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At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

ROP model for PDC bits in Geothermal drilling

Geothermal energy is a renewable source of energy, where heat extraction is preferentially balanced with the reservoir's natural heat recharge rate. The objective of this paper is to present and validate a novel rate of penetration (ROP) model for drilling hard and abrasive formations including granite formations for polycrystalline diamond compact (PDC) bits. The ROP model was developed based on a derived relationship of a threshold weight on cutter (WOC) and its corresponding depth of cut (DOC) for a single cutter. Laboratory data was used to scale the derived single cutter relationship to a full-hole ROP model for PDC bits. The ROP model includes a non-linear correlation for Phase I (inefficient drilling due to low WOB values) and a linear Phase II (efficient drilling) ROP response to WOB. The ROP model was verified using measured drilling parameter data from Utah FORGE well# 58-32 and data from Chocolate Mountains well # 17-8 in Southern California. When compared to oil and gas well drilling, geothermal drilling in granitic formations can be more difficult and complicated due to rock hardness and high temperatures. PDC bits can increase ROP and optimize drilling for these types of hard formations. This paper provides novel insight into the ROP response of PDC bits to drilling operational parameters.

15 GEOTHERMAL ENERGY↗
NASA NTRS2004

Novel Horn Designs for Power Ultrasonics

Ultrasonic horns are used in a variety of industrial and medical applications. At JPL a rock-sampling tool based on an ultrasonic horn was developed to drill, abrade and core rock samples including hard basalts. This device is an impact device, which uses ultrasonic vibratlons that occur at the horn tip to produce a sonic resonance with the aid of a loosely connected mass. Although standard horns are found in many current industrial designs they suffer from a few key limitations when used for USDC applications. Manufacturing a horn requires turning down stock material (e.g. Titanium) from the larger outer diameter to the horn tip diameter, and this process is both time consuming and wasteful. In this paper, we present novel horn designs that are specifically designed for impact applications as the USDC. One such design addressed the excasive length that is involved with the use of the horn limiting its applications when system dimensions are constrained. For this purpose, a folded horn design was conceived that reduces the overall length of the resonator (physical length) but maintains or increases the acoustic length. Initial experiments with horns having such P design indicate that the tip displacement can be further adjusted by phasing the bending displacements and the extensional displacements. Another conceived horn design is the 'dog bone' horn that uses an end mass on the horn tip io increase the impact efficiency of the horn. In this paper, the experimental results for these novel born designs are presented and compared to the results predicted by theory.

acutators↗
NASA NTRS2020

Percussion Mechanism for the Mars2020 Coring Drill

The Mars2020 rover includes a Sampling & Caching Subsystem (SCS) that is required to acquire core samples of hard rocks and to abrade rocky surfaces flat and smooth in order to facilitate surface science. Hard, high strength rocks exhibit brittle failure modes, and can be drilled and chiseled efficiently using percussive impacts. The coring drill percussion mechanism was designed to provide those impacts with variable output force and to be used with various drill bits. A unique hammering mechanism, using a base-driven hammer, powered by a conventional rotary actuator driving a Scotch yoke, was designed to robustly provide the required function in a Martian environment for a life exceeding 2 million impacts.

Chrystal, Kyle↗
NASA NTRS1975

Experimental system for drilling simulated lunar rock in ultrahigh vacuum

An experimental apparatus designed for studying drillability of hard volcanic rock in a simulated lunar vacuum of 5 x 10 to the minus 10th power torr is described. The engineering techniques used to provide suitable drilling torque inside the ultrahigh vacuum chamber while excluding all hydrocarbon are detailed. Totally unlubricated bearings and gears were used to better approximate the true lunar surface conditions within the ultrahigh vacuum system. The drilling system has a starting torque of 30 in-lb with an unloaded running torque of 4 in-lb. Nominal torque increase during drilling is 4.5 in-lb or a total drilling torque of 8.5 in-lb with a 100-lb load on the drill bit at 210 rpm. The research shows conclusively that it is possible to design operational equipment for moderate loads operating under UHV conditions without the use of sealed bearings or any need of lubricants whatsoever.

