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At least 343 records · Page 19
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

The EGS Collab Project: Status and Accomplishments

The EGS Collab project, supported by the US Department of Energy, is addressing challenges in implementing enhanced geothermal systems (EGS). This includes improving understanding of the 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 project is performing intensively monitored rock stimulation and flow tests at the 10-m scale in an underground research laboratory. Data and observations from the field test are compared to simulations to understand processes and to build confidence in numerical modeling of the processes. In Experiment 1, we examined hydraulic fracturing an underground test bed at the Sanford Underground Research Facility (SURF) in Lead, South Dakota, at a depth of approximately 1.5 km. We drilled eight sub-horizontal boreholes in a well-characterized phyllite. Six of the boreholes were instrumented with many sensor types to allow careful monitoring of stimulation events and flow tests, and the other two boreholes were used for water injection and production. We performed a number of stimulations and flow tests in the testbed. Our monitoring systems allowed detailed observations and collection of numerous data sets of processes occurring during stimulation and during dynamic flow tests. Long-term ambient temperature and chilled water flow tests were performed in addition to many tracer tests to examine system behavior. Data were rapidly analyzed, allowing adaptive control of the tests. Numerical simulation was used to answer key experimental design questions, to forecast fracture propagation trajectories and extents, and to analyze and evaluate results. Many simulations were performed in near-real-time in conjunction with the field experiments, with more detailed process study simulations performed on a longer timeframe. Experiment 2 will examine hydraulic shearing in a test bed being built at the SURF at a depth of about 1.25 km in amphibolite under a different set of stress and fracture conditions than Experiment 1. Five sets of fracture orientations were considered in design, and three orientations seem to be consistently observed.

EGS Collab↗
DOE OSTI2024

Chemo-Mechanical Instabilities in Lithium Cobalt Oxide at Higher State-Of-Charge in Li-Ion Batteries

Transition metal oxide cathodes are widely used in commercial Li-ion batteries. However, their practical charge capacity is limited due to severe chemo-mechanical instabilities at higher charge voltage, and state-of-charge condition. Here, in situ stress and strain measurements were synchronized to probe mechanical deformations in the lithium cobalt oxide (LCO) cathode via a multi-beam stress sensor and digital image correlation, respectively. In situ mechanical measurements revealed how Li removal from the electrode structure induces deformations on the LCO composite cathodes during cycling. The structure and morphology of the LCO cathodes were further investigated by X-ray diffraction (XRD) and scanning electron microscopy (SEM) studies. Two distinct electrochemical and mechanical behaviors were identified when the LCO was charged up to 4.65 V. The LCO undergoes a compressive stress generation when charged up to 4.2 V and surface fractures on the LCO particles were detected by SEM. LCO cathode experienced significantly large contractions (negative strains) when charged up to 4.65 V, where intergranular crack formation and phase transformation were detected on the LCO particles via SEM and XRD, respectively. Overall, the study bridges complicated structural deformations with in situ analysis of mechanical degradations in LCO cathodes charged at higher voltages. The correlation is vital to understanding instability mechanisms in transition metal oxides at high voltages for alkali metal ion batteries.

higher state-of-charge↗
DOE OSTI2020

Mesoscale informed parameter estimation through machine learning: A case-study in fracture modeling

Scale bridging is a critical need in computational sciences, where the modeling community has developed accurate physics models from first principles, of processes at lower length and time scales that influence the behavior at the higher scales of interest. However, it is not computationally feasible to incorporate all of the lower length scale physics directly into upscaled models. This is an area where machine learning has shown promise in building emulators of the lower length scale models, which incur a mere fraction of the computational cost of the original higher fidelity models. We demonstrate the use of machine learning using an example in materials science estimating continuum scale parameters by emulating, with uncertainties, complicated mesoscale physics. Additionally, we describe a new framework to emulate the fine scale physics, especially in the presence of microstructures, using machine learning, and showcase its usefulness by providing an example from modeling fracture propagation. Our approach can be thought of as a data-driven dimension reduction technique that yields probabilistic emulators. Our results show well-calibrated predictions for the quantities of interests in a low-strain simulation of fracture propagation at the mesoscale level. Furthermore, on average, we achieve ~10% relative errors on time-varying quantities like total damage and maximum stresses. Successfully replicating mesoscale scale physics within the continuum models is a crucial step towards predictive capability in multi-scale problems.

