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All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Fatigue-Like Behavior of Silver Metallization Gridlines and Proposed Damage Mechanics Model

In this work, we present a novel method to evaluate the fracture and fatigue-like behavior of crystalline silicon PV cell metallization. Initial results demonstrate that silver metal gridlines are capable of bridging a ~10–20 µm gap prior to becoming electrically open and do demonstrate fatigue-like behavior under cyclic straining conditions. This later phenomenon was well fit with a traditional power law equation for high cycle fatigue and enabled the development of a damage mechanics model for gridline failure.

41 EE - Solar Energy Technologies Office (EE-4S)↗
DOE OSTI2024

Fracture Network Influence on Rock Damage and Gas Transport following an Underground Explosion

Simulations of rock damage and gas transport following underground explosions that omit preexisting fracture networks in the subsurface cannot fully characterize the influence of geo-structural variability on gas transport. Previous studies do not consider the impact that fracture network structure and variability have on gas seepage. In this study, we develop a sequentially coupled, axi-symmetric model to look at the damage pattern and resulting gas breakthrough curves following an underground explosion given different fracture network realizations. We simulate 0.327 and 0.164 kT chemical explosives with burial depths of 100 m for 90 stochastically generated fracture networks. Gases quickly reach the surface in 30% of the higher yield simulations and 5% of the lower yield simulations. The fast breakthrough can be attributed to the formation of connected pathways between fractures to the surface. The formation of a connected damage pathway to the surface is not clearly correlated with the fracture intensity (P32) in our simulations. Breakthrough curves with slower transport are highly variable depending on the fracture network sample. The variability in the breakthrough behavior indicates that ignoring the influence of fracture networks on rock damage, which strongly influences the hydraulic properties following an underground explosion, will likely lead to a large underestimation of the uncertainty in the gas transport to the surface. This work highlights the need for incorporation of fracture networks into models for accurately predicting gas seepage following underground explosions.

58 GEOSCIENCES↗
DOE OSTI2026

DEMO-FTES: Development, Monitoring, and Control of Fracture Thermal Energy Storage in Crystalline Rock Formations (CRADA Final Report)

The DEMO-FTES project investigated the feasibility of Fracture Thermal Energy Storage (FTES) as a seasonal energy storage solution in crystalline rock formations. FTES leverages hydraulically induced fractures to exchange heat between circulating fluids and the surrounding rock mass, enabling long-term thermal energy retention due to the high specific heat and low thermal conductivity of rock. This approach has the potential to reduce heating and cooling energy demands and enhance building energy resilience. The project combined dimensional analysis, numerical modeling, laboratory experiments, and meso-scale field tests to evaluate FTES performance and advance its technology readiness level from 3 to 5. Scaling analysis identified key dimensionless parameters governing heat transfer and fluid flow, ensuring laboratory and field tests were representative of larger-scale systems. Numerical simulations using TOUGH and iTOUGH2 frameworks supported experiment design and interpretation, modeling fracture geometry, thermal-hydraulic behavior, and thermo-mechanical coupling. Laboratory tests at EPFL involved creating single and multiple fractures in 25 cm cubic samples of Gabbro and Granite under true triaxial stress.

