Comparing the Tribological Performance of Water-Based and Oil-Based Drilling Fluids in Diamond–Rock Contacts

Abstract

AbstractOil-based drilling fluids are usually assumed to provide lower friction compared to their water-based alternatives. However, clear evidence for this has only been presented for steel–rock and steel–steel contacts, which are representative of the interface between the drillstring and the borehole or casing. Another crucial interface that needs to be lubricated during drilling is that between the cutter (usually diamond) and the rock. Here, we present pin-on-disc tribometer experiments that show higher boundary friction for n-hexadecane-lubricated diamond–granite contacts than air- and water-lubricated contacts. Using nonequilibrium molecular dynamics simulations of a single-crystal diamond tip sliding on α-quartz, we show the same trend as in the experiments of increasing friction in the order: water < air < n-hexadecane. Analysis of the simulation results suggests that the friction differences between these systems are due to two factors: (i) the indentation depth of the diamond tip into the α-quartz substrate and (ii) the amount of interfacial bonding. The n-hexadecane system had the highest indentation depth, followed by air, and finally water. This suggests that n-hexadecane molecules reduce the hardness of α-quartz surfaces compared to water. The amount of interfacial bonding between the tip and the substrate is greatest for the n-hexadecane system, followed by air and water. This is because water molecules passivate terminate potential reactive sites for interfacial bonds on α-quartz by forming surface hydroxyl groups. The rate of interfacial bond formation increases exponentially with normal stress for all the systems. For each system, the mean friction force increases linearly with the mean number of interfacial bonds formed. Our results suggest that the expected tribological benefits of oil-based drilling fluids are not necessarily realised for cutter–rock interfaces. Further experimental studies should be conducted with fully formulated drilling fluids to assess their tribological performance on a range of rock types. Graphical Abstract