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DOE OSTI2026

Final Report for Closing the Loop Between In Situ Stress Complexity and EGS Fracture Complexity

Characterizing in situ stress is essential in Enhanced Geothermal System (EGS) for both risk assessment and operation design. Standard stress measurement techniques such as diagnostic fracture injection tests (DFITs) require creating hydraulic fractures and apply analytical methods such as the G -function analysis to estimate the stress. These classical approaches rely on several assumptions, including but not limited to: (i) the induced fracture is planar and persistent, and (ii) the fracture plane is normal to the minimum horizontal stress. However, these assumptions may not hold in EGS environments like Utah FORGE, where thermo-hydro-mechanical (THM) coupling, wellbore deviation, and rock heterogeneity can alter the local stress condition and consequently lead to fracture complexities in both near-well and far-field regions.

15 GEOTHERMAL ENERGY↗

DOE OSTI2026

Integrated Simulation of Weld Residual Stress Evolution and Crack Propagation Using XFEM

Nuclear power plant components operate in environments that promote multiple degradation mecha- nisms, several of which involve crack initiation and growth. An ongoing effort in the U.S. Department of Energy’s Nuclear Energy Advanced Modeling and Simulation (NEAMS) program is developing a general capability within the Multiphysics Object Oriented Simulation Environment (MOOSE) framework for simulating three-dimensional crack growth under a range of driving conditions, including fatigue, stress corrosion cracking (SCC), brittle fracture, and stress-relaxation cracking. This report demonstrates an end-to-end workflow that uses this capability to model weld-residual-stress-driven SCC in the J-groove weld of a pressurized-water reactor control rod drive mechanism penetration in the vessel head. The workflow consists of a thermomechanical welding simulation with temperature-dependent plasticity, followed by cooldown to ambient conditions, and a restart of the simulation using the MOOSE extended finite element method (XFEM) module to propagate a three-dimensional crack through the residual stress field. New welding capabilities were developed to properly initialize newly activated elements in the weld region, and robustness improvements were made to the mesh-based algorithm for defining cutting planes in the 3D XFEM algorithm, allowing it to handle complex crack fronts and stress fields. Together these advances allowed the simulated SCC crack to grow from an initial elliptical flaw in the weld, across the weld, through the tube wall, and almost to the triple point (where the weld, tube, and reactor pressure vessel head intersect) over roughly 36 years of simulated service. These results demonstrate a workflow that can be extended to fully three-dimensional welding simulations and more complex crack interaction problems.

42 - ENGINEERING↗

DOE OSTI2024

Object-oriented analysis as a foundation for building climate storylines of compounding short-term drought and crop heat stress

Introduction: Crops are vulnerable to precipitation and heat extremes during late spring through summer. Methods: We analyzed for a north-central U.S. region short-term drought and agricultural heat stress during April-May-June-July. We used the 4-km Parameter Elevation Regression on Independent Slopes Model (PRISM) for observations, aggregated to a 25-km grid, and two 25-km Regional Climate Model version 4 (RegCM4) simulns used either GFDL- or MPI-GCM boundary conditions. We chose 1981-2000 as our contemporary time period, and 2041- 2060 as our scenario time period, which used the Representative Concentration Pathway 8.5 emissions scenario. We used object-oriented analysis to identify events of interest in observations and simulations by identifying objects in a space-time domain that meet specified criteria, such as exceeding a heat-stress temperature threshold. The event diagnosis allowed analysis of compound events, occurring when temperature and drought objects overlap. Results: Identified objects yielded events that can undermine agricultural productivity and which are thus relevant to decision makers, making them building blocks for possible climate storylines. The observations and simulations showed similar spatial distributions of event frequencies across the analysis region. However, the simulations attained this distribution by having fewer events that tend to cover larger areas compared to observed events, suggesting that the effective resolution of the simulations was coarser than their 25-km grids. Short-term drought frequency increased and heat-stress frequency decreased in transitioning to the scenario climate. When compounding occurred heat-stress events generally preceded the short-term drought events. The overlapping, compound events tended to be more extreme compared to non-overlapping events of either type. Discussion: The information yielded projected changes in these agriculturally motivated events. One prominent conditional behavior emerging from the work was that a heat-stress event should be a warning to watch for potential drought, as both could compound each other to more intense levels.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

