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DOE OSTI2021

Impacts of Substrate Thinning on FPGA Performance and Reliability [Slides]

Substrate thinning is necessary in devices with flip-chip BGA packages to enable both radiation testing and component qualification and high-spatial resolution beam-based failure analysis methods. We investigated three factors affecting device performance: subsurface damage from the thinning process, reduced heat spreading in thin substrates, and changes in device switching speed. We conclude subsurface damage to crystalline Si caused by the thinning process is removable with sufficient SiO 2 slurry polishing. Local temperature differences increase minimally in devices thinned to 3 μm. Compressive stress in the Si increases globally after device thinning and leads to slowing of ring oscillator frequency by about 0.5% compared to full-thickness devices. Future work will include extending the results to submicron Si thickness values, which also has important benefits for failure analysis, debug, and security assessments. We also plan to extend this type of work to other FPGAs and other devices like memory and processors.

36 MATERIALS SCIENCE↗

DOE OSTI2021

NETL Well Integrity Workshop: Identifying Well Integrity Research Needs for Subsurface Energy Infrastructure

Wells are a critical component of subsurface energy infrastructure. Ensuring the integrity of wells as engineered pathways for the safe extraction, injection, and storage of fluids in the subsurface is key to maximizing the effectiveness and resilience of that infrastructure. Addressing well integrity issues in a technically robust manner that promotes environmental sustainability and social equity is also an important focus of the United States (U.S.) Department of Energy’s (DOE) Office of Fossil Energy and Carbon Management. Industry best practices, regulatory standards, modern monitoring data acquisition and control systems, and decades of research and development have dramatically improved the performance and reliability of wells for hydrocarbon extraction and underground injection in the oil and gas industry. Yet, important innovation is required to improve and ensure well integrity performance in engineered geologic systems where operational environments (fluid composition, temperature, pressure, and/or stress conditions) and long functional life cycles of well systems present unique challenges. Additionally, work is needed to understand and manage the long-term integrity and risks associated with legacy wells—especially those located adjacent to and presenting hazards for new subsurface activity.

02 PETROLEUM↗

NASA NTRS1995

Rings of the North Brazil Current: Their structure and behavior inferred from observations and a numerical simulation

Large anticyclonic rings are shed from the retroflecting North Brazil Current (NBC) near 8 deg N in the tropical western Atlantic. New subsurface velocity and temperature measurements within three such rings are presented here and are found to be consistent with previous in situ and remotely sensed NBC ring measurements. A high-resolution numerical model of the Atlantic Ocean forced by monthly wind stress and an imposed meridional overturning cell is found to shed NBC rings that approximate those observed. The model rings are more surface-intensified than those observed and somewhat smaller in diameter. Both observed and modeled NBC rings move northwestward along the coast of South America with a speed of 8-16 cm/s, considerably slower than predicted by analytical theories describing westward ring propagation. At least 2-3 rings per year separate from the NBC retroflection. Annually, 1-3 rings translate intact from their formation region near 50 deg W to the islands of the southeastern Caribbean, where they disintegrate after a lifetime of about 100 days. This study is the first to make use of subsurface temperature and velocity data to compute the volume of the anomalous ring core. NBC rings may be responsible for 3-4 Sv of direct mass transport across the equatorial-tropical gyre boundary or 20-25% of the total upper ocean cross-gyre transport required by the Atlantic meridional overturning cell. Translating NBC rings may contribute 20% of the total meridional heat transport by the ocean at this latitude.

Fratantoni, David M.↗

NASA NTRS2004

Lunar and Planetary Science XXXV: Mars Geophysics

The titles in this section include: 1) An Extraordinary Magnetic Field Map of Mars; 2) Mapping Weak Crustal Magnetic Fields on Mars with Electron Reflectometry; 3) Analytic Signal in the Interpretation of Mars Southern Highlands Magnetic Field; 4) Modeling of Major Martian Magnetic Anomalies: Further Evidence for Polar Reorientations During the Noachian; 5) An Improved Model of the Crustal Structure of Mars; 6) Geologic Evolution of the Martian Dichotomy and Plains Magnetization in the Ismenius Area of Mars; 7) Relaxation of the Martian Crustal Dichotomy Boundary in the Ismenius Region; 8) Localized Tharsis Loading on Mars: Testing the Membrane Surface Hypothesis; 9) Thermal Stresses and Tharsis Loading: Implications for Wrinkle Ridge Formation on Mars; 10) What Can be Learned about the Martian Lithosphere from Gravity and Topography Data? 11) A Gravity Analysis of the Subsurface Structure of the Utopia Impact Basin; 12) Mechanics of Utopia Basin on Mars; 13) Burying the 'Buried Channels' on Mars: An Alternative Explanation.

