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NASA NTRS1989

Observations on the brittle to ductile transition temperatures of B2 nickel aluminides with and without zirconium

The effect of a zirconium addition (0.05 at. pct) to a stoichiometric NiAl alloy on the brittle-to-ductile transition temperature (BDTT) of this alloy was investigated. Constant velocity tensile tests were conducted to fracture between 300 and 1100 K under initial strain rate 0.00014/sec, and the true stress and true strain values were determined from plots of load vs time after subtracting the elastic strain. The inelastic strain was measured under a traveling microscope. Microstructural characterization of as-extruded and fractured specimens was carried out by SEM and TEM. It was found that, while the addition of 0.05 at. pct Zr strengthened the NiAl alloy, it increased its BDTT; this shift in the BDTT could not be attributed either to variations in grain size or to impurity contents. Little or no room-temperature ductility was observed for either alloy.

Raj, S. V.↗

DOE OSTI2024

Seismic monitoring of EGS fracture stimulations at Utah FORGE (Part 1): Time-lapse variations of b-values and Shear-wave Splitting Rates of induced microearthquakes

Characterizing geologic formations near geothermal wells is crucial for efficient extraction of subsurface geothermal energy resources. To monitor effective fracture stimulation of enhanced geothermal systems (EGS), we analyze a catalog of induced microearthquakes to characterize seismicity induced by Phase 2C fracture stimulations of the Utah FORGE project and derive the b-values for 424 induced microearthquakes in three stages of fracture stimulation. Here, we find the time-lapse variations of these b-values. We apply eigenvector rotation and waveform correlation to 3C geophone data to separate fast S 1 and slow S 2 waves, determine their directions, measure their lag time, and calculate the S-wave splitting rate (SSR) for six induced microearthquakes in Stage 1 and 21 in Stage 3. Both SSR values and b-values increase with time. The increase in these values may be related to heavily fractured zones created by fracture stimulations during Stage 2 injections. Large and highly variable SSR values in Stage 3 may reflect heterogeneities in the fracture zones. Time-lapse variations of SSR values and b-values may be one of the most useful approaches to monitoring and characterizing the effectiveness and efficiency of various types of fracture stimulations.

58 GEOSCIENCES↗

DOE OSTI2024

CONSTRAINT-INDEPENDENT CONSTANT CTOA DETERMINATION FOR DUCTILE STABLE CRACK GROWTH

Crack tip opening angle (CTOA) has been used as a reliable fracture toughness parameter for decades to characterize stable ductile crack growth for thin-walled aerospace structures in the low-constraint conditions. Recently, the CTOA parameter was also applied to the pipeline industry, and a CTOA test standard ASTM E3039 was thus developed for testing a critical constant CTOA. Research showed that the constant CTOA can reasonably describe fracture toughness required to arrest a dynamic crack propagation for a modern gas pipeline. However, the CTOA fracture criterion requires constraint-independent CTOA toughness against stable ductile crack growth. ASTM E3039 recommends a drop weight tearing test (DWTT) specimen for CTOA testing. Since a shallow crack is used, DWTT measured CTOA may depend on constraint level at the crack tip. To understand if it is the case, this paper evaluates the critical CTOA for a set of fracture toughness tests on single edge notched bend (SENB) specimens with shallow and deep cracks based on four CTOA estimation models. In which, the Ln(P)-LLD linear fit model is similar to that used by ASTM E3039 in the CTOA calculation. Fracture test data for X80 pipeline steel and HY80 structural steel are considered in the CTOA evaluation. The results show that the four CTOA models can determine a crack size-independent constant CTOA over stable ductile crack growth for the SENB specimens. As a result, CTOA determined by ASTM E3039 is constraintindependent and transferable to use for an actual crack propagating in a gas pipeline.