Roepke, W. W.↗
NASA NTRS2016

Icebreaker-3 Drill Integration and Testing at Two Mars-Analog Sites

A decade of evolutionary development of integrated automated drilling and sample handling at analog sites and in test chambers has made it possible to go 1 meter through hard rocks and ice layers on Mars. The latest Icebreaker-3 drill has been field tested in 2014 at the Haughton Crater Marsanalog site in the Arctic and in 2015 with a Mars lander mockup in Rio Tinto, Spain, (with sample transfer arm and with a prototype life-detection instrument). Tests in Rio Tinto in 2015 successfully demonstrated that the drill sample (cuttings) was handed-off from the drill to the sample transfer arm and thence to the on-deck instrument inlet where it was taken in and analyzed ("dirt-to-data").

astrobiology↗
NASA NTRS2005

Powder-Collection System for Ultrasonic/Sonic Drill/Corer

A system for collecting samples of powdered rock has been devised for use in conjunction with an ultrasonic/sonic drill/corer (USDC) -- a lightweight, lowpower apparatus designed to cut into, and acquire samples of, rock or other hard material for scientific analysis. The USDC includes a drill bit, corer, or other tool bit, in which ultrasonic and sonic vibrations are excited by an electronically driven piezoelectric actuator. The USDC advances into the rock or other material of interest by means of a hammering action and a resulting chiseling action at the tip of the tool bit. The hammering and chiseling actions are so effective that unlike in conventional twist drilling, a negligible amount of axial force is needed to make the USDC advance into the material. Also unlike a conventional twist drill, the USDC operates without need for torsional restraint, lubricant, or a sharp bit. The USDC generates powder as a byproduct of the drilling or coring process. The purpose served by the present samplecollection system is to remove the powder from the tool-bit/rock interface and deliver the powder to one or more designated location(s) for analysis or storage

Sherrit, Stewart↗
DOE OSTI2024

RePED 250: Manufacturing and Market Analysis of High-Temperature Alternators

The novel repetitive pulsed electric drill 250 (RePED 250) has the potential to greatly lower the costs and drilling times of geothermal projects. This tool discharges electric pulses through hard rock formations, shattering the rock in tension and allowing it to be quickly removed. One hurdle in bringing this technology to market is the RePED 250 downhole alternator. This component is essential for supplying power to the electronic drilling tool. There are currently no downhole tools on the market that meet the RePED 250 alternator's high temperature and power requirements. This report focuses on the path to commercialization for this novel alternator technology being developed as part of the RePED 250 project. One aim of this work is to identify the geothermal market size for the RePED 250 alternator, as well as other potential markets for this technology outside of geothermal. The geothermal market is very small, with only approximately 13 wells drilled in the United States each year. The worldwide market is several times this size and growing each year. The ability of the RePED 250 technology to drastically reduce the cost of geothermal projects may also lead to an increase in this market size. Technology developed for the high-temperature, high-power RePED 250 alternator can also be used to create high-temperature and high-power motors. These motors and alternators will have potential applications in oil and gas drilling, a $300 billion dollar industry in the United States alone, as well as in more distant industries such as aircraft, weapon systems, space exploration, and electric vehicles. Other aspects of the RePED 250 alternator's path to commercialization are also analyzed, including the supply chain for production materials and potential manufacturing methods. The supply chain and manufacturing practices for low-temperature motors and alternators are well established and require relatively minor changes for the high-temperature and high-power RePED 250 alternator. Sourcing for high-temperature materials has been identified, as well as potential supply chain risks. These most notably include electrical steel and high-temperature samarium cobalt (SmCo) magnets. Overall, these risks are not expected to be significant at the likely manufacturing scale required for the RePED 250.

