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<p>Efficient and reliable drilling is critical for oil and gas extraction, especially in challenging geological conditions. This study presents a comprehensive failure analysis of tungsten carbide–cobalt (WC–Co) tool inserts used in rock drilling operations. The investigation involved visual inspection, optical microscopy, FESEM imaging, EDS, WDXRF, XRD, and microhardness testing. Results reveal that abrasive wear and material adhesion are the primary failure mechanisms, with wear localized at the tool edges due to high stress and thermal effects. Elemental analysis identified transferred materials such as Fe, Ca, and Si on worn surfaces, indicating tool–rock interaction during service. The WC inserts exhibited a high average hardness of 1350 Hv, consistent with their intended application. Despite excellent intrinsic properties, the study concludes that in-service degradation limits tool life. Recommendations include optimizing microstructure, suitable lubricant, binder content, and surface design to enhance performance in abrasive drilling environments.</p>

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Tribological Failure Analysis of Tungsten Carbide Tool Inserts Used in Drilling Operations

  • 期刊论文

  • 发表日期：

    2025年9月1日

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  • Javokhirbek Ziyamukhamedov,
  • M. F. Wani,
  • Mohd Nadeem Bhat

摘要

Efficient and reliable drilling is critical for oil and gas extraction, especially in challenging geological conditions. This study presents a comprehensive failure analysis of tungsten carbide–cobalt (WC–Co) tool inserts used in rock drilling operations. The investigation involved visual inspection, optical microscopy, FESEM imaging, EDS, WDXRF, XRD, and microhardness testing. Results reveal that abrasive wear and material adhesion are the primary failure mechanisms, with wear localized at the tool edges due to high stress and thermal effects. Elemental analysis identified transferred materials such as Fe, Ca, and Si on worn surfaces, indicating tool–rock interaction during service. The WC inserts exhibited a high average hardness of 1350 Hv, consistent with their intended application. Despite excellent intrinsic properties, the study concludes that in-service degradation limits tool life. Recommendations include optimizing microstructure, suitable lubricant, binder content, and surface design to enhance performance in abrasive drilling environments.