{"status":"ok","message-type":"work","message-version":"1.0.0","message":{"indexed":{"date-parts":[[2026,5,16]],"date-time":"2026-05-16T23:06:09Z","timestamp":1778972769417,"version":"3.51.4"},"reference-count":29,"publisher":"MDPI AG","issue":"8","license":[{"start":{"date-parts":[[2026,4,17]],"date-time":"2026-04-17T00:00:00Z","timestamp":1776384000000},"content-version":"vor","delay-in-days":0,"URL":"https:\/\/creativecommons.org\/licenses\/by\/4.0\/"}],"content-domain":{"domain":[],"crossmark-restriction":false},"short-container-title":["Materials"],"abstract":"<jats:p>As a key component in oil drilling, drill pipes are prone to failure in harsh operating service environments. Multiple severe cracks were identified in the S135 drill pipes following field service, with partial crack extensions of ~1 mm detected at the thread roots penetrating into the pipe wall, posing critical threats to structural integrity. This study investigated the failure mechanisms of the drill pipes and examined the potential effects of dynamic rotation on corrosion-assisted cracking. The results showed that this failure was close to the combined results of corrosion and torque. Cl\u2212 and S2\u2212 in the drilling fluid were the main sources of corrosive substances. Cl\u2212 preferentially accumulated on the drill pipe surface, initiating localized pitting corrosion. Under applied stress, these surface pits exacerbated local stress concentration. The synergistic action of S2\u2212 then promoted the transition from pitting to stress corrosion cracking. Regarding the corrosion stage, the rotational state of the drill pipe will affect the drilling fluid\u2019s corrosion results. The mud deposition during rotation leads to severe intergranular corrosion, which further causes material peeling. Dynamic rotation at 60 r\u00b7min\u22121 increased the corrosion rate to 0.55 mm\u00b7a\u22121 after 216 h of immersion, 41% higher than under static conditions, while maximum corrosion depth increased from 8.43 \u03bcm to 13.86 \u03bcm. These results indicate that rotational motion accelerates corrosion-assisted cracking.<\/jats:p>","DOI":"10.3390\/ma19081621","type":"journal-article","created":{"date-parts":[[2026,4,17]],"date-time":"2026-04-17T14:24:51Z","timestamp":1776435891000},"page":"1621","update-policy":"https:\/\/doi.org\/10.3390\/mdpi_crossmark_policy","source":"Crossref","is-referenced-by-count":1,"title":["Synergistic Stress\u2013Corrosion Cracking of S135 Drill Pipes Induced by Sulfide\u2013Chloride Drilling Fluid"],"prefix":"10.3390","volume":"19","author":[{"given":"Jinzhou","family":"Zhang","sequence":"first","affiliation":[{"name":"Material Science and Engineering Research Center, School of Mechanical, Electronic and Control Engineering, Beijing Jiaotong University, Beijing 100044, China"}],"role":[{"role":"author","vocabulary":"crossref"}]},{"given":"Zhunli","family":"Tan","sequence":"additional","affiliation":[{"name":"Material Science and Engineering Research Center, School of Mechanical, Electronic and Control Engineering, Beijing Jiaotong University, Beijing 100044, China"}],"role":[{"role":"author","vocabulary":"crossref"}]},{"given":"Lihong","family":"Han","sequence":"additional","affiliation":[{"name":"State Petroleum Drilling and Production Equipment Key Laboratory, CNPC Tubular Goods Research Institute, Xi\u2019an 710077, China"}],"role":[{"role":"author","vocabulary":"crossref"}]},{"given":"Ping","family":"Luo","sequence":"additional","affiliation":[{"name":"National College for Excellent Engineers, Beijing Jiaotong University, Beijing 100044, China"}],"role":[{"role":"author","vocabulary":"crossref"}]},{"given":"Min","family":"Zhang","sequence":"additional","affiliation":[{"name":"Material Science and Engineering Research Center, School of Mechanical, Electronic and Control Engineering, Beijing Jiaotong University, Beijing 100044, China"}],"role":[{"role":"author","vocabulary":"crossref"}]}],"member":"1968","published-online":{"date-parts":[[2026,4,17]]},"reference":[{"key":"ref_1","doi-asserted-by":"crossref","first-page":"308","DOI":"10.1016\/j.matdes.2013.05.073","article-title":"Effect of stress distribution on the tool joint failure of internal and external upset drill pipes","volume":"52","author":"Luo","year":"2013","journal-title":"Mater. Des."