Zhu, Xian-Kui↗

DOE OSTI2025

Learning the factors controlling mineral dissolution in three-dimensional fracture networks: applications in geologic carbon sequestration

We perform a set of high-fidelity simulations of geochemical reactions within three-dimensional discrete fracture networks (DFN) and use various machine learning techniques to determine the primary factors controlling mineral dissolution. The DFN are partially filled with quartz that gradually dissolves until quasi-steady state conditions are reached. At this point, we measure the quartz remaining in each fracture within the domain as our primary quantity of interest. We observe that a primary sub-network of fractures exists, where the quartz has been fully dissolved out. This reduction in resistance to flow leads to increased flow channelization and reduced solute travel times. However, depending on the DFN topology and the rate of dissolution, we observe substantial variability in the volume of quartz remaining within fractures outside of the primary subnetwork. This variability indicates an interplay between the fracture network structure and geochemical reactions. We characterize the features controlling these processes by developing a machine learning framework to extract their relevant impact. Specifically, we use a combination of high-fidelity simulations with a graph-based approach to study geochemical reactive transport in a complex fracture network to determine the key features that control dissolution. We consider topological, geometric and hydrological features of the fracture network to predict the remaining quartz in quasi-steady state. We found that the dissolution reaction rate constant of quartz and the distance to the primary sub-network in the fracture network are the two most important features controlling the amount of quartz remaining. This study is a first step towards characterizing the parameters that control carbon mineralization using an approach with integrates computational physics and machine learning.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS1980

Notched graphite polymimide composites at room and notched graphite polymide composites at room and elevated temperatures

The fracture behavior in graphite/polyimide (Gr/PI) Celion 6000/PMR-15 composites was characterized. Emphasis was placed on the correlation between the observed failure modes and the deformation characteristics of center-notched Gr/Pl laminates. Crack tip damage growth, fracture strength and notch sensitivity, and the associated characterization methods were also examined. Special attention was given to nondestructive evaluation of internal damage and damage growth, techniques such as acoustic emission, X-ray radiography, and ultrasonic C-scan. Microstructural studies using scanning electron microscopy, photomicrography, and the pulsed nuclear magnetic resonance technique were employed as well. All experimental procedures and techniques are described and a summary of representative results for Gr/Pl laminates is given.

Awerbuch, J.↗

NASA NTRS1996

Characterization of Microgravity Effects on Bone Structure and Strength Using Fractal Analysis

Protecting humans against extreme environmental conditions requires a thorough understanding of the pathophysiological changes resulting from the exposure to those extreme conditions. Knowledge of the degree of medical risk associated with the exposure is of paramount importance in the design of effective prophylactic and therapeutic measures for space exploration. Major health hazards due o musculoskeletal systems include the signs and symptoms of hypercalciuria, lengthy recovery of lost bone tissue after flight, the possibility of irreversible trabecular bone loss, the possible effect of calcification in the soft tissues, and the possible increase in fracture potential. In this research, we characterize the trabecular structure with the aid of fractal analysis. Our research to relate local trabecular structural information to microgravity conditions is an important initial step in understanding the effect of microgravity and countermeasures on bone condition and strength. The proposed research is also closely linked with Osteoporosis and will benefit the general population.

Acharya, Raj S.↗

NASA NTRS2006

Cryogenic Fracture Toughness Evaluation of an Investment Cast Al-Be Alloy for Structural Applications

Aluminum-Beryllium metal matrix composite materials are useful due to their desirable performance characteristics for aerospace applications. Desirable characteristics of this material includes light-weight, dimensional stability, stiffness, good vibration damping characteristics, low coefficient of thermal expansion, and workability, This material is 3.5 times stiffer and 22% lighter than conventional aluminum alloys. electro-optical systems, advanced sensor and guidance components for flight and satellite systems, components for light-weight high-performance aircraft engines, and structural components for helicopters. Aluminum-beryllium materials are now available in the form of near net shape investment castings. In this materials properties characterization study, the cryogenic tensile and fracture properties of an investment casting alloy, Beralcast 363, were determined. Tensile testing was performed at 21 C (70 F), -73.3 C (-100 F), -195.5 C (-320 F) and -252.8 C (-423 F), and fracture (K(sub lc) and da/dN) testing was performed at -73.3 C (-100 F), -195.5 C (-320 F) and -252.8 C (-423 F). Their use is attractive for weight critical structural applications such as advanced

