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All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Review of High‐Speed Digital Image Correlation: Advancements and Good Practices

This paper reviews the current state of the art in high‐speed (HS) and ultrahigh‐speed (UHS) digital image correlation (DIC) techniques, emphasizing their critical role in experimental research across various scientific domains. HS and UHS DIC have evolved significantly, driven by advancements in camera systems, image processing algorithms and experimental methodologies. These developments have opened new avenues for capturing and analysing dynamic events with unprecedented temporal and spatial detail, but not without introducing challenges such as optical distortions, motion blur and lighting issues that can affect measurement quality. This review advocates for standardized reporting practices in HS/UHS DIC methodologies to improve reproducibility and reliability across studies, drawing on guidelines from the International Digital Image Correlation Society (iDICs). Through a comprehensive analysis of over 150 articles, this review identifies key advancements in imaging technology and their application in six research domains: material characterization, test development, fracture mechanics, model validation, ballistic and explosive phenomena assessment and measurement uncertainties. Distinctions between two‐dimensional (2D) and stereo‐DIC applications are explored, offering insights into their practical implementation and trade‐offs. Good practices for HS/UHS DIC applications are proposed along with suggestions for future directions for this evolving field, highlighting the indispensable role of technological innovation in expanding the capabilities of optical metrology.

experimental mechanics↗
DOE OSTI2020

Local-nonlocal coupling in Emu/PDMS

A technique called the splice method for coupling local to peridynamic subregions of a body is described. The method relies on ghost nodes, whose values of displacement are interpolated from nearby physical nodes, to make each subregion visible to the other. In each time step, the nodes in each subregion treat the nodes in the other subregion as boundary conditions. Adaptively changing the subregions is possible through the creation and deletion of ghost nodes. Example problems in 2D and 3D illustrate how the method is used to perform multiscale modeling of fracture and impact events within a larger structure.

42 ENGINEERING↗
DOE OSTI2022

Stochastic Modeling in a Multimaterial Continuum Mixture Shock Physics Code

Stochastic modelling approaches are presented to capture random effects at multiple time and length scales. Random processes that occur at the microscale produce nondeterministic effects at the macroscale. Here we present three stochastic modeling approaches that describe random processes at microscopic length scales and map these processes to the macroscopic length scale. The first stochastic modeling approach is based upon a particle based numerical technique to solve a Stochastic Differential Equation (SDE) using an arbitrary diffusion process to capture random processes at the microstructural level. The second approach prescribes a Probability Density Function (PDF) for the drift and diffusion of the random variable derived using the forward and backward Kolmogorov equations. This method requires mean and drift evolution PDF transport equations. The third approach is the coupling of multiple random variables which are dependent on each other. The relationship of the PDFs and a coupling function, known as a copula, produces a Joint Probability Density Function (JPDF). These stochastic modeling approaches are implemented into a Multiple Component (MC) shock physics computational code and used to model statistical fracture and reactive flow applications.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2023

Structure and Process of Managing the UO2 Dry In-Pile Fracture Test Irradiation Experiment

The management and structure of a novel research and development (R&D) project can be hard to navigate. This is especially true when it involves nuclear fuel. Familiarity with institutional safety and procedural requirements, a well defined scope, and accurate cost estimates can all help ensure successful project management from start to finish. The Dry In-Pile Fracture Test (DRIFT) experiments performed at the Transient Test Reactor Facility are an excellent example of managing an R&D project within its scope and budget constraints. The objective of the DRIFT test was to develop fracture propagation data in a manner consistent with light-water reactors to validate and improve the fracture propagation models of uranium oxide fuels in the MOOSE (Multiphysics Object-Oriented Simulation Environment)-BISON-Marmot code framework [1].