},{"key":"ref_2","doi-asserted-by":"crossref","first-page":"605","DOI":"10.1016\/j.engfailanal.2015.10.012","article-title":"Failure analysis of drill pipe: A review","volume":"59","author":"Zamani","year":"2016","journal-title":"Eng. Fail. Anal."},{"key":"ref_3","doi-asserted-by":"crossref","first-page":"104874","DOI":"10.1016\/j.ijpvp.2022.104874","article-title":"Fatigue life analysis of rotary drill pipe","volume":"201","author":"Zou","year":"2023","journal-title":"Int. J. Press. Vessel. Pip."},{"key":"ref_4","doi-asserted-by":"crossref","first-page":"20491","DOI":"10.1038\/s41598-023-47156-y","article-title":"Optimal design and nonlinear dynamic characteristics of titanium\/steel drill pipe composite drill string for ultra-deep drilling","volume":"13","author":"Liu","year":"2023","journal-title":"Sci. Rep."},{"key":"ref_5","doi-asserted-by":"crossref","unstructured":"Yin, H., Liang, J., Ren, X.Y., Zhao, J., He, X., and Gu, Y.H. (2021). Corrosion and wear behavior of WC\u201310Co4Cr coating under saturated salt drilling fluid. Materials, 14.","DOI":"10.3390\/ma14237379"},{"key":"ref_6","doi-asserted-by":"crossref","first-page":"368","DOI":"10.1007\/s11668-023-01819-0","article-title":"Corrosion failure analysis of a S135 drill pipe","volume":"24","author":"Zhao","year":"2024","journal-title":"J. Fail. Anal. Prev."},{"key":"ref_7","doi-asserted-by":"crossref","first-page":"589","DOI":"10.3390\/surfaces7030040","article-title":"Analysis, assessment, and mitigation of stress corrosion cracking in austenitic stainless steels in the oil and gas sector: A review","volume":"7","author":"Vakili","year":"2024","journal-title":"Surfaces"},{"key":"ref_8","doi-asserted-by":"crossref","unstructured":"Zheng, Y.S., Zhang, Y.H., Sun, B.C., Zhang, B., Zhang, S.X., Jin, S.L., Xiao, Z.L., Chu, S.L., Jing, Y.H., and Zhang, Z. (2024). Corrosion behavior and mechanical performance of drill pipe steel in a CO2\/H2S-drilling-fluid environment. Processes, 12.","DOI":"10.3390\/pr12030502"},{"key":"ref_9","doi-asserted-by":"crossref","first-page":"63","DOI":"10.1016\/j.psep.2019.01.023","article-title":"Fatigue and corrosion fatigue behaviors of G105 and S135 high\u2212strength drill pipe steels in air and H2S environment","volume":"124","author":"Han","year":"2019","journal-title":"Process Saf. Environ. Prot."},{"key":"ref_10","doi-asserted-by":"crossref","first-page":"104392","DOI":"10.1016\/j.jngse.2021.104392","article-title":"Experimental and numerical simulation of fatigue corrosion behavior of V150 high-strength drill pipe in air and H2S-dilling mud environment","volume":"98","author":"Yu","year":"2022","journal-title":"J. Nat. Gas Sci. Eng."},{"key":"ref_11","unstructured":"(2020). Specification for Drill Pipe (Standard No. API Spec 5DP-2020)."},{"key":"ref_12","doi-asserted-by":"crossref","first-page":"030601","DOI":"10.1063\/5.0209756","article-title":"Comprehensive review of cuttings transport in wellbore drilling: Mechanisms, challenges, and future directions","volume":"2","author":"Xu","year":"2025","journal-title":"Int. J. Fluid Eng."},{"key":"ref_13","first-page":"671","article-title":"Drag reduction technology for ultra-long horizontal drilling in the Changqing tight gas reservoir","volume":"44","author":"Zhang","year":"2022","journal-title":"Oil Drill. Prod. Technol."},{"key":"ref_14","doi-asserted-by":"crossref","unstructured":"Liu, X.D., Yin, M., Zhang, S.H., Wei, H., Liu, B.S., Du, H.Y., Hou, L.F., and Wei, Y.H. (2018). Corrosion behavior of the as-cast and as-solid solution Mg-Al-Ge alloy. Materials, 11.","DOI":"10.3390\/ma11101812"},{"key":"ref_15","doi-asserted-by":"crossref","unstructured":"Chen, F., Liu, J.Q., Yang, S.Y., Zhang, S.N., Zhang, J.N., Wang, W.C., and Di, Q.F. (2026). Stress characteristics and sealing mechanism of steel-titanium heterogeneous drill pipe joints. Pet. Sci., in press.","DOI":"10.1016\/j.petsci.2026.02.001"},{"key":"ref_16","doi-asserted-by":"crossref","first-page":"236","DOI":"10.1016\/j.proeng.2011.05.037","article-title":"Simulation technology in failure analysis of drill pipe","volume":"12","author":"Liu","year":"2011","journal-title":"Proc. Eng."},{"key":"ref_17","doi-asserted-by":"crossref","first-page":"106484","DOI":"10.1016\/j.engfailanal.2022.106484","article-title":"Analysis of the causes of the cracking of tube bundles of 316L stainless steel Shell-and-Tube heat exchanger","volume":"139","author":"Wang","year":"2022","journal-title":"Eng. Fail. Anal."