Roles for epigenetics in wood formation and stress response intrees–from basic biology to forest management

Annual model and crop species have been the subject of most epigenetic studies for plants. In contrast to annuals, forest trees persist on natural landscapes and experience environmental variation within and across seasons, years, and decades or even centuries. Most forest trees species are undomesticated and typically grown on variable landscapes with no irrigation or application of agricultural chemicals. Forest trees must thus rely on their inherent ability to alter growth and physiology to mitigate the effects of changing abiotic and biotic stressors. Like other plants, trees have mechanisms encoded in their genomic DNA sequence that can respond directly to stress events such as drought or heat. Hypothetically, it would be highly advantageous to join these mechanisms with a dynamic “memory” of past exposure to stress. It is now well established that annual model and crop plants can establish epigenetic-based memory of stress events that support more rapid and robust response to stress in the future. Here, evidence is discussed for epigenetic regulation and “memory” in two fundamental biological processes in trees, wood formation and abiotic stress response. Wood formation is an ideal trait for epigenetic research in trees, as wood formation is highly responsive to environmental conditions and includes multiple rapid developmental changes as cells adopt distinct fates within complex tissues. This is followed by a discussion of research needs that would provide the foundation for new epigenetic applications for forestry.

Groover, Andrew↗

NASA NTRS1972

Theoretical study of stress concentrations at circular holes and inclusions in strain hardening materials.

Nonlinear boundary value problems of an infinite elastic-plastic plate with a circular hole subjected to pure tension and pure shear at infinity are solved by a method involving Fourier series and finite difference. On the basis of these solutions, the validity of Neuber's relationship between the stress and strain concentration factors for the plane stress problems is examined and a generalized Stowell formula for the stress concentration factor is proposed for problems in which the applied loading may be pure shear as well as pure tension and, furthermore, other stress states. By the same method of solution, the stress distributions around a rigid circular cylindrical inclusion embedded in an infinite rigid-plastic matrix subjected to uniform transverse pure shear and tension are obtained.

Huang, W. C.↗

NASA NTRS1972

Stresses, strains, and surface pressures in the lung caused by its weight.

In an effort to understand how the lung is deformed by its own weight, we have analyzed the distribution of regional expansion, stresses, and surface pressures in a theoretical elastic lung-shaped model using the technique of finite elements. In the upright position, the parenchyma was most expanded at the apex and least at the base. Stresses in both the vertical and lateral directions were maximal at the apex. As the lung was inflated from very low volumes to total lung capacity, parenchymal expansion and stress at the apex first decreased, then increased. This behavior can be explained by the increasing rigidity of the expanded lung which enabled it to resist distortion by its own weight. At functional residual capacity, the stress at the apex was near its minimum. The differences in intrapleural pressure down the lung were volume dependent, increasing at very low volumes. In the inverted lung, the regional differences in stress, strain, and surface pressures were less marked because of the shape of the chest.

West, J. B.↗

NASA NTRS1972

Some remarks on elastic crack-tip stress fields.

It is shown that if the displacement field and stress intensity factor are known as functions of crack length for any symmetrical load system acting on a linear elastic body in plane strain, then the stress intensity factor for any other symmetrical load system whatsoever on the same body may be directly determined. The result is closely related to Bueckner's (1970) weight function, through which the stress intensity factor is expressed as a sum of work-like products between applied forces and values of the weight function at their points of application. An example of the method is given wherein the solution for a crack in a remotely uniform stress field is used to generate the expression for the stress intensity factor due to an arbitrary traction distribution on the faces of a crack. A corresponding theory is developed in an appendix for three-dimensional crack problems, although this appears to be directly useful chiefly for problems in which there is axial symmetry.

