The cement plug-casing interface is critical for long-term wellbore integrity in well abandonment to prevent fluid channeling. However, traditional cement easily debonds under long-term in situ stress and fluid exposure, causing seal failure and safety risks. To address this issue and overcome the limitations of conventional cement, a three-dimensional finite element model was established based on stress-seepage coupling theory. A systematic comparative analysis of the interface debonding mechanisms for three materials—cement, resin, and alloy—and their different combination sequences was conducted. The entire process of interface damage was quantified. The effects of material combination, formation elastic modulus, and injection rate on sealing performance were analyzed. Results show that the stiffness gradient dominates the failure mode, and the “cement–resin–alloy” configuration best suppresses damage propagation, reducing failure height by about 30%. Additionally, interface integrity is sensitive to formation constraints and operational parameters: the interface failure height decreases as the formation elastic modulus increases, and increases as the injection rate rises. The findings of this study can provide a theoretical basis and engineering reference for the optimal design of composite plugging barriers in demanding operational conditions, such as those encountered in carbon sequestration wells.
Shen et al. (Fri,) studied this question.