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2022

Optimizing conformance control for gas injection EOR in unconventional reservoirs

Field observations have shown that interference between wells caused by connected fractures commonly exists in unconventional reservoirs. The well interference effect and conformance issues could lead to minimal enhanced oil recovery response (EOR) in actual operations if they are not properly controlled. A series of data analysis, modeling, and experimental activities were performed in this study to investigate the gas EOR strategies in the Bakken Formation. Employing the embedded discrete fracture modeling technology, a multiple-well, multiple-fracture model was developed to capture the well interference and conformance issues in the Bakken. The model made it possible to investigate the complex flow behavior between wells in the EOR (huff ‘n’ puff) processes. Alternative EOR and conformance control strategies using water and surfactant injections were studied to improve oil production performance based on experimental observations. Results showed that water injection could be used for conformance control in the Bakken because of its relatively low mobility compared to gas; however, water could also block oil flow around the conformance control wells because of the high interfacial tension between oil and water. Adding surfactant to the injection water is more effective for improving gas EOR performance since surfactant reduces the oil–water interfacial tension and contact angle effectively. Up to 9.4% more oil could be produced from the huff ‘n’ puff wells in 2 years of EOR operations when rich gas was injected at only 3 MMscf/d with 6000 psi of surfactant injection in the offset wells for conformance control.

42 ENGINEERING↗
DOE OSTI2024

Approaches for the Simulation of Coupled Processes in Evolving Fractured Porous Media Enabled by Exascale Computing

Models have historically represented fractured porous media with continuum descriptions that characterize the media using bulk parameters. The impact of small-scale features is not captured in these models, although they may be controlling the performance of subsurface applications. Pore-scale models can simulate processes in small-scale features by representing the pore space geometry explicitly but are computationally expensive for large domains. The alternative multiscale approach entails the combination of pore-scale and continuum-scale descriptions in a single framework. We use Chombo-Crunch, a computational capability that discretizes complex geometries with an adaptive, embedded boundary method to contrast these two approaches. Chombo-Crunch takes advantage of recent computational performance and memory bandwidth improvements resulting from the emergence of exascale computing resources. These combined improvements enable the efficient simulation of reactive transport in fractured media with a high degree of fidelity and the ability to capture the control small-scale processes exert on the overall medium evolution.

42 ENGINEERING↗
DOE OSTI2024

Cohesive phase-field chemo-mechanical simulations of inter- and trans- granular fractures in polycrystalline NMC cathodes via image-based 3D reconstruction

The optimal design and durable utilization of lithium-ion batteries necessitates an objective modeling approach to understand fracture and failure mechanisms. This paper presents a comprehensive chemo-mechanical modeling study focused on elucidating fracture-induced damage and degradation phenomena in the polycrystalline Li $\mathcal{x}$ Ni 0.5 Mn 0.3 Co 0.2 O 2 (NMC532) cathode. An innovative approach that utilizes image-based reconstructed 3D geometry as finite element (FE) mesh input is employed to enhance the precision in capturing the convoluted architecture and morphological features. For accurately representing the intricate crack configurations within the polycrystalline system, we adopted the cohesive phase-field fracture (CPF) model. Through the integration of advanced image-based geometry reconstruction technique and the promising CPF modeling approach, lithium (de)intercalation induced crack evolution (e.g., nucleation, propagation, branching and diverse modes including inter-/trans-(intra-) granular patterns) and the resulting chemical degradation can be precisely captured, which is also compared and validated with numerical predictions using a continuum damage model. In particular, this model predicts fracture induced degradation under varying fracture properties of grain boundaries and charging rates; the conclusion that NMC particles comprised of larger grains are predicted to have less degradation than those with smaller grains can also be drawn. This comprehensive analysis provides valuable insights into the fracture and degradation within polycrystalline NMC cathodes.