Source record↗

NASA NTRS1973

Ultrasonics

Ultrasonic testing is discussed as a primary means of nondestructive evaluation of subsurface flaws. The advantages and disadvantages are listed. The elementary principles, basic components of test units, scan modes, resonance testing, detection of fatigue cracks, monitoring fatigue crack growth, and determination of residual stress are discussed.

Leonard, B. E.↗

DOE OSTI2022

Mixed heavy metal stress induces global iron starvation response

Abstract Multiple heavy metal contamination is an increasingly common global problem. Heavy metals have the potential to disrupt microbially mediated biogeochemical cycling. However, systems-level studies on the effects of combinations of heavy metals on bacteria are lacking. For this study, we focused on the Oak Ridge Reservation (ORR; Oak Ridge, TN, USA) subsurface which is contaminated with several heavy metals and high concentrations of nitrate. Using a native Bacillus cereus isolate that represents a dominant species at this site, we assessed the combined impact of eight metal contaminants, all at site-relevant concentrations, on cell processes through an integrated multi-omics approach that included discovery proteomics, targeted metabolomics, and targeted gene-expression profiling. The combination of eight metals impacted cell physiology in a manner that could not have been predicted from summing phenotypic responses to the individual metals. Exposure to the metal mixture elicited a global iron starvation response not observed during individual metal exposures. This disruption of iron homeostasis resulted in decreased activity of the iron-cofactor-containing nitrate and nitrite reductases, both of which are important in biological nitrate removal at the site. We propose that the combinatorial effects of simultaneous exposure to multiple heavy metals is an underappreciated yet significant form of cell stress in the environment with the potential to disrupt global nutrient cycles and to impede bioremediation efforts at mixed waste sites. Our work underscores the need to shift from single- to multi-metal studies for assessing and predicting the impacts of complex contaminants on microbial systems.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2022

Physics-Informed and Data-Driven Prediction of Residual Stress in Three-Dimensional Machining

Efficient and reliable prediction of machining-induced residual stress (RS) is a key requirement for truly integrated computational materials engineering (ICME). Currently available process modeling approaches, including empirical, analytical, and numerical methodologies lack predictive power and require substantial calibration and validation data. Moreover, most model-based approaches consider only two-dimensional (2D) (i.e., orthogonal), cutting processes. Meanwhile, industrial processes such as milling, turning, and drilling are inherently three-dimensional (3D). The present work attempts to bridge the gap between 2D and 3D through careful consideration of the process physics, including geometric, kinematic, and size-effect constraints to realize robust prediction of how RS develops in 3D machining. Using a novel in-situ experimental technique and digital image correlation (DIC) to determine equivalent Hertzian contact widths, contact pressures, and friction coefficients, the proposed methodology leverages a discretized conversion algorithm that includes multi-pass shakedown effects. This paper presents a semi-analytical model to predict machining-induced RS in 3D turning operations, which are used representatively for 3D processes more generally. Rather than follow a ‘brute force’ 3D FEM approach or conduct countless experiments to train a purely data-driven machine learning algorithm, the proposed approach builds on previous 2D modeling work. Through careful consideration of the process physics, including complex geometry/kinematic considerations of 3D turning, the authors demonstrated an experimentally calibrated approach, as well as validation based on published RS data. Model predictions and previously published measurement data of RS depth profiles for turning of Inconel 718 were compared for a range of process parameters. Correlation between the proposed 3D model and validation data was found to be within the margin of experimental error for most conditions. The proposed model appears to capture the overall behavior of 3D RS depth profiles with acceptable accuracy, particularly the key metrics of near-surface stress, peak stress magnitude and location, as well as overall stress profile depth. This report presents a physics-informed, data-driven approach for efficient calibration of a 2D model for machining-induced RS through DIC analysis of in-situ characterized subsurface displacement fields.

42 ENGINEERING↗

DOE OSTI2023

High-resolution 3D strain and orientation mapping within a grain of a directed energy deposition laser additively manufactured superalloy

The industrialization of Laser Additive Manufacturing (LAM) is challenged by the undesirable microstructures and high residual stresses originating from the fast and complex solidification process. Non-destructive assessment of the mechanical performance controlling deformation patterning is therefore critical. Here, we use Dark Field X-ray Microscopy (DFXM) to map the 3D subsurface intragranular orientation and strain variations throughout a surface-breaking grain within a directed energy deposition nickel superalloy. DFXM results reveal a highly heterogenous 3D microstructure in terms of the local orientation and lattice strain. The grain comprises ≈ 5 μm-sized cells with alternating strain states, as high as 5 x10 -3 , and orientation differences <0.5°. The DFXM results are compared to Electron Backscatter Diffraction measurements of the same grain from its cut-off surface. Here, we discuss the microstructure developments during LAM, rationalising the development of the deformation patterning from the extreme thermal gradients during processing and the susceptibility for solute segregation.

