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DOE OSTI2021

Mechanism of Microseismic Generation During Hydraulic Fracturing - With Evidence From HFTS 2 Observations

The objective of this study is to understand how microseismic events are generated during hydraulic fracturing, as well as the role of geomechanical conditions (i.e., stress and mechanical stratigraphy) in this process. In the industry, microseismic event clouds have been generally used as an “outer-boundary” of the “stimulated reservoir volume” (SRV). However, by comparing with other surveillance data (Low frequency Distributed Acoustic Sensing, or LF-DAS strain) in the Hydraulic Fracturing Test Site (HFTS) 2 experiment, we show that this assumption is fundamentally flawed. The HFTS 2 data has three unique observations that have not been commonly observed in other datasets: 1. Due to influence of offset pad depletion, microseismic data shows that hydraulic fractures from the child well can propagate over 3000 feet into the depleted low stress zone. 2. By comparing microseismic and horizontal fiber LF-DAS strain data, we observe that microseismic event cloud does not necessarily reflect the created hydraulic fracture volume. Particularly, the extent of microseismic event clouds near heel stages are much shorter than what is shown with LF-DAS strain data. 3. Microseismic event magnitudes are larger in the depleted regions. Through geomechanical analysis, we demonstrate that the “bedding-plane-slip” model is likely the mechanism for microseismic generation during hydraulic fracturing. Furthermore, this model successfully explains the above field observations from HFTS 2 experiment. We also provide a quantitative relationship connecting the microseismic event magnitude with fracture width increment and layer mechanical property contrast.

58 GEOSCIENCES↗

DOE OSTI2022

Interpretation of HFTS 2 Microseismic Data Using Bedding-Plane-Slip Mechanism

Summary The objective of this study is to understand how microseismic events are generated during hydraulic fracturing, as well as the role of geomechanical conditions (i.e., stress and mechanical stratigraphy) in this process. In the industry, microseismic event clouds have been generally used as an “outer boundary” of the “stimulated reservoir volume” (SRV). However, by comparing with other surveillance data (low-frequency distributed acoustic sensing, or LF-DAS, strain) in the Hydraulic Fracturing Test Site (HFTS) 2 experiment, we show that this assumption is fundamentally flawed. The HFTS 2 data have three unique observations that have not been commonly observed in other datasets: (1) Due to the influence of offset pad depletion, microseismic data show that hydraulic fractures from the child well can propagate over 3,000 ft into the depleted low-stress zone. (2) By comparing microseismic and horizontal fiber LF-DAS strain data, we observe that the microseismic event cloud does not necessarily reflect the created hydraulic fracture volume. Particularly, the extent of microseismic event clouds near heel stages is much shorter than what is shown with LF-DAS strain data. (3) Microseismic event magnitudes are larger in the depleted regions. Through geomechanical analysis, we demonstrate that the “bedding-plane-slip” model is likely the mechanism for microseismic generation during hydraulic fracturing. This model successfully explains the above field observations from the HFTS 2 experiment. We also provide a quantitative relationship connecting the microseismic event magnitude with fracture width increment and layer mechanical property contrast.

Engineering↗

DOE OSTI2021

Anisotropic thermal-conductivity degradation in the phase-field method accounting for crack directionality

Dynamic loads applied to metals may lead to brittle or ductile fracture depending on the imposed strain rates, material properties, and specimen geometry. With an increase in the applied velocity, brittle to ductile failure mode transition may also be observed. Furthermore, at high strain rates, ductile fracture may be preceded by shear bands, which are narrow bands of intense plastic deformation, typically accompanied by a significant rise in temperature. Reliable models are needed to predict the response of metals subject to dynamic loads. In particular, capturing the interplay between heat conduction and crack propagation using the phase-field fracture method is still an open research field. To accurately capture the heat transfer physics across crack surfaces, damage models degrading thermal-conductivity are necessary. While isotropic thermal-conductivity degradation models were proposed, they may lead to errors as they are indifferent to crack directionality. In our current work, a new anisotropic approach is proposed in which thermal-conductivity, which depends on the phase-field gradient, is degraded solely across the crack. Here, it is shown that this approach improves the near-field approximation of temperature and heat flux compared with isotropic degradation, when taking the discontinuous crack solutions as reference. Additionally, the anisotropic degradation approach is implemented in a unified dynamic fracture model and a couple of examples demonstrate the viability of this approach.