36 MATERIALS SCIENCE↗
DOE OSTI2024

A macro-micro approach for identifying crystal plasticity parameters for necking and failure in nickel-based alloy haynes 282

Here, this work develops a two-scales macro-micro approach to address the challenge in calibrating crystal plasticity microstructural models when samples undergo necking prior to fracture. The crystal plasticity models are crucial for predicting the materials’ plastic deformation and failure at the microstructure level, identifying the materials’ intrinsic properties as well as investigating the microstructure-properties relationships. However, after necking occurs, the experimentally measured stress-strain curves fail to reflect the materials ‘true’ stress-strain behavior and cannot be directly fitted into crystal plasticity models. The proposed macro-micro approach employs a top-down strategy to address this challenge, which has been studied with experimental tests on precipitation-strengthened Ni-based superalloy Haynes® 282®. In this approach, a macro rate-dependent anisotropic plasticity model with Voce-type hardening and Rice-Tracey damage law is first utilized to model the deformation and failure of the tensile bar, and calibrated by matching the stress-strain curves, necking strain, and reduction of area. Especially, to match the testing results under different applied strain rates, the rate-sensitivity parameter m and saturation stress in the elasticity model are modified to incorporate dependence on the local strain rate. Then, the ‘true’ stress-strain behaviors are extracted from the necking zone of the macro-model, which are used to calibrate a micro-model with explicit microstructures and governed by an extended crystal plasticity law. The consistency between the micro-model and macro-model are enforced during calibration. The calibration outcomes from the crystal plasticity model elucidate the materials intrinsic properties for slip, hardening, and failure, which is vital for further investigations into the microstructure-properties relationship and for accurate prediction of the material behavior under various test and service conditions.

36 MATERIALS SCIENCE↗
DOE OSTI2021

A nonlinear elasto-plastic bond model for the discrete element modeling of woody biomass particles

This work presents an experiment-informed, semi-empirical, elasto-plastic bond model for the discrete element modeling of woody biomass particles. The model renders nonlinear plastic deformation of materials when subjected to compression/tension, bending, and twisting, essential for accurately simulating the behavior of biomass in comminution. The model is implemented in an open-source DEM package LIGGGHTS and is assessed in a number of verification tests. The model is applied to simulate the fracturing test of notched loblolly pine blocks. Reduced bond strength is prescribed to the weak planes along the growth rings. It is found that the square-root formulation for describing the elasto-plastic normal bond contact delivers the best agreement with the experimental data over its linear and quadratic counterparts. Furthermore, the model predicts a strong anisotropic behavior of wood blocks with regard to the grain orientations, indicating that the cutting angle should be an important attribute for the optimization of biomass comminution.

42 ENGINEERING↗
DOE OSTI2024

Variations in Bedrock and Vegetation Cover Modulate Subsurface Water Flow Dynamics of a Mountainous Hillslope

Abstract Predicting the hydrological response of watersheds to climate disturbances requires a detailed understanding of the processes connecting hillslopes and streams. Using a network of soil moisture and temperature sensors, electrical resistivity tomography monitoring, and a weather station we assess the above and below‐ground processes driving the hydrological response of a hillslope during snowmelt and summer monsoon. The transect covers bedrock and vegetation gradients, with a steep upper part characterized by shallow bedrock, and gentle lower part underlain by colluvium. The main vegetation cover is conifers on the upper, and grass and veratrum on the lower part. Combined with a simplified hydrological model, we show that the thin soil layer of the steep slope acts as a preferential flow path, leading to mostly shallow lateral flow, interrupted by vertical flow, mostly at tree locations, and likely facilitated by flow along fractures and roots. Vertical flow and upstream‐driven groundwater dynamics are prevailing at the colluvium, presenting a very different hydrological behavior compared to the upper part. These results show that subsurface structure and features have a strong control on the hydrological response of a hillslope and that those can create considerably varying hydrological dynamics across small spatial scales.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Utah FORGE: Fluid Injection Induced Shearing Experiments on Fractured Granitoid at Elevated Temperatures

This repository contains experimental data from a series of fluid injection-induced shearing tests conducted on Utah FORGE granitoid. The experiments were performed using an aluminum triaxial pressure vessel (TEMCO) apparatus at Pennsylvania State University. The primary aim was to investigate the impact of temperature on fault seismicity and to explore how different pre-stress ratios influence shearing behavior. The data includes results from experiments conducted under varying conditions of temperature, pre-stress ratios, and pore pressure increments. The rock samples used in these experiments were 60-grit granitoid with a single inclined fracture oriented at 60 degrees with respect to the horizontal cross-section. The dataset also includes measurements of normal stiffness at different temperatures and images of the experimental apparatus. The included README file details each experiential setup and outlines which data files represent which experimental conditions.