15 GEOTHERMAL ENERGY↗
DOE OSTI2022

Auto Indexer for Percussive Hammers Final Report

Geothermal energy has been underutilized in the U.S., primarily due to the high cost of drilling in the harsh environments encountered during the development of geothermal resources. Drilling depths can approach 5,000 m with temperatures reaching 170 C. In situ geothermal fluids are up to ten times more saline than seawater and highly corrosive, and hard rock formations often exceed 240 MPa compressive strength. This combination of extreme conditions pushes the limits of most conventional drilling equipment. Furthermore, enhanced geothermal systems are expected to reach depths of 10,000 m and temperatures more than 300 °C. To address these drilling challenges, Sandia developed a proof-of-concept tool called the auto indexer under an annual operating plan task funded by the Geothermal Technologies Program (GTP) of the U.S. Department of Energy Geothermal Technologies Office. The auto indexer is a relatively simple, elastomer-free motor that was shown previously to be compatible with pneumatic hammers in bench-top testing. Pneumatic hammers can improve penetration rates and potentially reduce drilling costs when deployed in appropriate conditions. The current effort, also funded by DOE GTP, increased the technology readiness level of the auto indexer, producing a scaled prototype for drilling larger diameter boreholes using pneumatic hammers. The results presented herein include design details, modeling and simulation results, and testing results, as well as background on percussive hammers and downhole rotation.

15 GEOTHERMAL ENERGY↗
DOE OSTI2022

Experimental Investigation of Drillstring Torsional Vibration Effect on Rate of Penetration with PDC Bits in Hard Rock

Polycrystalline diamond compact (PDC) bits have shown tremendous performance compared to roller cone bits and have gained attraction in deep geothermal drilling applications. While PDC bits can reach a higher rate of penetration compared to other bits, they are more prone to drilling vibrations. The scope of this paper is to quantify the effects of drillstring torsional vibrations on PDC bit performance using a laboratory testing facility. Here, the tests were performed with three drillstring configurations to evaluate the effect of drillstring vibrations. The results showed that rigid testing overestimates the bit rate of penetration by 35% due to torsional vibrations.

15 GEOTHERMAL ENERGY↗
NASA NTRS2009

Rotary Percussive Auto-Gopher for Deep Drilling and Sampling

The term "rotary percussive auto-gopher" denotes a proposed addition to a family of apparatuses, based on ultrasonic/ sonic drill corers (USDCs), that have been described in numerous previous NASA Tech Briefs articles. These apparatuses have been designed, variously, for boring into, and/or acquiring samples of, rock or other hard, brittle materials of geological interest. In the case of the rotary percussive autogopher, the emphasis would be on developing an apparatus capable of penetrating to, and acquiring samples at, depths that could otherwise be reached only by use of much longer, heavier, conventional drilling-and-sampling apparatuses. To recapitulate from the prior articles about USDCs: A USDC can be characterized as a lightweight, low-power jackhammer in which a piezoelectrically driven actuator generates ultrasonic vibrations and is coupled to a tool bit through a free mass. The bouncing of the free mass between the actuator horn and the drill bit converts the actuator ultrasonic vibrations into sonic hammering of the drill bit. The combination of ultrasonic and sonic vibrations gives rise to a hammering action (and a resulting chiseling action at the tip of the tool bit) that is more effective for drilling than is the microhammering action of ultrasonic vibrations alone. The hammering and chiseling actions are so effective that the size of the axial force needed to make the tool bit advance into soil, rock, or another material of interest is much smaller than in ordinary rotary drilling, ordinary hammering, or ordinary steady pushing. The predecessor of the rotary percussive auto-gopher is an apparatus, now denoted an ultrasonic/sonic gopher and previously denoted an ultrasonic gopher, described in "Ultrasonic/ Sonic Mechanism for Drilling and Coring" (NPO-30291), NASA Tech Briefs Vol. 27, No. 9 (September 2003), page 65. The ultrasonic/sonic gopher is intended for use mainly in acquiring cores. The name of the apparatus reflects the fact that, like a gopher, it periodically stops advancing at the end of the hole to bring excavated material (in this case, a core sample) to the surface, then re-enters the hole to resume the advance of the end of the hole. By use of a cable suspended from a reel on the surface, the gopher is lifted from the hole to remove a core sample, then lowered into the hole to resume the advance and acquire the next core sample.