42 ENGINEERING↗

NASA NTRS2005

Fatigue Crack Growth Database for Damage Tolerance Analysis

The objective of this project was to begin the process of developing a fatigue crack growth database (FCGD) of metallic materials for use in damage tolerance analysis of aircraft structure. For this initial effort, crack growth rate data in the NASGRO (Registered trademark) database, the United States Air Force Damage Tolerant Design Handbook, and other publicly available sources were examined and used to develop a database that characterizes crack growth behavior for specific applications (materials). The focus of this effort was on materials for general commercial aircraft applications, including large transport airplanes, small transport commuter airplanes, general aviation airplanes, and rotorcraft. The end products of this project are the FCGD software and this report. The specific goal of this effort was to present fatigue crack growth data in three usable formats: (1) NASGRO equation parameters, (2) Walker equation parameters, and (3) tabular data points. The development of this FCGD will begin the process of developing a consistent set of standard fatigue crack growth material properties. It is envisioned that the end product of the process will be a general repository for credible and well-documented fracture properties that may be used as a default standard in damage tolerance analyses.

Metallic materials↗

DOE OSTI2025

Impact of position and density of nanoscale voids on fracture initiation in iron from phase field fracture simulation

Understanding the impact of these bubbles on crack propagation, like that of helium bubble-induced cracking in irradiated materials is incredibly complex. A useful first study towards understanding bubble effects on fracture is to examine how voids impact fracture first. In this work, we used phase-field fracture simulations to examine the influence of voids and their distribution on Mode I fracture in Fe. Assuming brittle fracture, two simulation configurations were considered: (1) nanoscale systems with one or two voids, and (2) nanoscale systems with an experimentally relevant distribution of voids, with up to 20% void area. Results from simulations with one and two voids showed that voids within 10 nm of a crack tip reduce the stress required for crack growth, with the magnitude of reduction depending on void-to-crack orientation. Comparisons with linear elastic fracture mechanics and evaluation of one versus two void systems revealed deviations from linear superposition, implying complex interactions between void and crack tip stress fields. In multi-void simulations, as void sizes increase, the nearest void to the crack tip exerts a greater influence on fracture stress than the overall porosity. Furthermore this study provides valuable insights into the relationship between void size and concentration, and the stress necessary for crack growth, marking a step forward towards understanding He bubble-induced fracture in ferrous materials.

36 MATERIALS SCIENCE↗

NASA NTRS1974

The surface geometry of inherited joint and fracture trace patterns resulting from active and passive deformation

Hypothetical models are considered for detecting subsurface structure from the fracture or joint pattern, which may be influenced by the structure and propagated to the surface. Various patterns of an initially orthogonal fracture grid are modeled according to active and passive deformation mechanisms. In the active periclinal structure with a vertical axis, fracture frequency increased both over the dome and basin, and remained constant with decreasing depth to the structure. For passive periclinal features such as a reef or sand body, fracture frequency is determined by the arc of curvature and showed a reduction over the reefmound and increased over the basin.

Podwysocki, M. H.↗

NASA NTRS1976

Fracture of composite panels

The fracture problem in panels consisting of periodically arranged load carrying and buffer strips of different materials is considered. The main emphasis is placed on the problem of a crack terminating at and crossing the interfaces and on the stress free end problem. The problem is formulated in terms of a system of singular integral equations, and numerical solutions are obtained for certain material combinations. With the study of possible crack propagation and delamination in mind, certain stress intensity factors are defined and calculated. A main result is that when the crack touches or intersects a bimaterial interface, the stress state has no longer the standard square root singularity, and, to study further propagation of the crack, the conventional fracture models need to be modified, or new models need to be developed.

Erdogan, F.↗

NASA NTRS1971

The fracture energy and some mechanical properties of a polyurethane elastomer.

The energy required to form a unit of new surface in the fracture of a polyurethane elastomer is determined. The rate sensitivity of the material has been reduced by swelling it in toluene. This paper primarily describes the experimental work of measuring the lower limit of the fracture energy. With this value and the creep compliance as a basis, the rate dependence of fracture energy for the unswollen material has been determined. It is thus shown that the dependence of the fracture energy on the rate of crack propagation can be explained by energy dissipation around the tip of the crack. Good agreement between the theoretically and experimentally determined relationships for the rate-sensitive fracture energy is demonstrated.

Mueller, H. K.↗

NASA NTRS1982

Pre-HOST high temperature crack propagation

The highlights of NASA contract CR-167896, Fracture Mechanics Criteria for Turbine Engine Hot Section Components, are presented. The five technical tasks of the program are reviewed. Results of several tasks are presented.