15 GEOTHERMAL ENERGY↗
DOE OSTI2026

Analysis of attenuation data from the decommissioned ZIon unit 1 reactor pressure vessel beltline weld

In order to examine the attenuation of radiation damage through the thickness of an irradiated reactor pressure vessel (RPV), four segments were acquired from the Zion Unit 1 power plant RPV after the plant was decommissioned. The Zion Unit 1 RPV Beltline Weld Segment 1 was cut into seven blocks, consisting of five base metal and two beltline welds from the high fluence region of the segment. Through-wall test specimens were machined and tested. Specimens included those used for Charpy impact, Master Curve fracture toughness testing, and chemical analysis. The observed through-thickness ductile-to-brittle transition temperatures in the beltline weld deviated significantly from the expected behavior based on the attenuation of fast fluence as a function of depth into the RPV. Beginning at the inside surface, the 41-J Charpy transition temperature was either flat or slightly increasing until the ¾ -T location. The results of a simple, model-based analysis of the Zion beltline weld material that included the irradiation conditions and material chemistry were generally consistent with industry trend curves and the standard attenuation model, rather than the observed data. Although there was no archive material from the RPV available to permit measurement of the unirradiated properties, fracture toughness specimens fabricated from archive surveillance weld were used to obtain an estimate of the initial through-thickness values of the Charpy transition temperature. The Charpy shifts obtained using this approach were similarly in disagreement with the predictions of the US NRC Regulatory Guide 1.99, Rev. 2. However, testing of irradiated Charpy specimens taken from the RPV following post-irradiation annealing (10 hr. at 500 °C) provided a quite different estimate of the unirradiated properties which improved the agreement between the inferred through-thickness Charpy shifts and exponential attenuation model included in Regulatory Guide 1.99/2. In conclusion, the analysis of the Zion data and data obtained in previous post-mortem examinations of decommissioned RPVs indicates that more work is needed to understand the through-thickness properties of RPV materials in order to properly assess through-wall damage attenuation.

Charpy impact↗
DOE OSTI2024

Constitutive model development of aluminum alloy 1100 for elevated temperature forming process

Commercially pure aluminum alloy, AA1100, presents good electrical and thermal conductivity, high formability, and low cost. Those favorable characteristics have the potential to enable bipolar plates with improved economics and enhanced performance compared to current stainless steel bipolar plates for proton exchange membrane fuel cells. An accurate constitutive model is essential to develop and optimize processing parameters and effectively control the forming process. Here, the objective of this work is to develop a constitutive model of AA1100 that is able to simulate stress-strain relation, formed geometry, and predict the onset of fracture strain to avoid forming failure. Initially, a set of tensile tests at temperature between 300 and 500°C and strain rate between 0.005 and 1.0/s were conducted to examine the deformation behavior. Then, a set of damage-based unified visco-plastic constitutive equations is proposed and calibrated based on the results of stress-strain data. A genetic algorithm optimization method is applied to search for best fitting material constants in constitutive equations. The proposed model shows good predictability of both the stress-strain relation and fracture strain at low strain rate and high temperature conditions. The accuracy of proposed model is also evaluated statistically. A comparison of the proposed model with three popular models (Arrhenius-type mode, Johnson-Cook model and Zerilli-Armstrong model) was made. The proposed model shows the best experimental agreement with correlation coefficient of 0.96 in contrast to 0.25, 0.38 and 0.75 for the popular models, respectively. The proposed model can help to optimize the elevated temperature forming process and guide die design to enable optimal geometric features in the formed components.

08 HYDROGEN↗
DOE OSTI2020

Crack Growth Rate and Fracture Toughness Tests on Irradiated Ex-Plant Materials

The performance of structural materials is critical for the safe and economic operation of light water reactors. Exposed to neutron irradiation during service, the reactor core internal materials can undergo significant microstructural and microchemical changes, leading to irradiation hardening and embrittlement. To ensure the structural integrity and functionality of nuclear reactor components during long-term operation, material degradation and damage mechanisms must be understood and managed adequately. In this work, irradiated materials harvested from the decommissioned Zorita reactor were studied for their cracking susceptibility and fracture resistance as a function of irradiation dose up to 47 displacement per atom (dpa). The material is a Type 304 stainless steel sectioned from the baffle plates of this pressurized water reactor with 38 years of service. Crack growth rate and fracture toughness J-resistance (J-R) curve tests were performed in low-corrosion-potential environments at ~315°C. All samples behaved similarly under cyclic loading, and no deteriorated corrosion-fatigue behavior was observed in the test environments. Under constant stress intensity factors, most samples did not show elevated crack growth rates, suggesting an adequate stress corrosion cracking resistance in the test environments. However, an unstable cracking behavior was observed in a 47-dpa sample, resulting in significantly higher crack growth rates than expected at high stress intensity factors. Crack instability was also observed in a 0.06-dpa sample but did not lead to a sustained high crack growth rate. The impact of neutron irradiation was more evident in the fracture toughness J-R curve tests. As the dose increased, the J-R curve declined considerably and became very shallow at high doses. A fully intergranular fracture morphology was also observed among the high-dose samples ruptured in an air atmosphere at room temperature. This brittle fracture mode in the absence of high temperature water environment confirmed a high degree of embrittlement of this material resulting from its service exposure to neutron irradiation.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Sensitivity analysis of generic deep geologic repository with focus on spatial heterogeneity induced by stochastic fracture network generation