Bar-Cohen, Yoseph↗
NASA NTRS2008

Estimating Hardness from the USDC Tool-Bit Temperature Rise

A method of real-time quantification of the hardness of a rock or similar material involves measurement of the temperature, as a function of time, of the tool bit of an ultrasonic/sonic drill corer (USDC) that is being used to drill into the material. The method is based on the idea that, other things being about equal, the rate of rise of temperature and the maximum temperature reached during drilling increase with the hardness of the drilled material. In this method, the temperature is measured by means of a thermocouple embedded in the USDC tool bit near the drilling tip. The hardness of the drilled material can then be determined through correlation of the temperature-rise-versus-time data with time-dependent temperature rises determined in finite-element simulations of, and/or experiments on, drilling at various known rates of advance or known power levels through materials of known hardness. The figure presents an example of empirical temperature-versus-time data for a particular 3.6-mm USDC bit, driven at an average power somewhat below 40 W, drilling through materials of various hardness levels. The temperature readings from within a USDC tool bit can also be used for purposes other than estimating the hardness of the drilled material. For example, they can be especially useful as feedback to control the driving power to prevent thermal damage to the drilled material, the drill bit, or both. In the case of drilling through ice, the temperature readings could be used as a guide to maintaining sufficient drive power to prevent jamming of the drill by preventing refreezing of melted ice in contact with the drill.

Bar-Cohen, Yoseph↗
NASA NTRS2010

Miniature Low-Mass Drill Actuated by Flextensional Piezo Stack

Recent experiments with a flextensional piezoelectric actuator have led to the development of a sampler with a bit that is designed to produce and capture a full set of sample forms including volatiles, powdered cuttings, and core fragments. The flextensional piezoelectric actuator is a part of a series of devices used to amplify the generated strain from piezoelectric actuators. Other examples include stacks, bimorphs, benders, and cantilevers. These devices combine geometric and resonance amplifications to produce large stroke at high power density. The operation of this sampler/drill was demonstrated using a 3x2x1-cm actuator weighing 12 g using power of about 10-W and a preload of about 10 N. A limestone block was drilled to a depth of about 1 cm in five minutes to produce powdered cuttings. It is generally hard to collect volatiles from random surface profiles found in rocks and sediment, powdered cuttings, and core fragments. Toward the end of collecting volatiles, the actuator and the bit are covered with bellows-shaped shrouds to prevent fines and other debris from reaching the analyzer. A tube with a miniature bellows (to provide flexibility) is connected to the bit and directs the flow of the volatiles to the analyzer. Another modality was conceived where the hose is connected to the bellows wall directly to allow the capture of volatiles generated both inside and outside the bit. A wide variety of commercial bellows used in the vacuum and microwave industries can be used to design the volatiles capture mechanism. The piezoelectric drilling mechanism can potentially be operated in a broad temperature range from about-200 to less than 450 C. The actuators used here are similar to the actuators that are currently baselined to fly as part of the inlet funnel shaking mechanism design of MSL (Mars Science Laboratory). The space qualification of these parts gives this drill a higher potential for inclusion in a future mission, especially when considering its characteristics of low mass, small size, low power, and low axial loads for sampling.

Sherrit, Stewart↗
DOE OSTI2023

Utah FORGE: Reports on Northwestern Nevada Well Doublet Drilling and Testing by Fervo Energy

These reports review Fervo Energy's construction of a commercial enhanced geothermal system (EGS). Fervo has qualified full functionality of the system through production testing at commercially relevant operating conditions. The project site is located in a nearfield setting adjacent to an operating geothermal power station in north-central Nevada and is designed to deliver an uplift in high-temperature geothermal flow rates to increase the power capacity at the facility. The project involved drilling a first-of-a-kind EGS horizontal doublet well system consisting of an injection and production well pair within a high-temperature hard-rock geothermal formation. The lithology of the target reservoir is characterized as a mixed metasedimentary and igneous formation, comprised of phyllite, quartzite, diorite, and granodiorite, representative of the geology across the most prospective geothermal areas throughout the western US. This work included a 16-stage plug-and-perforate stimulation treatment which was the first of its kind in a high-temperature mixed metasedimentary and granitic formation in a fully horizontal doublet geothermal well.