Rice, J. R.↗

NASA NTRS1973

Combined environmental stresses

Tolerance levels, physiological effects, and performance degradation during simultaneous or sequential exposures to two environmental stresses, and also three or more simultaneous stresses are described. Environmental stress combinations are characterized by four descriptors: order of occurrence, duration of exposure, severity of exposure, and type of interaction. Combined stress data and facilities for combined stress study are briefly mentioned.

Murray, R. H.↗

NASA NTRS1971

Detection and Characterization of Stress Symptoms in Forest Vegetation

Techniques used at the Pacific Southwest Forest and Range Experiment Station to detect advanced and previsual symptoms of vegetative stress are discussed. Stresses caused by bark beetles in coniferous stands of timber are emphasized because beetles induce stress more rapidly than most other destructive agents. Bark beetles are also the most damaging forest insects in the United States. In the work on stress symptoms, there are two primary objectives: (1) to learn the best combination of films, scales, and filters to detect and locate injured trees from aircraft and spacecraft, and (2) to learn if stressed trees can be detected before visual symptoms of decline occur. Equipment and techniques used in a study of the epidemic of the Black Hills bark beetle are described.

Heller, R. C.↗

NASA NTRS1972

Time exposure studies on stress corrosion cracking of aluminum 2014-T6, aluminum 7075-T651, and titanium 6Al-4V

The effect of a constant applied stress in crack initiation of aluminum 2014-T6, 7075-T651 and titanium 6A1-4V has been investigated. Aluminum c-ring specimens (1-inch diameter) and u-band titanium samples were exposed continuously to a 3.5% NaCl solution (pH 6) and organic fluids of ethyl, methyl, and iso-propyl alcohol (reagent purity). Corrosive action was observed to begin during the first and second day of constant exposure as evidenced by accumulation of hydrogen bubbles on the surface of stressed aluminum samples. However, a similar observation was not noted for titanium stressed specimens. Results of this investigation seems to suggest that aluminum 2014-T6, aluminum 7075-T651 are susceptible to stress corrosion cracking in chloride solution (NaCl); while they (both alloys) seem to resist stress corrosion cracking in methyl alcohol, ethyl alcohol, iso-propyl alcohol, and demineralized distilled water. Titanium 6A1-4V showed some evidence of susceptibility to SCC in methanol, while no such susceptibility was exhibited in ethanol, iso-propyl alcohol and demineralized distilled water.

Terrell, J.↗

NASA NTRS1972

The effect of residual stress on performance of high temperature coatings

Techniques for measurement of residual stress in MoSi2 coatings and the determination of stress in coatings prepared by metalliding, pack and slurry processes are discussed. The stress level can be determined by stress induced deflections or by X-ray techniques. The deflection method is most direct. It is based on the fact that a thin substrate, coated on one side only, is usually curved at room temperature. The radius of curvature is easily measured and readily related to residual stress.

Source record↗

NASA NTRS1973

Apollo experience report: The problem of stress-corrosion cracking

Stress-corrosion cracking has been the most common cause of structural-material failures in the Apollo Program. The frequency of stress-corrosion cracking has been high and the magnitude of the problem, in terms of hardware lost and time and money expended, has been significant. In this report, the significant Apollo Program experiences with stress-corrosion cracking are discussed. The causes of stress-corrosion cracking and the corrective actions are discussed, in terminology familiar to design engineers and management personnel, to show how stress-corrosion cracking can be prevented.

Johnson, R. E.↗

NASA NTRS1973

Residual stress measurement and analysis using ultrasonic techniques.

A technique which utilizes ultrasonic radiation has been developed to measure residual stresses in metals. This technique makes it possible to detect and measure the magnitude of the principle stresses and also to obtain their direction. The velocities of ultrasonic waves in materials are measured as the time to travel a fixed path length, and the change in transit time is related to the applied stress. The linear relationship obtained allows a procedure based on this principle to be used for the measurement of residual stress using surface waves and shear waves. A method for plotting stress profiles through a material using surface waves uses varying frequencies for the ultrasonic wave. A limitation of the shear wave method is considered. The system used for this technique is called the Modified Time of Flight System.