25 ENERGY STORAGE↗
DOE OSTI2022

Foam Fracturing Study for Stimulation Development of Enhanced Geothermal Systems

This is a final technical report for the project: Foam Fracturing Study for Stimulation Development of Enhanced Geothermal Systems (EGS). The goal is to demonstrate the feasibility of foam fracturing in EGS applications. The project, led by Oak Ridge National Laboratory (ORNL), was conducted in collaboration with Temple University. The report describes the research activities with Task 1 at ORNL: foam fracturing testing system development and experimental study on foam fracturing, and Task 2 at Temple University: foam testing and foam characterization. Main findings are: 1. A foam fracturing test system has been developed at ORNL, which can be used to perform foam fracturing under pressure up to 6,000 psi. The system monitors foam density during fracturing online and is capable of testing materials in both monotonic and cyclic (up to 50 Hz) injections. 2. Foam fracturing tests were carried out on Charcoal black granite specimens with a blind borehole to the middle length. Two diameters of blind borehole were tested; G2 series: 9.53 mm and G3 series: 4.76 mm. N2-in-water foam was used with AOS as a surfactant. 3. There was a hole-size effect on fracture initiation pressure. The effect is smaller in the case of foam, which was influenced by the high penetrability of gas in foam. Breakdown pressure showed a behavior just as that of fracture pressure; namely an increased value for small hole samples, while the effect in water fracture was more impressive than in foam fracture. 4. Water mass was reduced in foam fracturing within similar range of breakdown pressures. In G2 series, it was decreased from 10.44 g for water fracturing to 5.17 g, representing more than 50% water reduction. Therefore, there is the potential to reduce water use in EGS stimulation through foam fracturing. 5. Use of cyclic injection has the potential to reduce the breakdown pressure and seismicity in EGS application. Experiments using 4-s cycle period found that specimens can be fractured with a low number of cycles. The fatigue pressure was approximately 64 - 77% of monotonic breakdown pressure for water fracturing and 58 - 94% of the breakdown pressure for foam fracturing. 6. A foam stability testing system has been developed that can test foam at 220 Deg C to 2,000 psi. Tested components of candidate foams included two gases: N2 and CO2; 4 surfactants: AOS, SDS, NP-40 and CTAC; 5 stabilizing agents: guar, bentonite clay, borate salt, silica NPs, and GO. 7. N2 and AOS provided the most stable performance over the tested ranges. Furthermore, the AOS foam with stabilizing agents of guar and borate salt (crosslinker) offered the highest half-life of 20 minutes at 200 Deg C and 1,000 psi. 8. Arrhenius equation and modified power law have been demonstrated to fit well the half-time vs. temperature and pressure data, respectively. These relations can be useful to provide the suggestion for future foam stability study. This submission contains the supporting data developed during the project: 1) A final technical report 2) Granite fracturing data in monotonic and cyclic injections with water and N2 foam Foam performance data in various temperatures and pressures, including half-time, is submitted separately.

15 GEOTHERMAL ENERGY↗
DOE OSTI2022

Wellbore cement fracture permeability as a function of confining stress and pore pressure

Cemented annulus fractures are a major leakage path in a wellbore system, and their permeability plays an important role in the behavior of fluid flow through a leaky wellbore. The permeability of these fractures is affected by changing conditions including the external stresses acting on the fracture and the fluid pressure within the fracture. Laboratory gas flow experiments were conducted in a triaxial cell to evaluate the permeability of a wellbore cement fracture under a wide range of confining stress and pore pressure conditions. For the first time, an effective stress law that considers the simultaneous effect of confining stress and pore pressure was defined for the wellbore cement fracture permeability. Here the results showed that the effective stress coefficient (λ) for permeability increased linearly with the Terzaghi effective stress ( -p) with an average of λ = 1 in the range of applied pressures. The relationship between the effective stress and fracture permeability was examined using two physical-based models widely used for rock fractures. The results from the experimental work were incorporated into numerical simulations to estimate the impact of effective stress on the interpreted hydraulic aperture and leakage behavior through a fractured annular cement. Accounting for effective stress-dependent permeability through the wellbore length significantly increased the leakage rate at the wellhead compared with the assumption of a constant cemented annulus permeability.

58 GEOSCIENCES↗
DOE OSTI2023

The role of stress and fluid saturation on the acoustic response of fractured rock

Standard rock physics models are formulated to describe the behavior of porous sedimentary reservoirs, with clean sandstones being the archetypal system; however, many situations demand geophysical monitoring of rocks with significantly different structures, such as low porosity, fractured reservoirs. Conventional models also suggest that these “stiff” reservoirs can be challenging to monitor seismically due to small fluid substitution effects, but the presence of fractures leads to stress dependence which may be leveraged for remote monitoring purposes. Using samples from the Duperow Formation (dolostone) obtained from the Danielson test well in Kevin Dome, MT, we conducted ultrasonic and multi-scale structural (profilometry, synchrotron micro-tomography, pressure sensitive film) measurements on naturally fractured core in order to characterize the effects of fluid substitution and effective stress on the acoustic response of fractured reservoir rock with a focus in particular on the textural and seismic characteristics of natural fractures. We find that changes in effective stress can yield changes in velocity of up to 20% and changes in attenuation up to 200%. Measured fluid substitution effects are resolvable, but stress effects dominate. These measurements provide insight into the physical processes controlling acoustic response of fractured rocks in general and can also be used to inform monitoring efforts in fractured reservoirs.