25 ENERGY STORAGE↗
DOE OSTI2022

Phase-field modeling of crack growth and mitigation in solid oxide cells

Fracture and crack growth is one of the main degradation mechanisms in solid oxide cells (SOCs). However, the modeling of crack growth in SOCs is challenging due to their complex microstructures and possible plasticity development within the Ni particles in Ni-based SOC electrodes. In this study, a phase-field fracture model is developed, which incorporates the SOC microstructures and phase-dependent material properties, including yield strength, fracture toughness in the bulk and at the interphase boundaries. The model is employed to study crack initiation and growth under thermal and redox cycling on the hydrogen electrode side of SOCs. The simulation results demonstrate that under thermal cycling, work-zone cracking dominates in electrolyte-supported SOCs with cracks initiated at the triple-phase boundaries, while only minor mechanical degradation occurs in hydrogen-electrode-supported SOCs after hundreds of thermal cycles. Under redox cycling, through-cracking of yttria-stabilized zirconia (YSZ) in the hydrogen electrode and electrolyte layers dominates. Finally, the simulation results suggest several crack-mitigation strategies, including decreasing the porosity in the hydrogen electrode support layer and synchronizing thermal strain to balance oxidation strain.

08 HYDROGEN↗
DOE OSTI2022

Observations and Modeling of Fiber Optic Strain on Hydraulic Fracture Height Growth in Hydraulic Fracturing Test Site 2 (HFTS-2)

Summary Understanding fracture height growth can be of great significance to optimizing field development and improving recovery. The Hydraulic Fracturing Test Site 2 (HFTS-2) has provided a unique opportunity and an advanced data set to allow us to observe and understand fracture geometries rigorously. Low-frequency distributed acoustic sensing (LF-DAS) data from a vertical well in HFTS-2 showed three key observations: (i) excessive upward height growth (>1,000 ft) and limited downward growth of the hydraulic fractures during pumping, (ii) considerable additional upward fracture height growth (~300 ft) after well shut in, and (iii) very complex LF-DAS strain rate patterns for a small fiber-to-stage offset. Advanced geomechanical modeling was performed to simulate the hydraulic fracture propagation and the resulting strain responses in the vertical direction. The modeling results demonstrated asymmetric upward and downward fracture height growths as observed in HFTS-2 with a similar upward height growth rate. Simulated waterfall plots of vertical strain rate showed distinct patterns for different fiber-to-fracture distances. The upward-growing fracture tip can be clearly identified by the interfaces between compressing and extending zones. It was also found that the complex strain rate patterns observed in HFTS-2 for small fiber-stage offsets were not caused by the mechanical layering but possibly result from the simultaneous propagation of multiple hydraulic fractures at different rates. The simulation results improved the understating of the HFTS-2 LF-DAS data, and the simulated strain rate patterns could also serve as templates for fracture height interpretation from LF-DAS data in future.

Engineering↗
DOE OSTI2022

Modeling gas breakthrough and flow phenomena through engineered barrier systems using a discrete fracture approach

Compacted clays are being considered to build engineered barrier systems (EBS) intended for the safe isolation of high-level nuclear waste (HLW) and spent nuclear fuel (SNF). The corrosion of the metallic canister containing the HLW/SNF will lead to the generation and buildup of the gas pressure in the more internal part of the clay buffer. This phenomenon would eventually trigger the formation and propagation of fractures in the clay barrier, jeopardizing its safety functions. Here, in this work, we propose to use the fragmentation technique (MFT) to model evolving fractures in clays triggered by gas pressurization. The MFT has been successfully used to model the formation of fractures in concrete, drying cracks in soil, hydraulic and thermo-fractures in rocks. In this work, we extend the MFT to deal with multiphase fluid flow in deformable porous media, and we upgraded a fully coupled computer finite element code using the extended technique. The proposed approach is first verified against analytical solutions and is then applied to model gas breakthrough experiments in clays. A very satisfactory performance of the method is observed in all the analyses, showing the potential of the MFT to tackle multiphase flow problems in deformable porous media with evolving discontinuities.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

A New Modeling Framework for Multi-Scale Simulation of Hydraulic Fracturing and Production from Unconventional Reservoirs