Gamwell, W. R.↗

DOE OSTI2021

Field Experiments and Model Validation: The EGS Collab Project

Implementing enhanced geothermal systems (EGS) will require improvements in understanding stimulation of crystalline rock to create appropriate flow pathways, and the ability to effectively simulate both the stimulation and the flow and transport processes in the resulting fracture network. The US Department of Energy (DOE) is addressing these and other challenges at multiple scales. The EGS Collab project, addressed here, is performing tests and modeling at the 10 m scale. The FORGE project is performing tests at the full reservoir scale. The EGS Collab team created an underground testbed at the Sanford Underground Research Facility (SURF) in Lead, South Dakota, at a depth of approximately 1.5 km to examine hydraulic fracturing (Experiment 1). We are currently building a second testbed at SURF at a depth of about 1.25 km aimed at investigating shear stimulation (Experiment 2). In Experiment 1, we drilled eight boreholes in a well-characterized phyllite and installed geophysical sensors in six of them to create a well-instrumented testbed to allow careful monitoring of stimulation events and flow tests. Numerical simulation was used to answer key experimental design questions, to forecast fracture propagation trajectories and extents, and to analyze and evaluate results both in near-real-time and in detailed process studies. Stimulations performed in this testbed allowed quantification of processes occurring during stimulation and the examination of dynamic flow occurrences. Long-term ambient temperature and chilled water flow tests were performed in addition to many tracer tests to examine system behavior. Our second testbed, targeted at shear stimulation, is currently being built at the SURF Facility at a depth of about 1.25 km in amphibolite under a different set of stress and fracture conditions than Experiment 1.

artificial intelligence↗

NASA NTRS1972

Investigation of the fracture mechanics of boride composites

Processing studies designed to produce boride composites with metal additives to lower fabrication temperatures and increase the impact strength are reported. Hot pressing experiments were performed with ZrB2 and Fe, Ti, and Zr employed singly as additives. Data for the characterization, impact tests, slow bend tests, and fracture strength are presented.

Kaufman, L. A.↗

DOE OSTI2020

Hydraulic fracturing experiments at 1500 m depth in a deep mine: Highlights from the kISMET project

In support of the U.S. DOE SubTER Crosscut initiative, we established a field test facility in a deep mine and designed and carried out in situ hydraulic fracturing experiments relevant to enhanced geothermal systems (EGS) in crystalline rock to characterize the stress field, understand the effects of rock fabric on fracturing, and gain experience in monitoring using geophysical methods. The project also included pre- and post-fracturing simulation and analysis, and laboratory measurements and experiments. The kISMET (permeability (k) and Induced Seismicity Management for Energy Technologies) site was established in the West Access Drift of the Sanford Underground Research Facility (SURF) 4757 ft (1450 m) below ground (on the 4850 ft level (4850L)) in phyllite of the Precambrian Poorman Formation. We drilled and continuously cored five near-vertical boreholes in a line on 3 m (10 ft) spacing, deviating the two outermost boreholes slightly to create a five-spot pattern around the test borehole centered in the test volume 40 m below the drift invert (floor) at a total depth of ~1490 m (4890 ft). Laboratory measurements of core from the center test borehole showed P-wave velocity heterogeneity along each core indicating strong, fine-scale (~1 cm or smaller) changes in the mechanical properties of the rock. Field measurements of the stress field by hydraulic fracturing showed that the minimum horizontal stress at the kISMET site averages 21.7 MPa (3146 psi) trending approximately N-S (356 degrees azimuth) and plunging slightly NNW at 12°. The vertical and horizontal maximum stresses are similar in magnitude at 42-44 MPa (6090-6380 psi) for the depths of testing, which averaged approximately 1530 m (5030 ft). Hydraulic fractures were remarkably uniform suggesting core-scale and larger rock fabric did not play a role in controlling fracture orientation. Analytical solutions suggest that the fracture radius of the large fracture (stimulation test) was more than 6 m (20 ft), depending on the unknown amount of leak-off.

Oldenburg, C↗

NASA NTRS1991

Preliminary 1:500,000-scale geologic mapping of Claritas Fossae, Mars

The Claritas Fossae system is a complex, linear fracture zone that extends from its northern intersection with Noctis Labyrinthus 1800 km south-southeast to its southern intersection with Thaumasia Fossae. The width of the fracture zone varies from 150 km in the north to 550 km in the south; topographic relief, based on radar data from Earth, is 1.0 to 1.5 km. Claritas Fossae and its coincident ridge or rise have been interpreted to be a horst with more than 8 km of vertical uplift, the greatest such uplift on Mars. Viking orbital images of sufficiently high resolution exist to provide the basis only for two 1:500,000 scale photomosaic base maps of Claritas Fossae. They extend en in echelon east and west, i.e., the southeast corner of the northern and western quadrangle (MTM-30102) is coincident with the northwest corner of the eastern and southern quadrangle (MTM-25107). Preliminary geologic maps of the two quadrangles were prepared. Materials in the quadrangles are Noachian and Hesperian age, and the quadrangles are characterized by the widespread occurrence of fractured and cratered plateau material, the oldest material in the map areas. Other information about the quadrangles is presented.

