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DOE OSTI2024

Relating Hydro–Mechanical and Elastodynamic Properties of Dynamically Stressed Tensile–Fractured Rock in Relation to Applied Normal Stress, Fracture Aperture, and Contact Area

We exploit nonlinear elastodynamic properties of fractured rock to probe the micro-scale mechanics of fractures and understand the relation between fluid transport and fracture aperture under dynamic stressing. Experiments were conducted on rough, tensile-fractured Westerly granite subject to triaxial stresses. We measure fracture permeability for steady-state fluid flow with deionized water. Pore pressure oscillations are applied at amplitudes ranging from 0.2 to 1 MPa at 1 Hz frequency. During dynamic stressing we transmit ultrasonic signals through the fracture using an array of piezoelectric transducers (PZTs) to monitor evolution of interface properties. We examine the influence of fracture aperture and contact area by conducting measurements at effective normal stresses of 10–20 MPa. Additionally, the evolution of contact area with stress is characterized using pressure sensitive film. These experiments are conducted separately with the same fracture and map contact area at stresses from 9 to 21 MPa. The measurements are a proxy for “true” contact area for the fracture surface and we relate them to elastic properties using the calculated PZT sensor footprints via numerical modeling of Fresnel zones. We compare the elastodynamic response of the fracture using the stress-induced changes in ultrasonic wave velocities for transmitter-receiver pairs to image spatial variations in contact properties. We show that nonlinear elasticity and permeability enhancement decrease with increasing normal stress. Additionally, post-oscillation wave velocity and permeability exhibit quick recoveries toward pre-oscillation values. Estimates of fracture contact area (global and local) demonstrate that the elastodynamic and permeability responses are dominated by fracture topology.

58 GEOSCIENCES↗

NASA NTRS1987

Geometry and relative age of large patterned fractures in southern Acidalia Planitia, Mars

Extraordinary patterned fractures occur in Elysium, Utopia, and Acidalia Planitiae of Mars. Theories as to their origin range from permafrost patterning to tectonic fracturing. Recent studies indicate the patterned fractures may be a surface reflection of rough, buried terrane in which fracturing occurs as a result of differential compaction. The patterned terrane in the southern portion of the Acidalia region (MC4-SE, MC4-SC) is being studied to determine its age relative to other terranes and events, and to constrain models for the origin of the fractures. Fracturing in this area occurs between 5 and 25 degrees west longitude and 37 and 50 degrees north latitude. Many fracture patterns are roughly polygonal, with polygons ranging in size from approximately 11 to 32 km in diameter. Fracture traces range from the limit of resolution (10's of meters) to 35 km in length.

Borrello, Murray C.↗

DOE OSTI2024

Computational Modeling of Proppants Transport in Rock Fractures

Presentation describing the direct numerical simulations (DNS) of fluid and particulate transport through rough-walled rock fractures showing transport properties of proppants as a function of fracture properties, injection velocity, and proppant size. Results demonstrate the particulate transport is highly influenced by the ratio of proppant diameter to mean fracture aperture, and quantified in terms of areal space that proppant coverage occurs.

Rousta, Farid↗

DOE OSTI2025

Characterizing Stress Roughness at Utah FORGE Through Simulation of Hydraulic Fracture Growth During 16A Stage 3 Stimulation

In most geologic formations, the vertical gradient of the minimum horizontal stress (𝜎 h ) exceeds the hydrostatic gradient, often driving hydraulic fractures to propagate upward. However, observations indicate that the upward growth of real hydraulic fractures is less pronounced than theoretical predictions based on smoothly varying 𝜎 h fields. In fact, the layered structure of sedimentary rocks hinders fracture propagation across layers, partially explaining the limited height growth observed in practice (Zoback et al., 2022). While crystalline rocks lack the pervasive layered fabric of sedimentary formations, they still possess structural fabric formed over their geologic history, resulting in inherently "rough" in situ stress fields. Recent studies have identified another key factor: the "roughness" of in situ stress, characterized by temporal, relatively short-wavelength fluctuations superimposed on the overall stress gradient. This stress roughness leads to apparent toughness anisotropy, where the vertical toughness appears significantly larger than the horizontal toughness (P. Fu et al., 2019; Dontsov & Suarez-Rivera, 2021). Neglecting the effects of rock fabric and stress roughness can yield inaccurate predictions of hydraulic fracture geometry and growth rates at larger length scales.