58 GEOSCIENCES↗
DOE OSTI2020

Hydro-mechanical coupled modeling of hydraulic fracturing using the mesh fragmentation technique

The inclusion of special interface elements between standard finite elements is becoming a common technique to model discontinuities in porous media using the finite element method (FEM). Recently, it was proved that high aspect ratio (HAR) elements can reproduce very satisfactorily the main features of behavior observed in a single hydraulically-induced fracture. In this paper, the mesh fragmentation technique (MFT) is proposed to extend the application of HAR elements to simulate more general problems involving the formation of hydraulic fractures in rocks by introducing this type of element in-between the standard FE of a typical mesh. The proposed framework makes use of standard FE techniques. Therefore, it is relatively easy to upgrade an existing FE program for continuous porous media to deal with evolving discontinuities. The proposed approach is verified and validated against available analytical and numerical solutions. The crack patterns predicted by the MFT are also compared with the ones observed in the laboratory. The formation of multiple fractures is also analyzed. In all cases, the proposed technique was able to properly capture the main features of rock behavior subjected to hydraulic fracturing.

58 GEOSCIENCES↗
DOE OSTI2023

Understanding Subsurface Fracture Evolution Dynamics Using Time‐Lapse Full Waveform Inversion of Continuous Active‐Source Seismic Monitoring Data

Abstract Predicting the behavior, geometry, and flow properties of subsurface fractures remains a challenging problem. Seismic models that can characterize fractures usually suffer from low spatiotemporal resolution. Here, we develop a correlative double‐difference time‐lapse full waveform inversion of continuous active source seismic monitoring data for determining high‐spatiotemporal‐resolution time‐lapse V p models of in‐situ fracture evolution at a shallow contamination site in Wyoming, USA. Assisted by rock physics modeling, we find that (a) rapidly increasing pore pressure initializes and grows the fracture, increasing the porosity slightly (from ∼13.7% to ∼14.6%) in the tight clay formation, thus decreasing V p (∼50 m/s); (b) the fluid injection continues decreasing V p , likely through the introduction of gas bubbles in the injectate; and (c) final V p reductions reach over ∼150 m/s due to a posited ∼4.5% gas saturation. Our results demonstrate that high‐resolution V p changes are indicative of mechanical and fluid changes within the fracture zone during hydrofracturing.

58 GEOSCIENCES↗
DOE OSTI2025

Enhanced Interfacial Bonding of Graft Copolymers

To understand how thermoplastic welding strength can be tuned through chemical modifications and macromolecular topology, we combined coarse-grained molecular dynamics (MD) simulations with experimental validation. Our simulations examined the diffusion dynamics of both linear and graft polymers across representative interfaces, revealing that diffusion-controlled interdigitation follows a power law, with the exponent decreasing from 0.34 to 0.11 as grafting density increases from 7.5 to 196% (with side chains grafted to both sides of a monomer unit). The addition of side chains enhances welding efficiency, as dense bottlebrush polymers with high grafting density reach maximum rupture strength faster than linear polymers. However, their saturated rupture strength is lower. This observation is subsequently corroborated by experimental lap-shear tests comparing linear polyethylene with octene grafted polyethylene elastomers. Our MD simulations show that unlike linear polymers, where backbone entanglements dominate, the grafted side chains introduce mechanisms in addition to entanglement dilution. The rapid interdigitation of side chains creates a dense mesh of entropic van der Waals contacts, which can also enhance the film welding. Furthermore, our MD simulations reveal a brittle rupture behavior in linear and comb-like (mildly grafted) polymers, while bottlebrush (densely grafted) polymers display elastomeric behavior with a pronounced stress plateau prior to fracture. Our simulations deconvolute the influence of polymer topology on deformation behavior. The rate of polymer deformation becomes lower than the applied strain rate prior to rupture, and the onset of this deviation is progressively delayed from linear to bottlebrush polymers. This trend highlights the critical role of molecular architecture in governing the mechanical response. In conclusion, these results provide deeper insight into the underlying welding mechanisms of topological polymers and present a potential approach for mitigating the interface anisotropy that is inherent in advanced manufacturing techniques such as fused filament fabrication.