Orange, T. W.↗

NASA NTRS1990

Fatigue crack propagation in aerospace aluminum alloys

This paper reviews fracture mechanics based, damage tolerant characterizations and predictions of fatigue crack growth in aerospace aluminum alloys. The results of laboratory experimentation and modeling are summarized in the areas of: (1) fatigue crack closure, (2) the wide range crack growth rate response of conventional aluminum alloys, (3) the fatigue behavior of advanced monolithic aluminum alloys and metal matrix composites, (4) the short crack problem, (5) environmental fatigue, and (6) variable amplitude loading. Remaining uncertainties and necessary research are identified. This work provides a foundation for the development of fatigue resistant alloys and composites, next generation life prediction codes for new structural designs and extreme environments, and to counter the problem of aging components.

Gangloff, R. P.↗

NASA NTRS1994

Investigation of the effects of manufacturing variations and materials on fatigue crack detection methods in gear teeth

The fatigue life of a gear tooth can be thought of as the sum of the number of cycles required to initiate a crack, N(sub i), plus the number of cycles required to propagate the crack to such a length that fracture occurs, N(sub p). The factors that govern crack initiation are thought to be related to localized stress or strain at a point, while propagation of a fatigue crack is a function of the crack tip parameters such as crack shape, stress state, and stress intensity factor. During a test there is no clear transition between initiation and propagation. The mechanisms of initiation and propagation are quite different and modeling them separately produces a higher degree of accuracy, but then the question that continually arises is 'what is a crack?' The total life prediction in a fracture mechanics model presently hinges on the assumption of an initial crack length, and this length can significantly affect the total life prediction. The size of the initial crack is generally taken to be in the range of 0.01 in. to 0.2 in. Several researchers have used various techniques to determine the beginning of the crack propagation stage. Barhorst showed the relationship between dynamic stiffness changes and crack propagation. Acoustic emissions, which are stress waves produced by the sudden movement of stressed materials, have also been successfully used to monitor the growth of cracks in tensile and fatigue specimens. The purpose of this research is to determine whether acoustic emissions can be used to define the beginning of crack propagation in a gear using a single-tooth bending fatigue test.

Wheitner, Jeffrey A.↗

NASA NTRS1995

Gear Crack Propagation Investigation

Reduced weight is a major design goal in aircraft power transmissions. Some gear designs incorporate thin rims to help meet this goal. Thin rims, however, may lead to bending fatigue cracks. These cracks may propagate through a gear tooth or into the gear rim. A crack that propagates through a tooth would probably not be catastrophic, and ample warning of a failure could be possible. On the other hand, a crack that propagates through the rim would be catastrophic. Such cracks could lead to disengagement of a rotor or propeller from an engine, loss of an aircraft, and fatalities. To help create and validate tools for the gear designer, the NASA Lewis Research Center performed in-house analytical and experimental studies to investigate the effect of rim thickness on gear-tooth crack propagation. Our goal was to determine whether cracks grew through gear teeth (benign failure mode) or through gear rims (catastrophic failure mode) for various rim thicknesses. In addition, we investigated the effect of rim thickness on crack propagation life. A finite-element-based computer program simulated gear-tooth crack propagation. The analysis used principles of linear elastic fracture mechanics, and quarter-point, triangular elements were used at the crack tip to represent the stress singularity. The program had an automated crack propagation option in which cracks were grown numerically via an automated remeshing scheme. Crack-tip stress-intensity factors were estimated to determine crack-propagation direction. Also, various fatigue crack growth models were used to estimate crack-propagation life. Experiments were performed in Lewis' Spur Gear Fatigue Rig to validate predicted crack propagation results. Gears with various backup ratios were tested to validate crack-path predictions. Also, test gears were installed with special crack-propagation gages in the tooth fillet region to measure bending-fatigue crack growth. From both predictions and tests, gears with backup ratios (rim thickness divided by tooth height) of 3.3 and 1.0 produced tooth fractures, whereas a backup ratio of 0.3 produced rim fractures. For a backup ratio of 0.5, the experiments produced rim fractures and the predictions produced both rim and tooth fractures, depending on the initial geometry of the crack. Good correlation between predicted and measured crack growth was achieved when the fatigue crack-closure concept was introduced into the analysis. As the gear rim thickness decreased, the compressive cyclic stress in the gear-tooth fillet region increased. This retarded crack growth and increased the number of crack-propagation cycles to failure.

Source record↗

DOE OSTI2024

Utah FORGE: Direct Shear Test Data for Investigating Seismic Precursors to Shear Failure of Fractures

This dataset includes results of direct shear tests to investigate the mechanical and geophysical response of dry and saturated fractures in Indiana limestone and Sierra White granite. Direct shear tests were performed on tensile-induced fractures in Indiana limestone and Sierra White granite in a custom water-pressurized chamber. The provided Excel files include the representative seismic wave signals and the normalized wave amplitudes of ultrasonic wave transducers. A link to the published journal article presenting the data and describing the experiment in detail is provided as well.