58 GEOSCIENCES↗

DOE OSTI2022

Improving fatigue performance of additively manufactured Ti-6Al-4V using sulfur-based self-terminating etching processes

The adoption of Additively Manufactured (AM) Ti-6Al-4V (Ti64) is continually increasing in the industry due to its benefits over the conventional manufacturing techniques. However, AM Ti64 parts are prone to poor surface finish, which significantly affects their fatigue performance. Therefore, AM Ti64 parts need post-processing to enhance surface finish and fatigue performance. Prior work with a sulfur-based self-terminating etching process for AM Ti64 demonstrated support removal and surface roughness reduction. To further this work, this manuscript details the impact of this sulfur-based post-processing technique on the mechanical properties and the fatigue life of AM Ti64 by characterizing the surface roughness, microstructural evolution, and fracture surfaces. Finally, this post-processing technique decreased the surface roughness parameter - S v by 55 % from 84 ± 11 µm to 38 ± 19 µm and increased the average fatigue life by 340 % from about 7000 cycles to 30,000 cycles.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Wellbore Fracture Imaging Using Inflow Detection Measurements

One of the most striking measurements taken during DOE’s EGS Collab project at the 4850-foot depth location was the so-called ‘sewer cam’, which enabled direct visualization of the flow of water into the production well through fractures during the stimulation. The ability to see directly which fractures were flowing and (roughly) how much was a breakthrough in understanding the topology of the created fracture network. Achieving this kind of fracture flow imaging at FORGE would be more challenging because of the 225°C temperature, but equally or even more valuable if it could be achieved. In 2017, a joint project between Sandia and Stanford developed a downhole tool concept to measure the enthalpy of multiphase fluid entering a geothermal well from individual fractures (Gao et al., 2017). For the FORGE project, measuring enthalpy is of less interest because the fluid is expected to be single-phase liquid water. However, the foundation of the device was the measurement of chloride ion concentration, which could form the basis for a direct measurement of inflow from fractures. During the 2017 project, this novel chloride sensing system was implemented into a laboratory test instrument, and we confirmed the capability of the system to measure the ion concentration of fluid entering a model wellbore through a small entry port. The wellbore was a 6-inch diameter model well, and the port was approximately 0.08 inch (2mm) in diameter. The device could measure the chloride concentration accurately even when the well was flowing in a bubbly flow. Given its accuracy, the tool should be able to identify locations of water entering the wellbore even if the ion concentration differs only slightly from that of the water in the well. It is likely that different fractures may flow slightly different chloride concentrations, which would make it feasible to detect individual fractures as well as to estimate the volume of their flow. Ultimately, we could also recognize different fractures flowing back significantly different ion concentrations after fracturing in the FORGE wells. This could be realized by adding different ions in the fracturing fluids in different fractures created at different stages of stimulation (and modifying the tool to include different ion specificity). Sandia’s tool was shown during the study to have the capability to withstand the 225°C temperature, and the electrochemical sensing elements were tested in the laboratory to 225°C at 1500 psia for 24 hours. An early implementation of the fully integrated downhole electrochemical tool, including high-temperature electronics, robust housing, and wireline truck interface, had previously been constructed and tested successfully at Sandia; thus, hardware development tasks focused on advancing the technology readiness level (TRL) of this promising technology for FORGE deployment, rather than on developing a new scientific basis for its operation. The data collection electronics in this tool allowed for several other sensors (pressure, temperature, flow spinner) to be implemented in parallel as well. The research was a new collaboration between Stanford and Sandia to modify and refine the tool for FORGE deployment, to make the downhole measurements, and to characterize the evolving fractures.

15 GEOTHERMAL ENERGY↗

NASA NTRS1974

Tectonism and volcanism of the Tharsis region of Mars

The Tharsis region of Mars, where the planet's largest shield volcanoes are located, is at the center of a fracture system that extends over almost half the surface of the planet. The fractures are tensional and aligned roughly radial to Tharsis and form two opposing fanlike arrangements that converge on the line of the Tharsis volcanoes. The fractures are attributed to a broad asymmetric updoming of the Martian crust centered to the southeast of the volcano line. Formation of the dome took place before the formation of the shield volcanoes. The location of the shields was controlled by the fractures, and volcano formation may have reactivated some of the fractures. The updoming, thought to result from mantle convection, separates eras of different volcanism and appears to have been a discrete and unique event in the history of Mars.