graft copolymers↗
DOE OSTI2021

Verification of Coupled Hydraulic Fracturing Simulators Using Laboratory-Scale Experiments

In this work, we aim to verify the predictions of the numerical simulators, which are used for designing field-scale hydraulic stimulation experiments. Although a strong theoretical understanding of this process has been gained over the past few decades, numerical predictions of fracture propagation in low-permeability rocks still remains a challenge. Against this background, we performed controlled laboratory-scale hydraulic fracturing experiments in granite samples, which not only provides high-quality experimental data but also a well-characterized experimental set-up. Using the experimental pressure responses and the final fracture sizes as benchmark, we compared the numerical predictions of two coupled hydraulic fracturing simulators—CSMP and GEOS. Both the simulators reproduced the experimental pressure behavior by implementing the physics of Linear Elastic Fracture Mechanics (LEFM) and lubrication theory within a reasonable degree of accuracy. The simulation results indicate that even in the very low-porosity (1–2 %) and low-permeability (10 -18 m 2 - 10 -19 m 2 ) crystalline rocks, which are usually the target of EGS, fluid-loss into the matrix and unsaturated flow impacts the formation breakdown pressure and the post-breakdown pressure trends. Therefore, underestimation of such parameters in numerical modeling can lead to significant underestimation of breakdown pressure. The simulation results also indicate the importance of implementing wellbore solvers for considering the effect of system compressibility and pressure drop due to friction in the injection line. The varying injection rate as a result of decompression at the instant of fracture initiation affects the fracture size, while the entry friction at the connection between the well and the initial notch may cause an increase in the measured breakdown pressure.

15 GEOTHERMAL ENERGY↗
DOE OSTI2022

Tuscaloosa Marine Shale Laboratory

The Tuscaloosa Marine Shale (TMS) in Louisiana and Mississippi is an Upper Cretaceous source rock formation sandwiched between the sands of the upper and lower Tuscaloosa sections. The TMS is believed to be the source rock for underlying prolific Tuscaloosa sand formation. The TMS has an unproven estimate of 7,000,000,000 bbls of recoverable oil while its current total average production is about 3,000 bbls of oil per day in 2017. In 2013 and 2014, more than 80 wells were drilled horizontally into the TMS that were fractured using multi-stage fracturing technology. The results from this have been mixed, but recent production for several wells show an appealing initial oil production rate of more than 1000 bbl/day. The preliminary core analysis by industry partners and a few literature studies shows that the TMS is one of the most clay-rich and sensitive shales to water. Due to these and other technical problems, there is high risk for the economic development of TMS compared to other shale plays. The experiences of major industrial players in the TMS show the necessity of open and collaborative efforts to better understand the critical gaps in the development of this challenging and potentially highly economic shale play to enable more cost-efficient and environmentally-sound recovery from this unconventional liquid-rich shale play. The overall objective of this project is to form a consortium of science and industry partners to address the following six major objectives using scientific and technical approaches: 1. To improve wellbore integrity by better understanding the sources of the wellbore instability issues, proposing innovative mud and cement design for the TMS. 2. To improve formation evaluation using laboratory techniques for the evaluation of mineralogical composition, organic content, and produced-water chemistry as well as well log and geophysical analysis. 3. To determine the role of geologic discontinuities on fracture growth and shale creep behavior using digital image correlation technique. 4. To investigate the application of stable CO 2 foam and super-hydrophobic proppants for improved reservoir stimulation. 5. To better understand the nature of water/hydrocarbon/CO 2 flow in clay and organic-rich formation and the role of water/fluid interaction on recovery. 6. To prepare better socio-economic environment for TMS development by community engagement. Subsequently, the TMS virtual laboratory conducted testing and analysis of various properties of rock and formation fluids from the TMS, including but not limited to the following: Analyzing reports and logs to better understand the source of wellbore instability in TMS wells; Experiments to design a customized cement based on TMS requirements; Experiments to obtain the mineralogical and geochemical composition of TMS samples; Seismic analysis of TMS geophysical data to better predict total organic carbon (TOC) content and brittleness in TMS; Well log analysis to better estimate the TOC and geo-mechanical properties of TMS; Experiments on formation water to understand the chemistry of produced water; Experiments to determine the role of lamination and natural fractures on fracture propagation or rock deformation using digital image correlation technique in in-direct tensile tests, semi-circular bend test and creep tests Experiments to determine the stability and rheological properties of nanoparticle-stabilized CO 2 foam in TMS rock samples; Experiments to determine fluid dynamics in un-propped TMS fractures and the role of nano-coating of proppants on fluid dynamics in fractures with proppants; Micro-fluidics experiments to enhance the understanding of fluid dynamics in tight liquidrich pores with high clay content; Socio-economic studies to better engage communities in TMS development.