15 GEOTHERMAL ENERGY↗

NASA NTRS2013

Modeling Delamination in Postbuckled Composite Structures Under Static and Fatigue Loads

The ability of the Abaqus progressive Virtual Crack Closure Technique (VCCT) to model delamination in composite structures was investigated for static, postbuckling, and fatigue loads. Preliminary evaluations were performed using simple Double Cantilever Beam (DCB) and Mixed-Mode Bending (MMB) specimens. The nodal release sequences that describe the propagation of the delamination front were investigated. The effect of using a sudden or a gradual nodal release was evaluated by considering meshes aligned with the crack front as well as misaligned meshes. Fatigue simulations were then performed using the Direct Cyclic Fatigue (DCF) algorithm. It was found that in specimens such as the DCB, which are characterized by a nearly linear response and a pure fracture mode, the algorithm correctly predicts the Paris Law rate of propagation. However, the Abaqus DCF algorithm does not consider different fatigue propagation laws in different fracture modes. Finally, skin/stiffener debonding was studied in an aircraft fuselage subcomponent in which debonding occurs deep into post-buckling deformation. VCCT was shown to be a robust tool for estimating the onset propagation. However, difficulties were found with the ability of the current implementation of the Abaqus progressive VCCT to predict delamination propagation within structures subjected to postbuckling deformations or fatigue loads.

Bisagni, Chiara↗

NASA NTRS1984

Inelastic and Dynamic Fracture and Stress Analyses

Large deformation inelastic stress analysis and inelastic and dynamic crack propagation research work is summarized. The salient topics of interest in engine structure analysis that are discussed herein include: (1) a path-independent integral (T) in inelastic fracture mechanics, (2) analysis of dynamic crack propagation, (3) generalization of constitutive relations of inelasticity for finite deformations , (4) complementary energy approaches in inelastic analyses, and (5) objectivity of time integration schemes in inelastic stress analysis.

Atluri, S. N.↗

NASA NTRS1982

Fracture mechanics criteria for turbine engine hot section components

The application of several fracture mechanics data correlation parameters to predicting the crack propagation life of turbine engine hot section components was evaluated. An engine survey was conducted to determine the locations where conventional fracture mechanics approaches may not be adequate to characterize cracking behavior. Both linear and nonlinear fracture mechanics analyses of a cracked annular combustor liner configuration were performed. Isothermal and variable temperature crack propagation tests were performed on Hastelloy X combustor liner material. The crack growth data was reduced using the stress intensity factor, the strain intensity factor, the J integral, crack opening displacement, and Tomkins' model. The parameter which showed the most effectiveness in correlation high temperature and variable temperature Hastelloy X crack growth data was crack opening displacement.

Meyers, G. J.↗

DOE OSTI2025

Large scale polymer toughening of two-dimensional materials revealed by in situ TEM fracture tests and multiscale simulations

Two-dimensional (2D) materials offer significant potential for applications in energy-harvesting devices, batteries, sensors, and transistors. However, their intrinsic brittleness makes them prone to mechanical failure, limiting their practical use. In this work, we perform in situ transmission electron microscopy (TEM) fracture tests on monolayer MoSe2 and uncover an extrinsic toughening effect induced by an ultrathin adsorbed polystyrene adlayer. This adlayer substantially enhances the fracture resistance of the 2D flakes. Through a combination of molecular dynamics simulations and finite element analysis, we elucidate the molecular mechanism behind this toughening effect. Further, it arises from the active crack-bridging behavior of entangled polymer chains and the formation of a fracture process zone that stabilizes crack propagation and increases the energy required for crack extension. The proposed toughening mechanism offers a pathway to improving the mechanical reliability of 2D material-based devices by mitigating the risk of sudden failure.

2D materials↗

NASA NTRS2003

Fracture Evaluation of In-Situ Sensors for High Temperature Applications

The feasibility of fabricating an in-situ crack sensor for real-time detection of surface cracks propagating in engine components was evaluated using a computational fracture mechanics model. The in-situ sensor system would be required to: (1) Be capable of sustaining normal function in a severe environment; (2) Transmit a signal if a detected crack in the component was above a predetermined length, but below a critical length that would lead to failure; (3) Act neutrally upon the overall performance of the engine system and not interfere with the engine maintenance operations. In this work, fracture mechanics methodologies are used to identify the requirements for an in-situ sensor system that could withstand the engine operating environment, foreign object damage, and minimally degrade engine performance. A computational fracture mechanics model was developed to evaluate the feasibility of fabricating an in-situ crack sensor for real-time damage propagation detection in engine components.

Forth, Scott C.↗