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<p>In this study, various experiments were conducted to analyze the fracture and failure of top drive during the drilling operation. The experiments included macroscopic observation of fracture surface, magnetic particle inspection near the fracture, chemical composition analysis, mechanical properties testing and metallographic&#xa0;analysis of the failed top drive guide rail, and also the scanning electron microscopy (SEM) analysis of fracture position and fillet weld. The results indicated that: (1) The torsion joint at the top drive guide rail was made of 35CrMo material and the mechanical properties did not meet the requirements of GB/T 3077-2015. The microstructure of the torsion joint is pearlite + ferrite, which did not undergone quenching and tempering heat treatment. (2) The torsion joint without good welding organization conditions, with a carbon equivalent of 0.62%, is a difficult to weld material. (3) The fillet weld between the vertical plate and the guide plate was not V-shaped and the lack of post-weld heat treatment leads to multiple cracks under the residual stresses in the welds, resulting in insufficient load-bearing capacity of the fillet weld. Therefore, poor material qualiy issues and lack of quenching and tempering&#xa0;heat treatment, poor welding quality and the lack of post-weld heat treatment were the fundamental reason for the early initiation of fatigue and residual stress cracks. Finally, fracture occured at the fillet weld under the action of alternating torque, swinging force, and deflection force.</p>

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Fracture Failure Analysis of Top Drive Guide Rail

  • 期刊论文

  • 发表日期：

    2025年6月16日

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  • Jinlan Zhao,
  • Feng Cao,
  • Dejun Li,
  • Li Wang,
  • Pengju Zhang,
  • Zhenjin Li

摘要

In this study, various experiments were conducted to analyze the fracture and failure of top drive during the drilling operation. The experiments included macroscopic observation of fracture surface, magnetic particle inspection near the fracture, chemical composition analysis, mechanical properties testing and metallographic analysis of the failed top drive guide rail, and also the scanning electron microscopy (SEM) analysis of fracture position and fillet weld. The results indicated that: (1) The torsion joint at the top drive guide rail was made of 35CrMo material and the mechanical properties did not meet the requirements of GB/T 3077-2015. The microstructure of the torsion joint is pearlite + ferrite, which did not undergone quenching and tempering heat treatment. (2) The torsion joint without good welding organization conditions, with a carbon equivalent of 0.62%, is a difficult to weld material. (3) The fillet weld between the vertical plate and the guide plate was not V-shaped and the lack of post-weld heat treatment leads to multiple cracks under the residual stresses in the welds, resulting in insufficient load-bearing capacity of the fillet weld. Therefore, poor material qualiy issues and lack of quenching and tempering heat treatment, poor welding quality and the lack of post-weld heat treatment were the fundamental reason for the early initiation of fatigue and residual stress cracks. Finally, fracture occured at the fillet weld under the action of alternating torque, swinging force, and deflection force.