58 GEOSCIENCES↗
DOE OSTI2024

Crack opening calculation in phase-field modeling of fluid-filled fracture: A robust and efficient strain-based method

The phase-field method has become popular for the numerical modeling of fluid-filled fractures, thanks to its ability to represent complex fracture geometry without algorithms. However, the algorithm-free representation of fracture geometry poses a significant challenge in calculating the crack opening (aperture) of phase-field fracture, which governs the fracture permeability and hence the overall hydromechanical behavior. Although several approaches have been devised to compute the crack opening of phase-field fracture, they require a sophisticated algorithm for post-processing the phase-field values or an additional parameter sensitive to the element size and alignment. Here, we develop a novel method for calculating the crack opening of fluid-filled phase-field fracture, which enables one to obtain the crack opening without additional algorithms or parameters. Here we transform the displacement-jump-based kinematics of a fracture into a continuous strain-based version, insert it into a force balance equation on the fracture, and apply the phase-field approximation. Through this procedure, we obtain a simple equation for the crack opening which can be calculated with quantities at individual material points. We verify the proposed method with analytical and numerical solutions obtained based on discrete representations of fractures, demonstrating its capability to calculate the crack opening regardless of the element size or alignment.

58 GEOSCIENCES↗
DOE OSTI2022

Compatibility of Medium Density Polyethylene (MDPE) for Distribution of Gaseous Hydrogen

Hydrogen has emerged as a convenient energy storage medium and is being considered as an alternative for reducing the use of carbon-based fuels. Numerous projects are looking into distributing blends of natural gas and different amounts of gaseous hydrogen through the existing natural gas distribution system, which is widely composed of medium density polyethylene (MDPE) line pipes. The mechanical behavior of MDPE with hydrogen is not well understood; therefore, the effect of gaseous hydrogen on the mechanical properties of MDPE needs to be examined. In the current study, we investigate the effects of gaseous hydrogen on fatigue crack growth rate, fracture resistance, and fatigue life of MDPE in the presence of 3.4 MPa gaseous hydrogen. Fatigue crack growth behavior and fracture resistance are measured using compact tension specimens, while the fatigue life tests are carried out using circumferential notched tensile specimens. In addition, fatigue and fracture tests were conducted in air to determine the baseline properties of MDPE, which was then compared with the ones observed in gaseous hydrogen environment. After the completion of mechanical testing, fracture surfaces are also analyzed using optical and scanning electron microscopes to understand salient fracture features of MDPE with and without the presence of gaseous hydrogen.

Shrestha, Rakish↗
DOE OSTI2021

Gouge formation and dilation impacts to flow during fracture shearing

We report flow in fractures is of critical importance to fluid flow in low-permeability shales, particularly when they restrict vertical migration from reservoirs. The Mt. Simon Sandstone is a target for geologic CO 2 sequestration and the overlying Eau Claire Formation is the sealing formation capping this reservoir. The lower Eau Claire, a primary barrier to upward migration of CO 2 from the Mt. Simon, is lithologically heterogenous with a mixture of sandstone and shale. We use a series of flow-through experiments on fractured samples from the Eau Claire to document the morphological changes taking place in the fracture and surrounding rock as it is sheared in a stepwise fashion. The samples were imaged using computed tomography after each shearing episode and flow resistance was calculated based on the pressure differential across each core. We found that gouge accumulations in the fracture plane led to specific instances of self-sealing behavior despite the fact that most samples increased in average fracture aperture and transmissivity. Gouge limited the increase or, in some cases, decreased flow through these samples. Fractures adjacent to shale-rich zones and concordant with bedding were more likely to show evidence of self-sealing, while increased sandstone content and fracture orientation perpendicular to bedding planes was more likely to result in fracture dilation and fracture permeability increases. Reactivation and shearing of vertical fractures in lithologically heterogenous caprocks is more likely to pose risks to long term CO 2 storage scenarios.