Geologic Disposal Safety Assessment Framework is a state-of-the-art simulation software toolkit for probabilistic post-closure performance assessment of systems for deep geologic disposal of nuclear waste developed by the United States Department of Energy. This paper presents a generic reference case and shows how it is being used to develop and demonstrate performance assessment methods within the Geologic Disposal Safety Assessment Framework that mitigate some of the challenges posed by high uncertainty and limited computational resources. Variance-based global sensitivity analysis is applied to assess the effects of spatial heterogeneity using graph-based summary measures for scalar and time-varying quantities of interest. Behavior of the system with respect to spatial heterogeneity is further investigated using ratios of water fluxes. This analysis shows that spatial heterogeneity is a dominant uncertainty in predictions of repository performance which can be identified in global sensitivity analysis using proxy variables derived from graph descriptions of discrete fracture networks. New quantities of interest defined using water fluxes proved useful for better understanding overall system behavior.

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

The effects of free surfaces on deformation twinning in HCP metals

Deformation twinning is a predominant mode of plastic deformation for hexagonal close packed metals, like Mg and Ti. The heterogenous microstructure and the local stresses associated with twinning play a key role in their mechanical response and fracture. Surface analyses, like electron microscopy, are frequently employed to spatially map microstructure and micromechanical fields in order to study twinning behavior. However, these measurements are inherently influenced by the vicinity of the free surface. In this work, an elasto-visco-plastic fast-Fourier-transform (EVP-FFT) polycrystal modeling approach is employed to investigate the effects of free surfaces on twin development before and after loading. We compare calculated micromechanical fields on free surfaces with those calculated inside the bulk and, in some cases, experimental surface measurements. The results indicate that the creation of free surfaces can promote twin propagation and growth and can influence twin morphology by causing a twin lamella to become larger, more blunted and irregular. The structure along the twin boundaries are also affected, due to the higher driving stresses that extend prismatic-basal and basal-prismatic facets. Furthermore, free surfaces invoke different slip activities in the twin and the surrounding parent crystal by enhancing basal, prismatic and pyramidal slip in some localized regions, while reducing slip in others. We demonstrate that the simulated free-surface effects lead to better qualitative and quantitative agreement with experimental measurements from scanning electron microscopy and digital image correlation.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Mo-100 Disk Structural Integrity Tests II

This report is a continuation of the work performed in the report, Mo-100 Disk Structural Integrity Tests I [1]. The NorthStar pressed and sintered 29 mm diameter, 0.5 mm thick Mo-100 disks will be subjected to large temperature gradients when in-beam during production. These large temperature gradients cause high stress and deformation within the disks that could prove detrimental to the target assembly’s cooling performance. Disk fracture is also a possibility that must be understood. Therefore, disk structural integrity tests were performed to understand the thermal induced behavior of these disks. In order to replicate the in-beam conditions, the Mo-100 disks were subjected to large temperature gradients using a 30kW induction heater and coil. A series of transient tests were conducted in a similar fashion as the previous work, as well as an attempt to create steady state conditions for more accurate temperature gradients. The transient thermal test setup and results are described in this report.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Potential Formation Damage: An Integrated Reservoir Characterization Study of the Naturally Fractured Carbonate Middle Duperow Formation at the Kevin Dome, Montana

In this study, we integrate geologic and engineering data of a naturally fractured carbonate reservoir at the Kevin Dome, Montana. Well test data are correlated with core description, geochemical and lithology study to determine the flow behavior and communication within the injection test interval and to the surrounding area. Based on a dual-continuum geologic model, numerical brine injection simulations are carried out to validate the interpretation results from our well test analytical models and forecast the probability of CO 2 injection success using current reservoir properties. As a result, our well test analytical models as well as lithology/core description suggest that fluid flow may be mainly restricted to the injection interval and the assumption of radial (horizontal) flow may be appropriate. The well test models also indicate that there is potentially formation damage with a positive skin factor although prior to brine injection well tests, well stimulation through acid treatment was performed. Our numerical simulation results appear to confirm this formation damage by showing additional pressure buildup in the injection data during later test periods. To explain this, acid may have dissolved dolomite then dolomite or calcite may have been formed again further into the matrix/fracture system. Another possible explanation is mechanical clogging of the fractures due to acid dissolving dolomite and dislodging fine grains. Our work also predicts that if no additional well stimulation is performed, the project will have a lower probability of successfully injecting 1 million tons of CO 2 into the Middle Duperow formation over 4 years.