36 MATERIALS SCIENCE↗

DOE OSTI2024

De-risking fault leakage risk and containment integrity for subsurface storage applications

The subsurface is pivotal in the energy transition, for the sequestration of CO 2 and energy storage. It is crucial to understand to what extent geological faults may form leakage pathways that threaten the containment integrity of these projects. Fault flow behavior has been studied in the context of hydrocarbon development, supported by observations from wells drilled through faults, but such observations are rare in geoenergy projects. Focusing on mechanical behavior as early indicator of potential leakage risks, a probabilistic Coulomb Failure Stress workflow is developed and demonstrated using data from the Decatur CO 2 sequestration project to rank faults based on their containment risk. The analysis emphasizes the importance of fault throw relative to reservoir thickness and pore pressure change in assessing reactivation risks. Integrating this mechanical assessment with geological and dynamic fault analyses contributes to derisking fault containment for geoenergy applications, providing valuable insights for the successful development of subsurface storage projects.

58 GEOSCIENCES↗

DOE OSTI2020

Ecological Assembly Processes Are Coordinated between Bacterial and Viral Communities in Fractured Shale Ecosystems

The ecological drivers that concurrently act upon both a virus and its host and that drive community assembly are poorly understood despite known interactions between viral populations and their microbial hosts. Hydraulically fractured shale environments provide access to a closed ecosystem in the deep subsurface where constrained microbial and viral community assembly processes can be examined. Here, we used metagenomic analyses of time-resolved-produced fluid samples from two wells in the Appalachian Basin to track viral and host dynamics and to investigate community assembly processes. Hypersaline conditions within these ecosystems should drive microbial community structure to a similar configuration through time in response to common osmotic stress. However, viral predation appears to counterbalance this potentially strong homogeneous selection and pushes the microbial community toward undominated assembly. In comparison, while the viral community was also influenced by substantial undominated processes, it assembled, in part, due to homogeneous selection. When the overall assembly processes acting upon both these communities were directly compared with each other, a significant relationship was revealed, suggesting an association between microbial and viral community development despite differing selective pressures. These results reveal a potentially important balance of ecological dynamics that must be in maintained within this deep subsurface ecosystem in order for the microbial community to persist over extended time periods. More broadly, this relationship begins to provide knowledge underlying metacommunity development across trophic levels.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

TReactMech v4.217

TReactMech couples geomechanical processes (poroelasticity, failure, and inelastic strain) with multiphase nonisothermal flow (derived from TOUGH2) and reactive geochemical transport. At its core is the reactive-transport code TOUGHREACT v4.13. TReactMech is an efficient hybrid parallel simulator, solving the geomechanics using finite elements and MPI/PetSc, the multiphase flow using integrated finite difference and MPI/PETSc, and the reactive chemistry using OpenMP. The advantages of TReactMech are in its multiphase flow capabilities (e.g., supercritical CO2, supercritical water, air) and parallel geomechanics including full 3-D stress tensor, shear and tensile failure, coupled to porosity and permeability changes. It is backwardly compatible with TOUGH2 and TOUGHREACT v4.13, allowing for easier transitions between the codes. TReactMech can be used to simulate many natural and engineered subsurface systems, including geothermal reservoirs, borehole heat exchangers, geologic carbon sequestration, geologic storage of nuclear waste, groundwater resources, weathering, sediment diagenesis, seafloor hydrothermal circulation, hydrofracturing in unconventional reservoirs, and injection/production-induced surface deformation.

Sonnenthal, Eric↗

NASA NTRS2003

Global Characterization of Polygonally Fractured Terrain on Venus and Implications for a Climate Change Origin

On Earth, polygonal fractures with spacings of 1-100 cm form in lava flows that cool slowly under isotropic stress conditions. On Venus, polygonal fractures are observed with typical fracture spacings of 1-2 km, covering regions 10s to 100s of km across. These features have been proposed to form via cooling of lava flows or above subsurface intrusions, or due to surface cooling caused by climate change. A watershed algorithm was modified to search the entire Magellan image database autonomously for terrains with polygonal fractures. Here we characterize the 204 polygon terrains found using this method (including over 170 newly identified regions) with respect to size, morphology, stratigraphy, and geologic setting. These results are used to examine different models of origin.