This paper describes a new modeling framework for microscopic to reservoir-scale simulations of hydraulic fracturing and production. The approach builds upon a fusion of two existing high-performance simulators for reservoir-scale behavior: the GEOS code for hydromechanical evolution during stimulation and the TOUGH+ code for multi-phase flow during production. The reservoir-scale simulations are informed by experimental and modeling studies at the laboratory scale to incorporate important micro-scale mechanical processes and chemical reactions occurring within the fractures, the shale matrix, and at the fracture-fluid interfaces. These processes include, among others, changes in stimulated fracture permeability as a result of proppant behavior rearrangement or embedment, or mineral scale precipitation within pores and microfractures, at µm to cm scales. In our new modeling framework, such micro-scale testing and modeling provides upscaled hydromechanical parameters for the reservoir scale models. We are currently testing the new modeling framework using field data and core samples from the Hydraulic Fracturing Field Test (HFTS), a recent field-based joint research experiment with intense monitoring of hydraulic fracturing and shale production in the Wolfcamp Formation in the Permian Basin (USA). Below, we present our approach coupling the reservoir simulators GEOS and TOUGH+ informed by upscaled parameters from micro-scale experiments and modeling. We provide a brief overview of the HFTS and the available field data, and then discuss the ongoing application of our new workflow to the HFTS data set.

58 GEOSCIENCES↗
DOE OSTI2026

Effects of Dissolution Regimes on Flow Channelization and Solute Transport in 3D Fracture Networks: Insights From Graph‐Based Reactive Transport Modeling

We investigate how mineral dissolution reshapes flow pathways and solute transport in three‐dimensional discrete fracture networks using a computationally efficient graph‐based reactive transport model. The DFNs are inspired by field‐site observations of fractured carbonate and represent realistic connectivity and structural heterogeneity. Flow is simulated with the Reynolds equation, and dissolution follows first‐order kinetics with diffusive limitations captured through an effective mass‐transfer coefficient. By systematically varying two key dimensionless parameters, the effective Damköhler number (Da), governing reaction versus advection rates, and a transport parameter (Da), analogous to the Thiele modulus, distinct flow channelization regimes emerge: mildly channelized at low G, highly channelized at intermediate Da, and extreme wormhole formation at high Da and low G. Eulerian and Lagrangian analyses, including breakthrough curves, particle tortuosity, dispersivity, and flow channeling indicators quantitatively characterize the progression of dissolution‐driven network restructuring. Across all regimes, initial fracture heterogeneity persists. The results underscore how the interplay between this initial structure, advection, reaction, and diffusion critically shapes subsurface flow pathways, with implications for applications ranging from groundwater remediation to enhanced geothermal systems.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Developing Upscaling Approach for Swarming Hydraulic Fractures Observed at Hydraulic Fracturing Test Site through Multiscale Simulations

We show that this work aims to address a challenge posed by recent observations of tightly spaced hydraulic fractures in core samples from the hydraulic fracturing test site (HFTS) in the Middle Wolfcamp Formation. Many fractures in retrieved cores have subfoot spacing, which is at odds with conventional models in which usually one hydraulic fracture is initiated per cluster. Models assuming a single fracture at each cluster, although a common practice, often predict excessive fracture propagation that is inconsistent with microseismic observation. Here, we aim to develop a numerical approach to effectively account for densely spaced hydraulic fractures in field-scale simulations. Because it is impractical to explicitly model all aforementioned fractures, we develop a new upscaling law that enables existing simulation tools to predict reservoir response to fracture swarms. The upscaling law is derived based on an energy equivalence argument and validated through multiscale simulations using a high-fidelity code, GEOS. The swarming fractures are first modeled with a spacing that is much smaller than the cluster spacing; these fractures are then approximated by an upscaled, single fracture based on the proposed upscaling law. The upscaled fracture is shown to successfully match the energy input rate and produce the total fracture aperture and average propagation length of the explicitly simulated swarm. Afterward, the upscaling approach is further implemented in 3D field-scale simulations and validated against the HFTS microseismic data of a horizontal well. Our results show that hydraulic fracture swarming can significantly affect fracture propagation behaviors compared with the propagation of single fractures as assumed by conventional modeling approaches. Under the considered situations, the conventional treatment yields fast propagation speed that far exceeds that indicated by the microseismic data. We also illustrate that this discrepancy can be reduced readily through the implementation of the upscaling law. Our results demonstrate the importance of accounting for the fracture swarming effect in field-scale simulations and the efficacy of this approach to enable realistic predictions of reservoir responses to fracture swarms, without the need to model tightly spaced fractures individually.