42 ENGINEERING↗
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↗
DOE OSTI2020

Thermo-hydrologic processes in maar eruptions: The role of vapor transport and condensation

Phreatomagmatic eruptions occur when magma interacts directly with water or slurries, commonly from groundwater in the shallow crust, resulting in rapid conversion of thermal energy to mechanical energy in a set of processes known as molten fuel-coolant interaction (MFCI). The efficiency of MFCI is controlled by properties of the magma and coolant, contact surface geometry, and system conditions, such as pressure and temperature; phreatomagmatic behavior can range from passive thermal granulation to violent thermohydraulic explosions (Zimanowski et al., 2015). Maar-diatreme eruptions, characterized by repetitive phreatomagmatic explosions, can form in a wide range of near-surface environments, from soft sediment substrate (e.g., Tecuitlapa, Mexico, Ort and Carrasco-Núñez, 2009; Hopi Buttes, AZ, Lefebvre et al., 2013) to hard, fractured country rock (e.g., West Eifel volcanic field, Germany and Massif Central, France, Lorenz, 2003). Country-rock structure, including faults and joints, rock type, and shallow crustal hydrologic properties, can influence an eruption’s behavior by controlling how much and at what rate water can be supplied to the magma (hydraulic flow rate), and determining the sediment: water ratio in the case of soft-sediment substrate eruptions. In a “soft” substrate environment, volcanic tremor can lead to liquefaction of saturated sediment, producing a slurry that may then interact with magma in unique ways (White, 1996; Auer, et al., 2006).

58 GEOSCIENCES↗
DOE OSTI2024

Unraveling the Highly Plastic Behavior of ALD-Aluminum Oxide Encapsulations by Small-Scale Tensile Testing

We present a study directly measuring the electron-beam-induced plasticity of amorphous Al 2 O 3 coatings. Core–shell nanostructures are employed as small-scale model systems for two-dimensional coatings made by atomic layer deposition (ALD). Copper nanowires (NWs) are used as substrates for ALD deposition, representing a model system for interconnects commonly found in integrated circuits. Experiments are performed in situ in a transmission electron microscope (TEM) and further analyzed with electron energy loss spectroscopy (EELS). Our in situ TEM tensile experiments reveal the highly plastic behavior of the ALD shell, which withstands a maximum strain of 188%. Comparable samples under beam-off conditions show a brittle fracture, which underlines the effect of electron irradiation. The electron-beam-activated bond switching within the amorphous network enables compensation of the applied tensile strain, leading to viscous flow. By incorporating an intermediate nanocrystalline layer within the Al 2 O 3 shell, the plasticity is suppressed and brittle fracture occurs. This work directly demonstrates the tuning of mechanical properties in amorphous ALD structures through electron irradiation.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Graphene nanoplatelets reinforced cement as a solution to leaky wellbores reinforcing weak points in hydrated Portland cement with graphene nanoparticles improves mechanical and chemical durability of wellbore cements

In this work, to improve the performance of wellbore cement under subsurface environments, graphene nanoplatelets (GNPs) were added in various percentages to Class-H cement slurry. Microstructural characterization of cement slurries cured at 90 °C and 95% RH indicates that GNP modifies the microstructure of hydrated cement by reinforcing pore spaces. As a result, the mechanical properties, such as Young's modulus and axial peak stress, obtained from high temperature triaxial compression tests are significantly improved based on different percentages of added GNPs. Furthermore, the hydrated 1 × 2 inch GNP- Portland cement cores tested under simulated deep wellbore conditions of high-temperature and high pressure (HTHP), appear to have a ductile-like behavior, when compared to a typical brittle nature of Portland cement pastes. From our observations and published data on graphene resistance to fracture, GNP addition to cement is evidently enhancing the flexibility of cement. These improvements would reduce the risks associated with wellbore cement deterioration and a consequent leakage in fossil fuel production, geothermal energy production, CO 2 storage as well as long-term sealing materials in plugging and abandonment of all wellbores at the end of their service life.

36 MATERIALS SCIENCE↗