Smrekar, S. E.↗

DOE OSTI2024

Experimental and numerical investigation of fracture conductivity between non-smooth rock surfaces with and without proppant

The enhancement of fracture conductivity is vital for the efficient recovery of subsurface resources, such as geothermal energy and petroleum hydrocarbons. Proppants, granular materials injected into hydraulic fractures to maintain their conductivity, have been studied primarily in the context of smooth fractures (i.e., fractures between smooth rock surfaces). However, non-smooth fractures (i.e., fractures between rough rock surfaces) are common in geoenergy reservoirs and thus require further investigations. In this study, we conducted laboratory measurements of fracture conductivity on shale slabs with non-smooth surfaces and carried out numerical simulation using the lattice Boltzmann (LB) method, which aimed to investigate the conductivity of non-smooth fractures with and without proppants placement. When ceramic proppant with an areal concentration of 2 lb/ft 2 was placed in the fracture, the conductivity was enhanced by roughly 3-8 times compared to fractures without proppant. In fractures with proppant, gas-measured conductivity was higher than that measured with water due to proppant embedment caused by water. The experiments demonstrate the advantages of using proppant in fractures, even if the rock surface roughness can provide certain fracture conductivity via the self-propping mechanism. For fractures without proppants, high rock surface roughness is not necessarily favorable for enhancing fracture conductivity because the self-propping mechanism requires shear slip along the fracture surface. If there is no shear slip, high rock surface roughness can cause a detrimental effect on the fracture conductivity due to the interlocking effect. Utilizing advanced experimental equipment and LB modeling, this research explores the interplays between proppant placement, fracture geometry, and stress conditions to develop a comprehensive understanding of the productivity in non-smooth fractures. Further, the outcomes of this investigation indicate the importance of creating fractures with surface roughness during hydraulic fracturing and will contribute to the development of more efficient stimulation techniques for subsurface energy extraction.

15 GEOTHERMAL ENERGY↗

DOE OSTI2025

Factors controlling injection-induced rupture of intersecting faults during geological sequestration of CO 2

This study addresses coupled multiphase fluid flow and geomechanics effects on potential fault activation associated with subsurface CO 2 injection around intersecting faults. An enhanced fault-representation model is used to capture geomechanical responses of two intersecting faults with finite length during CO 2 injection. The faults are embedded in a strike-slip stress regime of a caprock-reservoir-basement system with the faults represented by zero-thickness interfaces with adjacent finite-thickness damage zones. A sensitivity analysis is conducted to study the effect of fault permeability, slip-weakening behavior, well location relative to the orientation of faults, and well placement (the number and location of injection wells). Five metrics (pressure, CO 2 plume, shear state on the fault, as well as shear displacement and stress path at selected fault monitoring points) are selected to assess CO 2 migration and reactivation of intersecting faults. The results show that induced ruptures are favored by low permeability faults due to high pressure buildup and by slip-weakening behavior resulting from fault strength reduction. The location of one injection well relative to fault orientation determines the magnitude of changes in effective normal stress and shear stress, affecting the location of induced ruptures. Well placement (two injection wells used in the paper) dominates pressure diffusion around the intersection and tips of faults. This redistributes changes in effective normal stress caused by each injection well, influencing the spatial distribution of ruptures along faults. A larger injection volume induces far-field ruptures that are controlled by stress transfer within the injection layer. The findings presented here can provide valuable insights into engineering operations for a long-term, safe, and reliable geologic CO 2 storage.

Fault permeability↗

DOE OSTI2020

Creation of a Mixed-Mode Fracture Network at Mesoscale Through Hydraulic Fracturing and Shear Stimulation

Enhanced Geothermal Systems could provide a substantial contribution to the global energy demand if their implementation could overcome inherent challenges. Examples are insufficient created permeability, early thermal breakthrough, and unacceptable induced seismicity. In this study we report on the seismic response of a mesoscale hydraulic fracturing experiment performed at 1.5-km depth at the Sanford Underground Research Facility. We have measured the seismic activity by utilizing a 100-kHz, continuous seismic monitoring system deployed in six 60-m length monitoring boreholes surrounding the experimental domain in 3-D. The achieved location uncertainty was on the order of 1 m and limited by the signal-to-noise ratio of detected events. These uncertainties were corroborated by detections of fracture intersections at the monitoring boreholes. Three intervals of the dedicated injection borehole were hydraulically stimulated by water injection at pressures up to 33 MPa and flow rates up to 5 L/min. We located 1,933 seismic events during several injection periods. The recorded seismicity delineates a complex fracture network comprised of multistrand hydraulic fractures and shear-reactivated, preexisting planes of weakness that grew unilaterally from the point of initiation. We find that heterogeneity of stress dictates the seismic outcome of hydraulic stimulations, even when relying on theoretically well-behaved hydraulic fractures. Once hydraulic fractures intersected boreholes, the boreholes acted as a pressure relief and fracture propagation ceased. In order to create an efficient subsurface heat exchanger, production boreholes should not be drilled before the end of hydraulic stimulations.

