Risk Assessment of Stress Corrosion Cracking in 42CrMo Substrates Induced by Coating Failure of the Screw Rotor

Cracking occurred in the surface coating of a screw rotor during shale gas well operations. To determine whether the coating cracks could contribute to the failure of the 42CrMo substrate, the microstructure and morphology of surface cracks and local corrosion pits were examined and analyzed using a metallographic microscope, an SEM, and an EDS. To investigate the cross-sectional morphology and elemental distribution of corrosion pits, EDS mapping was performed. The composition of the corrosion products was characterized using Raman spectroscopy and XPS. In addition, four-point bend stress corrosion tests were conducted on screw rotor specimens under simulated service conditions. The results indicate that the P and S contents in the screw rotor substrate exceeded the specified limits, whereas its tensile and impact strengths satisfied the standard requirements. The microstructure consisted of tempered sorbite and ferrite, along with a small amount of sulfide inclusions. The corrosion products on the fracture surface were primarily identified as FeOOH, Fe3O4, and Cr(OH)3. All specimens failed during the four-point bend tests. The chlorine (Cl) content in the corroded regions reached up to 8.05%. These findings demonstrate that the crack resistance of the 42CrMo screw rotor was markedly reduced under the simulated service conditions of 130 °C in a saturated, oxygenated 25% CaCl2 solution. The study concludes that stress concentration induced by sulfide inclusions in the screw rotor, together with the combined effects of chloride ions, dissolved oxygen, and applied load, promotes the initiation and propagation of stress corrosion cracking. Therefore, it is recommended to strictly control the chemical composition and inclusion content of the screw rotor material and to reduce the oxygen content of the drilling fluid, thereby mitigating the risk of corrosion-induced cracking of the rotor.