02 PETROLEUM↗
DOE OSTI2024

FORGE STRESS annual report

The project's goal is to combine high-fidelity numerical models and true-triaxial block fracturing tests at high temperatures to understand the relationship between in situ stress, thermal effects, wellbore orientations and hydraulic fracture patterns. The numerical models are calibrated against field data, such as well pressures and microseismic data, and employed to estimate the in situ stress at the FORGE site. Laboratory experiments investigate the complex physics driving hydraulic fracture nucleation in EGS, enhancing understanding of the role of parameters like temperature, well orientation, and stress. Additionally, they are employed to validate some of the numerical tools used in the project. The project will have a significant impact by: (1) improving the characterization of the in-situ stress field at FORGE; (2) demonstrating the use of high-fidelity modeling tools for EGS; (3) providing a unique set of high-temperature hydraulic fracturing results to identify key components for in-situ stress estimation, validate current theories, and propose new ones; (4) offering a validated set of numerical tools within an open-source simulation framework, GEOS, that will be available to any future user.

15 GEOTHERMAL ENERGY↗
DOE OSTI2021

Attaining regularization length insensitivity in phase-field models of ductile failure

In this work, a cohesive phase-field model of ductile fracture in a finite-deformation setting is presented. The model is based on a free-energy function in which both elastic and plastic work contributions are coupled to damage. Using a strictly variational framework, the field evolution equations, damage kinetics, and flow rule are jointly derived from a scalar least-action principle. Particular emphasis is placed on the use of a rational function for the stress degradation that maintains a fixed effective strength with decreasing regularization length. The model is employed to examine crack growth in pure mode-I problems through the generation of crack growth resistance (J-R) curves. In contrast to alternative models, the current formulation gives rise to J-R curves that are insensitive to the regularization length. Numerical evidence suggests convergence of local fields with respect to diminishing regularization length as well.

42 ENGINEERING↗
DOE OSTI2024

Selecting Appropriate Model Complexity: An Example of Tracer Inversion for Thermal Prediction in Enhanced Geothermal Systems

Abstract A major challenge in the inversion of subsurface parameters is the ill‐posedness issue caused by the inherent subsurface complexities and the generally spatially sparse data. Appropriate simplifications of inversion models are thus necessary to make the inversion process tractable and meanwhile preserve the predictive ability of the inversion results. In this study, we investigate the effect of model complexity on fracture aperture inversion and thermal performance prediction in a field‐scale EGS model. Principal component analysis was used to map the aperture field to a low‐dimensional latent space. The complexity of the inversion model was quantitatively represented by the percentage of total variance in the original aperture fields preserved by the latent space. Tracer, pressure and flow rate data were used to invert for fracture aperture through an ensemble‐based inversion method, and the inferred aperture field was used to predict thermal performance. With an over‐simplified aperture model, ensemble collapse occurred. The inverted aperture models failed to resolve necessary flow and transport features, leading to a biased thermal performance prediction. A complex aperture model involved excessive features and was prone to overinterpreting the inversion data. Both the tracer/pressure/flow rate data reproduction and thermal prediction showed significant uncertainties, making it difficult to properly estimate long‐term thermal performance. Fortunately, our results indicate that there exists an appropriate model complexity which can simultaneously match inversion data and predict thermal performance with an acceptable uncertainty. The quality of the fit of tracer data appears to be a useful indicator of such an appropriate model complexity.

15 GEOTHERMAL ENERGY↗