Carr, M. H.↗

NASA NTRS2009

Dynamic Mechanical Properties and Fracture Surface Morphologies of Core-Shell Rubber (CSR) Toughened Epoxy at Liquid Nitrogen (Ln2) Temperatures

The dynamic mechanical properties and fracture surface morphologies were evaluated for a commercial epoxy resin toughened with two types of core-shell rubber (CSR) toughening agents (Kane Ace(Registered TradeMark) MX130 and MX960). The impact resistance (R) was evaluated by the resulting breaking energy measured in Charpy impact tests conducted on an instrumented drop tower. The resulting fracture surface morphologies were examined using Scanning Electron Microscopy (SEM). Fractographic observations of the CSR toughened epoxy tested at ambient temperature, showed a fracture as characterized by slender dendrite textures with large voids. The increasing number of dendrites and decreasing size of scale-like texture with more CSR particles corresponded with increased R. As the temperature decreased to Liquid Nitrogen (LN 2), the fracture surfaces showed a fracture characterized by a rough, torn texture containing many river markings and deep furrows.

Wang, J.↗

NASA NTRS1994

Damage Mechanisms and Controlled Crack Propagation in a Hot Pressed Silicon Nitride Ceramic

The subcritical growth of cracks from pre-existing flaws in ceramics can severely affect the structural reliability of a material. The ability to directly observe subcritical crack growth and rigorously analyze its influence on fracture behavior is important for an accurate assessment of material performance. A Mode I fracture specimen and loading method has been developed which permits the observation of stable, subcritical crack extension in monolithic and toughened ceramics. The test specimen and procedure has demonstrated its ability to generate and stably propagate sharp, through-thickness cracks in brittle high modulus materials. Crack growth for an aluminum oxide ceramic was observed to be continuously stable throughout testing. Conversely, the fracture behavior of a silicon nitride ceramic exhibited crack growth as a series of subcritical extensions which are interrupted by dynamic propagation. Dynamic initiation and arrest fracture resistance measurements for the silicon nitride averaged 67 and 48 J/sq m, respectively. The dynamic initiation event was observed to be sudden and explosive. Increments of subcritical crack growth contributed to a 40 percent increase in fracture resistance before dynamic initiation. Subcritical crack growth visibly marked the fracture surface with an increase in surface roughness. Increments of subcritical crack growth loosen ceramic material near the fracture surface and the fracture debris is easily removed by a replication technique. Fracture debris is viewed as evidence that both crack bridging and subsurface microcracking may be some of the mechanisms contributing to the increase in fracture resistance. A Statistical Fracture Mechanics model specifically developed to address subcritical crack growth and fracture reliability is used together with a damaged zone of material at the crack tip to model experimental results. A Monte Carlo simulation of the actual experiments was used to establish a set of modeling input parameters. It was demonstrated that a single critical parameter does not characterize the conditions required for dynamic initiation. Experimental measurements for critical crack lengths, and the energy release rates exhibit significant scatter. The resulting output of the model produces good agreement with both the average values and scatter of experimental measurements.

Calomino, Anthony Martin↗

DOE OSTI2021

Role of Mineralogy in Controlling Fracture Formation

The presence of fractures in caprocks can pose increased risks in subsurface energy systems and processes like CO 2 sequestration by introducing high-permeability leakage paths. Fracture apertures and permeability can be altered through mineral dissolution and precipitation reactions, but the reactive evolution of fractures is not well understood. In fractures, minerals that are otherwise inaccessible to reactive fluids can become exposed, resulting in mineral reactions unpredicted by bulk formation data. This work seeks to understand the relationship between mineralogy and fracture formation to enhance our understanding of reactive fracture evolution and CO 2 leakage potential. Here, the mineral compositions of mechanically induced fracture surfaces in samples of the Mancos and Marcellus shales have been quantified and compared to those of the near-fracture matrices using imaging and bulk X-ray diffraction (XRD) data. In the Mancos shale, the concentrations of clay minerals are enhanced along fracture surfaces with respect to the bulk, and the fracture is most likely to form at kaolinite–kaolinite interfaces. Further, evaluation of the mineralogical spatial variability through cross-correlation analysis of the surrounding matrix in images of samples cut perpendicular to the fracture shows that clay is 16.7 times more likely to be present than carbonate minerals near the fracture surface. The high correlation persists roughly 200 μm into the surrounding matrix for the Mancos sample and implies that the fracture formed within a defined clay-rich lithofacies.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