58 GEOSCIENCES↗
DOE OSTI2025

Modeling hydraulic fracture opening and closure with proppant transport and settlement

Hydraulic fracturing is a widely used reservoir stimulation technique for improving fluid circulation in rock formations with extremely low permeability, particularly in enhanced geothermal systems (EGS). To better understand the complex processes involved and improve hydraulic stimulation performance, we have developed ELK (ELectrical fracKing), a MOOSE-based 3D finite element application designed to model the behavior of proppant-fluid mixtures in propagating fractures. ELK integrates both the fluid and proppant components, incorporating particle-driven processes such as gravity settling, particle-particle interactions, and strong density and viscosity contracts, in addition to conventional fluid-driven fracture propagation. In this contribution, we extend ELK to model propped fracture closure, which occurs after the injection phase due to a dramatic drop in the effective stress on the fracture plane. During the shut-in, flowback, and production periods, the fracture width decreases, with the closure behavior depending on proppant concentration.. At low concentrations, closure follows a nonlinear joint law linked to the stiffness of asperities in the fracture walls. While at high concentrations, it is controlled by the properties of packed proppant bed. The extended ELK application is validated against several benchmark examples, including the propagation of an inclined frictional crack, fracture opening and sliding in response to fluid injection, and flowback analysis. We believe that ELK’s enhanced capabilities can serve as a valuable tool for the design and optimization of EGS deployment.

15 - GEOTHERMAL ENERGY↗
DOE OSTI2021

Scale–Bridging in Three–Dimensional Fracture Networks: Characterizing the Effects of Variable Fracture Apertures on Network–Scale Flow Channelization

Here, we incorporate observations of real fracture aperture variability observed in laboratory experiments into an ensemble of three-dimensional discrete fracture network (DFN) simulations to characterize how variations of this micro-scale feature can influence flow and transport behavior at the network scale. A shear fracture is created within a Marcellus shale sample, and the fracture aperture is measured using a triaxial direct-shear device coupled with real-time X-ray imaging at in-situ stress conditions. We construct an ensemble of fracture networks based on natural fractures in Marcellus shale and project regions of the experimental aperture field onto each fracture in the networks. Our calculations demonstrate that the degree of flow channelization, a network-scale flow field structure, is dramatically increased by local changes in the aperture field that in turn affects flow and transport properties.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2022

HFTS-2 (Final Report)

This report delves into the research program, identified tasks, various studies, observations, results, and conclusions under the Hydraulic Fracturing Test Site (HFTS-2) project. This test site is located in Loving County close to the Texas, New Mexico border. The program targeted the Wolfcamp formation in Delaware Basin. The aim of the project was to improve our understanding of hydraulic fracturing processes to not only optimize unconventional resource development in US Basins but to minimize environmental footprint as well. Various new diagnostic technologies were demonstrated at this site, including distributed acoustic microseismic, high resolution strain using Rayleigh frequency band (DSS-RFS), and in-fill proppant logging tool. Significant conclusions from this study include: 1) lateral and vertical fracture growth mapping as well as proppant transport behavior, 2) Use of DSS-RFS as a diagnostic tool to understand cluster level behavior, 3) Validation of proppant log, both at core scale as well as in-fill well implementation, and 4) New modeling tools to map far-field strain response using distributed strain sensing data. Specifically, far-field fracture distribution is influenced by linear fracture corridors defined by the stress-state as well as clustering behavior influenced by spatio-temporal effects. Depletion impacts on new stimulation was demonstrated and technically quantified. Significant vertical fracture height growth was observed. However, our understanding is limited by available gauge data availability. Numerical strain modeling techniques have been developed and demonstrated to help understand observed strain response behavior. Finally, proppant log has been further validated as a useful tool to map propped zones within the SRV. It has also shown very strong correlation with observed drawdown behavior at this test site. This report will detail many of these studies as well as technical results and conclusions from said studies. These include general subsurface characterization work, completion designs as implemented, studies looking at fracture geometry, high resolution microseismic study including source mechanisms, advanced DSS-RFS studies including drainage characterization, core characterization results, proppant analysis (core and in-fill child well), geochemistry, etc.

02 PETROLEUM↗