laminates, wherein each stack of laminates comprises (i) a plurality of first laminates comprising a first material dispersed among a plurality of second laminates comprising a second material, wherein the second material has a higher wear resistance than the first material, (ii) a plurality of laminates comprising a composite matrix of a first material and a second material, wherein the second material is a filler having a higher wear resistance than the first material, (iii) a combination of (i) and (ii), or (iv) solely laminates comprising a second material, wherein the second material has a higher wear resistance than a first material, and wherein the first material comprises steel; (b) the rotor comprises a stack of laminates; or (c) both (a) and (b).

[0082] B: A stator for a progressive cavity pump or motor, comprising: a stator assembly having a radially outer surface, and a radially inner surface defining a helical-shaped through- bore extending axially through the stator about a central axis, wherein the stator assembly comprises one or a plurality of stacks of laminates, wherein each stack of laminates comprises:

(i) a plurality of first laminates comprising a first material dispersed among a plurality of second laminates comprising a second material, wherein the second material has a higher wear resistance than the first material, (ii) a plurality of laminates comprising a composite matrix of a first material and a second material, wherein the second material is a filler having a higher wear resistance than the first material, (iii) a combination of (i) and (ii), or (iv) solely laminates comprising a second material, wherein the second material has a higher wear resistance than a first material, and wherein the first material comprises steel.

[0083] C: A method of forming a stator or a rotor component of a progressive cavity pump, the method comprising: providing a plurality of laminates; stacking the plurality of laminates to form a stack of laminates; and binding the laminates together to form the stator or the rotor component, wherein the stack of laminates comprises (i) a plurality of first laminates comprising a first material dispersed among a plurality of second laminates comprising a second material, wherein the second material has a higher wear resistance than the first material

(ii) a plurality of laminates comprising a composite matrix of a first material and a second material, wherein the second material is a filler having a higher wear resistance than the first material, (iii) a combination of (i) and (ii), or (iv) solely laminates comprising a second material, wherein the second material has a higher wear resistance than a first material, and wherein the first material comprises steel.

[0084] D: A rotor for a progressive cavity pump or motor, comprising: a stack of laminates.

[0085] E: A method of forming a rotor of a progressive cavity pump, the method comprising: providing a plurality of laminates; stacking the plurality of laminates to form a stack of laminates; and binding the laminates together to form the rotor.

[0086] Each of embodiments A, B, C, D, and E may have one or more of the following additional elements: Element 1 : wherein the first material is metallic and the second material is non-metallic. Element 2: wherein the first material is metallic and the second material is a ceramic. Element 3: wherein each laminate of the stack of laminates has a thickness of less than or equal to about 100, 50, 45, 40, 35, 30, 25, 20, or 15 thousandths of an inch (thou). Element 4: (i) wherein each laminate of the plurality of first laminates has a thickness of less than or equal to about 100, 50, 45, 40, 35, 30, 25, 20, or 15 thousandths of an inch (thou); (ii) wherein each laminate of the plurality of second laminates has a thickness of less than or equal to about 100, 50, 45, 40, 35, 30, 25, 20, or 15 thousandths of an inch (thou); or (iii) both (i) and (ii). Element 5: wherein the stack of laminates comprises a binder either between each pair of laminates of the stack of laminates or metallurgically introduced within the microstructure of each laminate. Element 6: further comprising a stator outer casing in which the stator assembly is coaxially disposed. Element 7 : further comprising a binder between the radially outer surface and the stator outer casing, whereby the stator outer casing is attached to the stator assembly. Element 8: further comprising a winding around the stator assembly, wherein the winding is configured to bind the stack of laminates with the stator outer casing or comprises the stator outer casing. Element 9: wherein each laminate of the stack of laminates has an outside perimeter, wherein the outside perimeters of the laminates of the stack of laminates define the radially outer surface of the stator assembly, and wherein the outside perimeter of at least a portion of the laminates of the stack of laminates is patterned to increase friction between the stack of laminates and the stator outer casing. Element 10: wherein the stack of laminates comprises either a binder between each pair of laminates of the stack of laminates or metallurgically introduced within the microstructure of each laminate itself. Element 11: wherein the second material is a ceramic. Element 12: wherein from about 10% to 100% of the plurality of laminates of the stack of laminates comprise the second material. Element 13: further comprising adjusting a distribution along a length of the laminate stack, a percentage, or both the distribution and the percentage of the plurality of second laminates, the plurality of laminates comprising the composite matrix of the first material and the second material, or both in the laminate stack and/or a composition of the composite matrix of the plurality of laminates comprising the composite matrix of the first material and the second material in the laminate stack to provide a desired wear resistance of the stator component, a desired wear resistance of the rotor component, or a relative wear resistance of the stator component relative to the wear resistance of the rotor component. Element 14: wherein the stack of laminates comprises (i) a plurality of first laminates comprising a first material dispersed among a plurality of second laminates comprising a second material, wherein the second material has a higher wear resistance than the first material, (ii) a plurality of laminates comprising a composite matrix of the first material and the second material, (iii) a combination of (i) and (ii), or (iv) solely laminates comprising the first material or the second material. [0087] While preferred embodiments of the invention have been shown and described, modifications thereof can be made by one skilled in the art without departing from the teachings of this disclosure. The embodiments described herein are exemplary only, and are not intended to be limiting. Many variations and modifications of the invention disclosed herein are possible and are within the scope of the invention.

[0088] Numerous other modifications, equivalents, and alternatives, will become apparent to those skilled in the art once the above disclosure is fully appreciated. It is intended that the following claims be interpreted to embrace all such modifications, equivalents, and alternatives where applicable. Accordingly, the scope of protection is not limited by the description set out above but is only limited by the claims which follow, that scope including all equivalents of the subject matter of the claims. Each and every claim is incorporated into the specification as an embodiment of the present invention. Thus, the claims are a further description and are an addition to the detailed description of the present invention. The disclosures of all patents, patent applications, and publications cited herein are hereby incorporated by reference.