Noronha, P. J.↗

NASA NTRS1973

Stress wave calculations in composite plates using the fast Fourier transform.

The protection of composite turbine fan blades against impact forces has prompted the study of dynamic stresses in composites due to transient loads. The mathematical model treats the laminated plate as an equivalent anisotropic material. The use of Mindlin's approximate theory of crystal plates results in five two-dimensional stress waves. Three of the waves are flexural and two involve in-plane extensional strains. The initial value problem due to a transient distributed transverse force on the plate is solved using Laplace and Fourier transforms. A fast computer program for inverting the two-dimensional Fourier transform is used. Stress contours for various stresses and times after application of load are obtained for a graphite fiber-epoxy matrix composite plate. Results indicate that the points of maximum stress travel along the fiber directions.

Moon, F. C.↗

NASA NTRS1974

Mixed mode stress intensity factors for semielliptical surface cracks

The three-dimensional equations of elasticity are solved for a flat elliptical crack which has nonuniform shear stresses applied to its surfaces. An alternating method is used to determine the mode two and mode three stress intensity factors for a semielliptical surface crack in the surface of a finite thickness solid. These stress intensity factors are presented as a function of position along the crack border for a number of crack shapes and crack depths. This same technique is followed to determine the mode one stress intensity factors for the semielliptical surface crack which has normal loading applied to its surface. Mode one stress intensity factors are presented and compared with the results obtained from previous work.

Smith, F. W.↗

NASA NTRS1975

Kinetic studies of the stress corrosion cracking of D6AC steel

The effect of load interactions on the crack growth velocity of D6AC steel under stress corrosion cracking conditions was determined. The environment was a 3.5 percent salt solution. The modified-wedge opening load specimens were fatigue precracked and subjected to a deadweight loading in creep machines. The effects of load shedding on incubation times and crack growth rates were measured using high-sensitivity compliance measurement techniques. Load shedding results in an incubation time, the length of which depends on the amount of load shed and the baseline stress intensity. The sequence of unloading the specimen also controls the subsequent incubation period. The incubation period is shorter when load shedding passes through zero load than when it does not if the specimen initially had the same baseline stress intensity. The crack growth rates following the incubation period are also different from the steady-state crack growth rate at the operating stress intensity. These data show that the susceptibility of this alloy system to stress corrosion cracking depends on the plane-strain fracture toughness and on the yield strength of the material.

Noronha, P. J.↗

NASA NTRS1975

The effect of bending on the stresses in adhesive joints

The problem of stress distribution in adhesive joints where two orthotropic plates are bonded through a flexible adhesive layer is analyzed. It is shown that the effect of bending of the adherends on the stresses in the adhesive layer is very significant. The transverse shear deformations of the adherends appear to have little influence on the adhesive layer stresses. The maximum transverse normal stress in the adhesive is shown to be larger than the maximum longitudinal shear stress. The method of solution is applied to several examples of specific joint geometries and material combinations, and is proven to be applicable to other related problems.

Yuceoglu, U.↗

NASA NTRS1976

Ultrasonic measurement of stress in 2219-T87 aluminum plate

The basic relationship of ultrasonic signal velocity to directional subsurface stress is reviewed. Inappropriateness of dependency on a single correlative value of constant for a three dimensional stress field in metallic materials is discussed. Implementation of conventional ultrasonic nondestructive testing capabilities integrated to provide a composite technique for the measurement of orthogonal stress components is described, and the procedures for performing the preparatory calibration and subsequent stress field measurements are presented. In conclusion, the prime effect of stress on ultrasonic signal velocity occurs only in the direction of material excitation or particle motion.

Clotfelter, W. N.↗