Underwood, James R., Jr.↗

NASA NTRS1988

Elevated temperature durability of ceramic materials

Fast fracture, stress rupture, and cyclic high temperature durability characterizations have been conducted for advanced silicon carbide and silicon nitride ceramics applicable to gas turbine hot section components. The fast fracture and stress rupture tests were conducted in four-point flexure at temperatures of up to 1540 C; the durability tests involved cycling specimens to temperatures of 1370 C and air quenching at 200 C for up to 3500 hrs. Materials with further reliability improvements are noted to be required for gas turbine hot section component applications.

Lindberg, Laura J.↗

DOE OSTI2021

Characteristics and mechanisms of hydrogen-induced quasi-cleavage fracture of lath martensitic steel

Here this study presents an in-depth characterization of the microstructures, crystallographic orientations, and dislocation characteristics beneath hydrogen-induced quasi-cleavage fracture features of an as-quenched, lath martensitic (α') 22MnB5 steel. The fracture surfaces of gaseous hydrogen-embrittled martensitic specimens were analyzed by a combination of multiple analytical tools: scanning electron microscopy (SEM), electron backscatter diffraction (EBSD), transmission electron microscopy (TEM), and transmission Kikuchi diffraction (TKD). The dominant fracture mode in the hydrogen-affected zones was quasi-cleavage fracture, which involved significant plasticity, evidenced by plastic zones near tear ridges and a high density of dislocations beneath the quasi-cleavage facets. The martensite constituent sizes, variant orientations, and boundaries influenced the quasi-cleavage surface morphologies. Fractography revealed the occurrence of {100} α' -type cleavage across martensitic laths, developing relatively “flat” quasi-cleavage surfaces, in addition to {110} α' -type cracking likely along lath and block boundaries, and fracture along non-cleavage planes. The likelihood of the formation of the relatively “flat” quasi-cleavage surfaces increased with increasing martensitic constituent sizes. Substantial dislocation bands formed on intersecting {112} α' slip planes within a martensite block below the hydrogen-induced cleavage fractures on {100} α' planes. River markings on the quasi-cleavage surfaces were found to originate from the complex, hierarchical lath martensitic microstructure. Steps and ridges on the quasi-cleavage facets generally linked with the various martensitic boundaries, suggesting that they were produced as a result of crack deviations at those boundaries. The fracture paths and martensite quasi-cleavage mechanisms are discussed in the context of the role of hydrogen and Cottrell cleavage model.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Newly acquired core enhances geologic understanding of the northern Paradox Basin Cane Creek play, southeastern Utah

The Cane Creek interval is an emerging unconventional heterolithic play within the Pennsylvanian Paradox Formation of the northern Paradox Basin, southeastern Utah. Structural controls (basement uplifts, salt movement, faults, fractures) likely control production from the Cane Creek, where total oil production of ~10 MMBO is just a fraction of current estimates of the undiscovered resource (up to 1.2 BBOE). Oil production has been most successful from unstimulated horizontal wells in the Cane Creek Unit in the central play area, whereas areas to the north (Greentown and Gunnison Valley) have to date proven to be largely unproductive from vertical and horizontal wells drilled without the benefit of 3D seismic or the deployment of modern hydraulic fracturing techniques. However, the limited historical drilling has shown significant promise (e.g., significant shows). The lack of core data in the northern part of the play has impeded thorough assessment of reservoir quality, character, and lithological facies heterogeneity. The Cane Creek is informally divided into three distinct zones. The upper A and basal C zones are composed of fabric destructive and wavy bedded anhydrite, dolomitic mudstone, and organic-rich algal laminated mudstones (source rock). The middle B zone is generally wave rippled and burrowed, low-permeability sandstone-siltstone (reservoir) with subordinate displacive anhydrite. Recent potash cores collected from the Salt Valley anticline near Crescent Junction, Utah (but east of the main play area), show thicker reservoir sandstone/siltstone packages (~40 ft) in the B zone, and parts of the C zone, in the northern part of the Paradox Basin in comparison to the central (~35 ft) and southern (~30 ft) areas. Source rock analyses from northern core/cuttings also indicate that it is well positioned within the oil window (VRo ~0.8), with thin organic-rich mudstone beds containing up to 20 wt% TOC. Because the siliciclastic reservoir rocks have low permeabilities (0.009–0.202 mD) and variable porosities (6–17%) due to dolomite-anhydrite cement, naturally occurring and possibly stimulated fractures may be essential for hydrocarbon recovery. To better understand the northern part of the Cane Creek play, a new core was obtained from the research stratigraphic well State 16-2 (January 2021). Details from this new core will help characterize reservoir quality via core analyses, petrography, fracture orientations, geomechanics, and correlation of facies and depositional trends. Additionally, an evaluation of matrix porosity/permeability will be conducted to determine its contribution to productivity.