},{"key":"ref_18","doi-asserted-by":"crossref","first-page":"124826","DOI":"10.1016\/j.matchemphys.2021.124826","article-title":"Effect of Cl\u2212 and rust layer on stress corrosion cracking behavior of X100 steel base metal and heat-affected zone in marine alternating wet\/dry environment","volume":"270","author":"Gong","year":"2021","journal-title":"Mater. Chem. Phys."},{"key":"ref_19","doi-asserted-by":"crossref","first-page":"524","DOI":"10.1016\/j.msea.2008.07.036","article-title":"Fractographic changes caused by phosphorus grain boundary segregation for a low alloy structural steel","volume":"497","author":"Song","year":"2008","journal-title":"Mater. Sci. Eng. A"},{"key":"ref_20","doi-asserted-by":"crossref","first-page":"37","DOI":"10.1016\/j.msea.2014.06.091","article-title":"Effect of microstructural parameters, microtexture and matrix strain on the Charpy impact properties of low carbon HSLA steel containing MnS inclusions","volume":"613","author":"Ghosh","year":"2014","journal-title":"Mater. Sci. Eng. A"},{"key":"ref_21","doi-asserted-by":"crossref","first-page":"1043","DOI":"10.1007\/s42243-018-0149-5","article-title":"Effect of coarse TiN inclusions and microstructure on impact toughness fluctuation in Ti micro-alloyed steel","volume":"25","author":"Liu","year":"2018","journal-title":"J. Iron Steel Res. Int."},{"key":"ref_22","doi-asserted-by":"crossref","first-page":"104988","DOI":"10.1016\/j.engfailanal.2020.104988","article-title":"Investigation on the welding-induced multiple failures in boiler water wall tube","volume":"121","author":"Liu","year":"2021","journal-title":"Eng. Fail. Anal."},{"key":"ref_23","doi-asserted-by":"crossref","first-page":"1453","DOI":"10.1016\/j.corsci.2009.03.033","article-title":"Effect of stress corrosion cracking on stress\u2013strain response of steel wires used in prestressed concrete beams","volume":"51","author":"Vu","year":"2009","journal-title":"Corros. Sci."},{"key":"ref_24","doi-asserted-by":"crossref","unstructured":"Antony Jose, S., John, M., Misra, M., and Menezes, P.L. (2025). Peening techniques for mitigating chlorine-induced stress corrosion cracking of dry storage canisters for nuclear applications. Materials, 18.","DOI":"10.3390\/ma18020438"},{"key":"ref_25","doi-asserted-by":"crossref","unstructured":"Pinoski, L., Antony Jose, S., and Menezes, P.L. (2026). Stress corrosion cracking: Mechanisms, materials challenges, and engineering solutions. Materials, 19.","DOI":"10.3390\/ma19050898"},{"key":"ref_26","first-page":"628505","article-title":"Corrosion behavior of carbon steel in synthetically produced oil field seawater","volume":"2014","author":"Paul","year":"2014","journal-title":"Int. J. Met."},{"key":"ref_27","doi-asserted-by":"crossref","first-page":"2763","DOI":"10.1007\/s11665-017-2684-9","article-title":"Effects of H2S\/HS\u2212 on stress corrosion cracking behavior of X100 pipeline steel under simulated sulfate-reducing bacteria metabolite conditions","volume":"26","author":"Liu","year":"2017","journal-title":"J. Mater. Eng. Perform."},{"key":"ref_28","doi-asserted-by":"crossref","first-page":"10423","DOI":"10.1016\/j.ijhydene.2020.12.140","article-title":"High cycle fatigue behaviors of API X65 pipeline steel welded joints in air and H2S solution environment","volume":"46","author":"Gao","year":"2021","journal-title":"Int. J. Hydrogen Energy"},{"key":"ref_29","doi-asserted-by":"crossref","first-page":"125449","DOI":"10.1016\/j.surfcoat.2020.125449","article-title":"Pitting corrosion mechanism of Cl\u2212- and S2\u2212-induced by oxide inclusions in Fe-based amorphous metallic coatings","volume":"385","author":"Wang","year":"2020","journal-title":"Surf. Coat. Technol."}],"container-title":["Materials"],"original-title":[],"language":"en","link":[{"URL":"https:\/\/www.mdpi.com\/1996-1944\/19\/8\/1621\/pdf","content-type":"unspecified","content-version":"vor","intended-application":"similarity-checking"}],"deposited":{"date-parts":[[2026,4,24]],"date-time":"2026-04-24T04:17:10Z","timestamp":1777004230000},"score":1,"resource":{"primary":{"URL":"https:\/\/www.mdpi.com\/1996-1944\/19\/8\/1621"}},"subtitle":[],"short-title":[],"issued":{"date-parts":[[2026,4,17]]},"references-count":29,"journal-issue":{"issue":"8","published-online":{"date-parts":[[2026,4]]}},"alternative-id":["ma19081621"],"URL":"https:\/\/doi.org\/10.3390\/ma19081621","relation":{},"ISSN":["1996-1944"],"issn-type":[{"value":"1996-1944","type":"electronic"}],"subject":[],"published":{"date-parts":[[2026,4,17]]}}}