15 GEOTHERMAL ENERGY↗
NASA NTRS2011

Scoring Dawg Core Breakoff and Retention Mechanism

This novel core break-off and retention mechanism consists of a scoring dawg controlled by a set of two tubes (a drill tube and an inner tube). The drill tube and the inner tube have longitudinal concentric holes. The solution can be implemented in an eccentric tube configuration as well where the tubes have eccentric longitudinal holes. The inner tube presents at the bottom two control surfaces for controlling the orientation of the scoring dawg. The drill tube presents a sunk-in profile on the inside of the wall for housing the scoring dawg. The inner tube rotation relative to the drill tube actively controls the orientation of the scoring dawg and hence its penetration and retrieval from the core. The scoring dawg presents a shaft, two axially spaced arms, and a tooth. The two arms slide on the control surfaces of the inner tube. The tooth, when rotated, can penetrate or be extracted from the core. During drilling, the two tubes move together maintaining the scoring dawg completely outside the core. After the desired drilling depth has been reached the inner tube is rotated relative to the drill tube such that the tooth of the scoring dawg moves toward the central axis. By rotating the drill tube, the scoring dawg can score the core and so reduce its cross sectional area. The scoring dawg can also act as a stress concentrator for breaking the core in torsion or tension. After breaking the core, the scoring dawg can act as a core retention mechanism. For scoring, it requires the core to be attached to the rock. If the core is broken, the dawg can be used as a retention mechanism. The scoring dawg requires a hard-tip insert like tungsten carbide for scoring hard rocks. The relative rotation of the two tubes can be controlled manually or by an additional actuator. In the implemented design solution the bit rotation for scoring was in the same direction as the drilling. The device was tested for limestone cores and basalt cores. The torque required for breaking the 10-mm diameter limestone cores was 5 to 5.8 lb-in. (0.56 to 0.66 N-m).

Badescu, Mircea↗
NASA NTRS2010

Ultrasonic/Sonic Rotary-Hammer Drills

Ultrasonic/sonic rotary-hammer drill (USRoHD) is a recent addition to the collection of apparatuses based on ultrasonic/sonic drill corer (USDC). As described below, the USRoHD has several features, not present in a basic USDC, that increase efficiency and provide some redundancy against partial failure. USDCs and related apparatuses were conceived for boring into, and/or acquiring samples of, rock or other hard, brittle materials of geological interest. They have been described in numerous previous NASA Tech Briefs articles. To recapitulate: A USDC can be characterized as a lightweight, lowpower, piezoelectrically driven jackhammer in which ultrasonic and sonic vibrations are generated and coupled to a tool bit. A basic USDC includes a piezoelectric stack, an ultrasonic transducer horn connected to the stack, a free mass ( free in the sense that it can bounce axially a short distance between hard stops on the horn and the bit), and a tool bit. The piezoelectric stack creates ultrasonic vibrations that are mechanically amplified by the horn. The bouncing of the free mass between the hard stops generates the sonic vibrations. The combination of ultrasonic and sonic vibrations gives rise to a hammering action (and a resulting chiseling action at the tip of the tool bit) that is more effective for drilling than is the microhammering action of ultrasonic vibrations alone. The hammering and chiseling actions are so effective that unlike in conventional twist drilling, little applied axial force is needed to make the apparatus advance into the material of interest. There are numerous potential applications for USDCs and related apparatuses in geological exploration on Earth and on remote planets. In early USDC experiments, it was observed that accumulation of cuttings in a drilled hole causes the rate of penetration of the USDC to decrease steeply with depth, and that the rate of penetration can be increased by removing the cuttings. The USRoHD concept provides for removal of cuttings in the same manner as that of a twist drill: An USRoHD includes a USDC and a motor with gearhead (see figure). The USDC provides the bit hammering and the motor provides the bit rotation. Like a twist drill bit, the shank of the tool bit of the USRoHD is fluted. As in the operation of a twist drill, the rotation of the fluted drill bit removes cuttings from the drilled hole. The USRoHD tool bit is tipped with a replaceable crown having cutting teeth on its front surface. The teeth are shaped to promote fracturing of the rock face through a combination of hammering and rotation of the tool bit. Helical channels on the outer cylindrical surface of the crown serve as a continuation of the fluted surface of the shank, helping to remove cuttings. In the event of a failure of the USDC, the USRoHD can continue to operate with reduced efficiency as a twist drill. Similarly, in the event of a failure of the gearmotor, the USRoHD can continue to operate with reduced efficiency as a USDC.