58 GEOSCIENCES↗

DOE OSTI2019

Collapse of Reacted Fracture Surface Decreases Permeability and Frictional Strength

Abstract Geochemical and geomechanical perturbations of the subsurface caused by the injection of fluids present risks of leakage and seismicity. This study investigated how acidic fluid flow affects hydraulic and frictional properties of fractures using experiments with 3.8‐cm‐long specimens of Eagle Ford shale, a laminated shale with carbonate‐rich strata. In low‐pressure flow cells, one set of samples was exposed to acidic brine and another set was exposed to neutral brine. X‐ray computed tomography and energy‐dispersive X‐ray spectroscopy revealed that samples exposed to acidic brine were calcite‐depleted and had developed a porous altered layer, while the other set showed no evidence of alteration. After reaction, samples were compressed and sheared in a triaxial cell that supplied normal stress and differential pore pressure at prescribed sliding velocities, independently measuring friction and permeability. During the initial compression, the porous altered layer collapsed into fine particles that filled the fracture. This effectively impeded flow and sealed the fracture, resulting in fracture permeability to decrease 1 to 2 orders of magnitude relative to the unaltered fractures. This is a favorable outcome in subsurface applications where the goal is to reduce leakage risks. However, during shear the reacted fracture had lower frictional strength because the fine‐grained particles in the collapsed layer prevented the formation of interlocking microasperities. Therefore, coupled geochemical and geomechanical processes that could favorably seal fractures could also increase the likelihood of induced seismicity. These findings have important implications for geological carbon sequestration, pressurized fluid energy storage, geothermal energy, and other subsurface technologies.

58 GEOSCIENCES↗

DOE OSTI2023

Wide-field probing of silica laser-induced damage precursors by photoluminescence photochemical quenching

Here, we describe a wide-field approach to probe transient changes in photoluminescence (PL) of defects on silica surfaces. This technique allows simultaneous capture of spatially resolved PL with spontaneous quenching behavior. We attribute the quenching of PL intensity to photochemical reactions of surface defects and/or subsurface fractures with ambient molecules. Such quenching curves can be accurately reproduced by our theoretical model using two quenchable defect populations with different reaction rates. The fitting parameters of our model are spatially correlated to fractures in silica where point defects and mechanical stresses are known to be present, potentially indicating regions prone to laser-induced damage growth. We believe that our approach allows rapid spatial resolved identification of damage prone morphology, providing a new pathway to fast, non-destructive predictions of laser-induced damage growth.

47 OTHER INSTRUMENTATION↗

DOE OSTI2022

Evidence of Nonlinear Seismic Effects in the Earth from Downhole Distributed Acoustic Sensors

Seismic velocities and elastic moduli of rocks are known to vary significantly with applied stress, which indicates that these materials exhibit nonlinear elasticity. Monochromatic waves in nonlinear elastic media are known to generate higher harmonics and combinational frequencies. Such effects have the potential to be used for broadening the frequency band of seismic sources, characterization of the subsurface, and safety monitoring of civil engineering infrastructure. However, knowledge on nonlinear seismic effects is still scarce, which impedes the development of their practical applications. To explore the potential of nonlinear seismology, we performed three experiments: two in the field and one in the laboratory. The first field experiment used two vibroseis sources generating signals with two different monochromatic frequencies. The second field experiment used a surface orbital vibrator with two eccentric motors working at different frequencies. In both experiments, the generated wavefield was recorded in a borehole using a fiber-optic distributed acoustic sensing cable. Both experiments showed combinational frequencies, harmonics, and other intermodulation products of the fundamental frequencies both on the surface and at depth. Laboratory experiments replicated the setup of the field test with vibroseis sources and showed similar nonlinear combinations of fundamental frequencies. Amplitudes of the nonlinear signals observed in the laboratory showed variation with the saturating fluid. These results confirm that nonlinear components of the wavefield propagate as body waves, are likely to generate within rock formations, and can be potentially used for reservoir fluid characterization.

58 GEOSCIENCES↗