02 PETROLEUM↗

NASA NTRS1990

Origin of the Martian global dichotomy by crustal thinning in the late Noachian or early Hesperian

The marked dichotomy in topography, surface age, and crustal thickness between the northern lowland (NL) and southern upland of Mars has been explained as due to an initially inhomogeneous crust, a single megaimpact event, several overlapping large basin impacts, and first-order convective overtum of the Martian mantle. All of these hypotheses propose that the dichotomy was formed before the end of the primordial heavy bombardment. Geological data indicate episodes of fracturing and faulting in the late Noachian and the early Hesperian, within the NL and along the lowland/highland boundary. Igneous activity also peaked in the late Noachian and early Hesperian. These data suggest a tectonic event near the Noachian/Hesperian boundary characterized by enhanced heat loss and extensive fracturing, including formation of the faults that define much of the highland/lowland boundary. It is argued that the major result of this tectonic event was formation of the dichotomy by thinning of the crust above a large convection cell or plume.

Mcgill, George E.↗

DOE OSTI2026

Low-Rate Cycling Regeneration Sustains NMC811–Graphite Battery Performance through Extreme Ultrafast Charging

Urban air mobility (UAM) systems, such as electric vertical takeoff and landing (eVTOL) aircraft, require batteries capable of extreme ultrafast charging to support high-frequency operations. Here, in this work, we evaluate the electrochemical stability of NMC811–graphite full cells using a complex mixed-modal protocol designed to simulate the aggressive turnaround demands of UAM missions. We demonstrate that incorporating a periodic low-rate (0.3C) “regeneration” cycle enables cells to maintain 96% capacity retention over 900 cycles, despite repeated exposure to ultrafast pulses. To validate the efficacy of this regeneration mechanism, we performed simplified control experiments comparing continuous 10C charging against a 10C–0.3C interleaved protocol. Advanced characterization reveals that while mechanical particle fracture is pervasive at these rates, the regeneration cycles decelerate the electrochemical degradation by resolving spatially heterogeneous Ni oxidation states and relaxing lithium-ion concentration gradients. These findings provide a vital mechanistic framework for battery operation, proving that restorative charging can effectively delay and mitigate failure in demanding UAM applications.

batteries↗

DOE OSTI2020

EGS Collab Experiment 1: SIMFIP Notch-164 GRL Paper

Characterizing the stimulation mode of a fracture is critical to assess the hydraulic efficiency and the seismic risk related to deep fluid manipulations. We have monitored the three-dimensional displacements of a fluid-driven fracture during water injections in a borehole at ~1.5 km depth in the crystalline rock of the Sanford Underground Research Facility (USA). The fracture initiates at 61% of the minimum horizontal stress by micro-shearing of the borehole on a foliation plane. As the fluid pressure increases further, borehole axial and radial displacements increase with injection time highlighting the opening and sliding of a new hydrofracture growing ~10 m away from the borehole, in accordance with the ambient normal stress regime and in alignment with the microseismicity. Our study reveals how fluid-driven fracture stimulation can be facilitated by a mixed-mode process controlled by the complex hydromechanical evolution of the growing fracture. The data presented in this submission refer to the SIMFIP measurements and analyses of the stimulation tests conducted on the 164 ft (50 m) notch of the Sanford Underground Research Facility (SURF), during the EGS-Collab test 1. In addition to the datafiles, there is the draft of a manuscript submitted to Geophysical Research Letters (GRL).

15 GEOTHERMAL ENERGY↗

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↗