Onset dynamics of air-water menisci on rock fracture surfaces

Information on menisci dynamics and equilibrium contact angles, θ e , is needed for modeling multiphase flow of fluids in geologic formations. The wettability of fracture faces is relevant to applications such as waterflooding in enhanced oil recovery and evaluation of caprock integrity for geologic carbon sequestration. We investigated the vertical capillary rise of air-water menisci on exposed fracture faces for a sandstone, a shale, and three granites. The experimental design approximated that employed in the Wilhelmy plate method. Replicate fracture faces were prepared by fracturing cylindrical rock cores using the Brazilian method and splitting the fractured cores apart along their fracture planes. Meniscus onset was imaged from a cross-sectional perspective using dynamic neutron radiography, and quantified with change point analysis. An existing model for meniscus onset fitted the experimental data very well (median R 2 = 0.96). Capillary rise was typified by t 2/3 scaling (where t is time), followed by a constant equilibrium height, z e . The average time taken for the menisci to reach z e was 0.39 s, with no differences between rock types. The menisci achieved a greater vertical extent on the fracture faces of the sedimentary rocks as compared to those of the granites. Apparent θ e values were calculated from the best fit estimates of z e using the Wilhelmy plate equation for a smooth and planar vertical surface. Despite the fractal roughness of some of the fracture faces, there was a significant linear relationship (R 2 = 0.80) between the apparent θ e values and intrinsic θ e values measured on polished surfaces of the same rocks using the sessile drop method. The regression equation indicated the apparent θ e values were consistently greater than the intrinsic values. This overestimation may be due to averaging of pixels at the air-water-solid interface, a required step in the image analysis. Further exploration of the range of applicability and measurement accuracy of this proposed new technique would be valuable.

58 GEOSCIENCES↗

NASA NTRS1981

Creep shear behavior of the oxide dispersion strengthened superalloy MA 6000E

The shear rupture life of the oxide dispersion strengthened (ODS) superalloy MA 6000E was determined at 650 and 760 C was 250 MPa. Comparisons were made at 760 C with the conventional cast superalloy B-1900+Hf, the ODS alloy MA 754, and the directionally solidified eutectic alloy gamma/gamma prime-delta was 170 MPa, and for B-1900+Hf was 360 MPa. The ODS alloy MA 6000E and gamma/gamma prime-delta failed with very little indication of ductile accommodation. Both MA 754 and B-1900+Hf showed some ductile tearing. Fracture surfaces of the ODS alloy MA 754 showed discontinuities similar size, shape, and roughness to its grain structure, but the fracture surfaces of MA 6000E were much smoother than its grain boundaries.

Glasgow, T. K.↗

NASA NTRS1990

Deformation and fracture of aluminum-lithium alloys: The effect of dissolved hydrogen

The effects of dissolved hydrogen on the mechanical properties of 2090 and 2219 alloys are studied. The work done during this semi-annual period consists of the hydrogen charging study and some preliminary mechanical tests. Prior to SIMS analysis, several potentiostatic and galvanostatic experiments were performed for various times (going from 10 minutes to several hours) in the cathodic zone, and for the two aqueous solutions: 0.04N of HCl and 0.1N NaOH both combined with a small amount of As2O3. A study of the surface damage was conducted in parallel with the charging experiments. Those tests were performed to choose the best charging conditions without surface damage. Disk rupture tests and tensile tests are part of the study designed to investigate the effect of temperature, surface roughness, strain rate, and environment on the fracture behavior. The importance of the roughness and environment were shown using the disk rupture test as well as the importance of the strain rate under hydrogen environment. The tensile tests, without hydrogen effects, have not shown significant differences between low and room temperature.

Rivet, F. C.↗

NASA NTRS1990

Hydrogen induced fracture characteristics of single crystal nickel-based superalloys

A stereoscopic method for use with x ray energy dispersive spectroscopy of rough surfaces was adapted and applied to the fracture surfaces single crystals of PWA 1480E to permit rapid orientation determinations of small cleavage planes. The method uses a mathematical treatment of stereo pair photomicrographs to measure the angle between the electron beam and the surface normal. One reference crystal orientation corresponding to the electron beam direction (crystal growth direction) is required to perform this trace analysis. The microstructure of PWA 1480E was characterized before fracture analysis was performed. The fracture behavior of single crystals of the PWA 1480E nickel-based superalloy was studied. The hydrogen-induced fracture behavior of single crystals of the PWA 1480E nickel-based superalloy was also studied. In order to understand the temperature dependence of hydrogen-induced embrittlement, notched single crystals with three different crystal growth orientations near zone axes (100), (110), and (111) were tensile tested at 871 C (1600 F) in both helium and hydrogen atmospheres at 34 MPa. Results and conclusions are given.