Badescu, Mircea↗
NASA NTRS2012

Evaluating Core Quality for a Mars Sample Return Mission

Sample return missions, including the proposed Mars Sample Return (MSR) mission, propose to collect core samples from scientifically valuable sites on Mars. These core samples would undergo extreme forces during the drilling process, and during the reentry process if the EEV (Earth Entry Vehicle) performed a hard landing on Earth. Because of the foreseen damage to the stratigraphy of the cores, it is important to evaluate each core for rock quality. However, because no core sample return mission has yet been conducted to another planetary body, it remains unclear as to how to assess the cores for rock quality. In this report, we describe the development of a metric designed to quantitatively assess the mechanical quality of any rock cores returned from Mars (or other planetary bodies). We report on the process by which we tested the metric on core samples of Mars analogue materials, and the effectiveness of the core assessment metric (CAM) in assessing rock core quality before and after the cores were subjected to shocking (g forces representative of an EEV landing).

Mars samples↗
DOE OSTI2026

A ModEx Framework for Watershed Subsurface Investigation With Limited Geophysical Data Using Machine Learning and Hydrologic Modeling

Abstract Subsurface heterogeneity influences watershed hydrology strongly but remains difficult to characterize at catchment scales with sparse and costly field data. Geophysical surveys such as electromagnetic induction (EMI) provide local spatial subsurface images yet scaling them to watershed scales and converting EMI‐derived resistivity into hydraulic properties remains a challenge. We present a Model–Experiment (ModEx) framework that integrates limited EMI data with machine learning (ML) and hydrologic modeling to improve process representation and guide field investigations. Sparse EMI surveys were scaled to the catchment scale using a Random Forest model, and the resulting resistivity fields were combined with nearby borehole constraints to parameterize a hydrologic model. The EMI‐informed hydrological simulations improved predictions of streamflow sustained by subsurface flow and shallow saturation patterns. By combining EMI data and ML with hydrologic modeling, the ModEx framework guides future subsurface surveys, providing a transferable and efficient strategy for data–model integration across diverse watersheds. Plain Language Summary Mapping the underground network of soil and rock that controls water is essential for predicting floods and droughts, but seeing underground is difficult and expensive. We cannot drill everywhere, so scientists use geophysical tools to scan broad areas. There are two key challenges: these geophysical scans are often sparse across the whole watershed, and the geophysical data is hard to translate into water‐related properties. We used artificial intelligence to solve these problems. We taught a computer to find patterns linking the limited geophysical data to the land surface properties. This allowed it to fill in the gaps and create a complete, useful subsurface map for the entire watershed. This new map improves hydrologic simulations, leading to more accurate predictions of water movement in the watershed. It also helps scientists build better models with less data and generates a priority map showing where to measure next, making future investigations more efficient. Key Points Limited EMI scaled with ML improves catchment‐scale subsurface parameterization for hydrologic models The framework integrates hydrologic modeling with limited geophysical data to support subsurface investigation design ModEx framework offers a transferable data–model integration strategy that quantifies and reduces uncertainty guiding watershed studies

Chen, Hang↗
NASA NTRS2014

Single Piezo-Actuator Rotary-Hammering (SPaRH) Drill

A Single Piezo-Actuator Rotary-Hammering (SPaRH) Drill includes a horn actuator having high power piezoelectric materials and a flexure pre-stress to increase the actuators effectiveness. The drill is a low mass, low power, compact coring drill measuring 20-cm high by 7-cm diameter and having a total weight of 2 kg including drive electronics. Using an average power of 50-Watts, the drill basalt is expected to cut basalt at a rate of 0.2 cm/min down to depth of 10-cm and create cuttings and an intact core. The drill is expected to operate under different environments including Martian ambient (6 Torr and down to -50 degree C), and liquid nitrogen temperatures (77 K) and low pressure (<<1 Torr) to simulate lunar polar and Europa conditions. Materials expected to be sampled include Kaolinite, Saddleback Basalt, Limestone, Volcanic Breccia, Siltstone, ice, permafrost and layered rocks with different hardness.

Sherrit, Stewart↗