Chen, Po-Shou↗

NASA NTRS2020

Experimental Reexamination of Transverse Tensile Strength for IM7/8552 Tape-Laminate Composites

Due to the observed dependence of transverse-tensile strength, YT, on test geometry and specimen size, there is no consensus regarding a test method that can uniquely measure YT. This study reexamines characterization of YT by comparing results from established flexure tests with results from a new tensile test that exhibits consistent failure in the gage region. Additionally, the effects of surface preparation and direction of transverse fracture are investigated. Results show that YT is inversely proportional to specimen volume and surface roughness, and is insensitive to direction of transverse fracture. The relationship between specimen volume and YT is adequately captured by Weibull strength-scaling theory, except at the tails of the YT distributions. However, specimens exhibited microcracking prior to failure, which violates the “weak-link” assumptions of the Weibull theory. These findings highlight the challenges of using deterministic YT values in progressive damage analysis.

Arndt, Caitlin M.↗

NASA NTRS1987

Hot corrosion attack and strength degradation of SiC and Si(sub)3N(sub)4

Thin films of Na2SO4 and Na2CO3 molten salt deposits were used to corrode sintered SiC and Si3N4 at 1000 C. The resulting attack produced pitting and grain boundary etching resulting in strength decreases ranging from 15 to 50 percent. Corrosion pits were the predominant sources of fracture. The degree of strength decrease was found to be roughly correlated with the depth of the pit, as predicted from fracture toughness considerations. Gas evolution and bubble formation were key aspects of pit formation. Many of the observations of furnace exposures held true in a more realistic burner rig test.

Smialek, James L.↗

DOE OSTI2022

A Novel Rotating Flexure-Test Technique for Brittle Materials with Circular Geometries

The four-point bend test is one of the simplest and often the preferred flexural strength evaluation method for brittle materials. In this loading mode, fracture often initiates from a critical surface (or subsurface) flaw when subjected to a tensile stress state. However, if the critical flaw exists on the compression side of the test specimen, it may not activate to grow a crack and hence the resulting flexural strength will be higher than the true value. The goal of this study is to measure the true flexural strength of a solid or hollow cylindrical brittle specimen by ensuring that failure occurs at its weakest point by rotating along its longitudinal axis, thereby exposing and activating its critical surface flaw during a four-point bend test. A novel test fixture has been designed and fabricated, and the true flexural strengths of cylindrical brittle and quasi-brittle tubular specimens have been measured and compared to existing experimental data obtained through traditional four-point bend tests. In this work, experimental results showcase the orientation dependance on flexural strength for various materials. Additionally, similarities between experimental findings and those available in literature, including observations of fracture surfaces and relationships between surface roughness and material strength, are discussed.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Osmotic control of the spacing of parallel shear cracks in shale growing subcritically in geologic past

The geological genesis of natural cracks in sedimentary rocks such as shale is a problem that needs to be understood to improve the technology of hydraulic fracturing as well as deep sequestration of harmful fluids. Why are the vertical natural cracks roughly parallel and equidistant, and why is the spacing roughly 10 cm rather than 1 cm or 100 cm? Fracture mechanics of critical cracks cannot answer this question. Neither can the material heterogeneity. The growth of critical parallel cracks is impossible because the relative crack face displacements would immediately localize into one crack, leading to an earthquake. The cracks must have formed, on the tectonic time scale, by a slow growth of subcritical shear cracks governed by the Charles-Evans law. The idea advanced here is that what controls the crack spacing is the balance between the reduction, due to shear dilatancy, of the concentration of ions such as Na + and Cl - in each fracture process zone (PFZ), which decelerates the cracks, and the restoration of ion concentration by diffusion of ions from the space between the cracks into the FPZ. This diffusion of water is driven mainly by the osmotic pressure gradient, which offsets the deceleration and depends strongly on the crack spacing. A simple analytical solution of the steady state is rendered possible by approximating the ion concentration profiles between adjacent cracks by parabolic arcs. Applying this theory to Woodford shale yields the approximate crack spacing of 10 cm, which is realistic. Furthermore, the stability of unlimited parallel mode II frictional crack growth is proven by examining the second variation of the free energy. Water concentration drop in the FPZ due to shear dilatancy and its restoration by water diffusion from the inter-crack space have similar effect, although probably much weaker.

42 ENGINEERING↗