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Repeatable method of thermal stress fracture test of brittle materials
Method heats specimens slowly and with sufficient control so that the critical temperature gradient in the specimens cannot occur before temperature equilibrium is reached.
Experimentally validated multiphysics modeling of fracture induced by thermal shocks in sintered UO 2 pellets
Uranium Dioxide (UO 2 ) fuel powers almost all commercial Nuclear Power Plants (NPPs) worldwide, generating carbon-free energy and contributing to the fight against climate change. UO 2 fuel incurs damage and fractures due to large thermal gradients that develop across the fuel pellet during normal and transient operating conditions. A comprehensive understanding of the underlying mechanisms by which these processes take place is still lacking. A combined experimental and computational approach is utilized here to quantify the behavior of UO 2 fuel fracture induced by thermal shock. Here, this work introduces both (1) an experimental study to understand the fuel fracturing behavior of sintered UO 2 pellets when exposed to thermal shock, and (2) a Multiphysics phase-field fracture model capable of simulating this process. Parametric studies were conducted to evaluate the effects of uncertainties in fracture properties on the fracture behavior of UO 2 due to thermal shocking. A set of energy release rate (or equivalently fracture toughness) and contract area (the part of the fuel pellet in direct contact with the cold bath) were able to capture the overall fracture trends of the corresponding experimental data. Our combined approach presents a new method for accounting for the effects of microstructure and sample size on the energy release rate/fracture toughness. The experimental data were collected from multiple experiments that exposed UO 2 pellets to high-temperature conditions (589–676 °C) followed by a quench in sub-zero water. This work demonstrates that joint experimental and computational efforts are able to advance the understanding of thermal fracture in the primary fuel source for existing and future NPPs.
Recent Developments at the Raft River Geothermal Field
The Raft River geothermal field, located in Cassia County in southwestern Idaho, is the site of a Department of Energy Enhanced Geothermal System project. U.S. Geothermal, Inc. currently produces about 11 MWe from Precambrian metamorphic rocks. These lie beneath ~5,000 ft of Quaternary and Tertiary volcaniclastic and volcanic deposits. Maximum temperatures range from 271°F to 300°F. Well RRG-9 ST1, the well targeted for stimulation is located approximately 1 mile south of the main bore field. The open hole section of the well, from 5,551 to 5,900 ft MD, consists of Precambrian Elba Quartzite, the stimulation target, granite and minor diabase. Prior to setting the casing acoustic, gamma ray, and density logs were run. After completing the well, a step rate/step down test was conducted. The maximum injection rate achieved was 18 bpm at a wellhead pressure of 1,150 psig. A borehole televiewer run in the open hole section showed evidence of more than eighty fractures. The majority of these fractures trend from N20⁰W to N20°E and dip from 40° to 60°W. Permeable fractures were encountered in the Elba Quartzite at 5,640-5,660 ft MD. Analysis of the injection test indicates that the minimum in-situ principal stress in this zone is 3,050-3,200 psi, corresponding to a fracture gradient of 0.59-0.62 psi/ft. A discrete fracture network model was developed using measured and inferred fracture orientations, distributions and dimensions. A three-phase stimulation program is proposed for RRG-9 ST-1. During the first two stages, water at 140°F, and later 40°F, will be injected to pre-condition and thermally fracture the reservoir. Here, the third stage will consist of a high rate, large volume conventional hydraulic stimulation.
Experimental Study of Underground Heat Storage via Hydraulic Fractures
In this study, we present a laboratory setup to test the energy flow in the form of underground heat storage using hydraulic fractures, a so-called Fracture Thermal Energy Storage (FTES) system. In the experiment, de-ionized water is circulated under high pressure through steel tubing automatically heated to a target temperature. The fluid adjusts to the tubing temperature during its flow before entering a production well drilled into a 250 mm edge length block of Zimbabwe Gabbro. The warm fluid then circulates through a previously created hydraulic fracture at mid-height of the block to a production well drilled at the block periphery. External fracture appearances are sealed using an epoxy resin and the production well by a cork of polydimethylsiloxane. In this cork, tubing to an open outlet is glued. We demonstrated through the results of a preliminary heating experiment that we can transfer nearly all of the heat from the circulating fluid to the block. An efficient charging of the thermal battery is achieved. This first-order demonstration is currently under further improvement and serves as a knowledge basis for the upscaling of mid- to large-scale field implementation of FTES systems.
Thermal-Mechanical Stability of Single Crystal Oxide Refractive Concentrators for High-Temperature Solar Thermal Propulsion
Single crystal oxides such as yttria-stabilized zirconia (Y2O3-ZrO2), yttrium aluminum garnet (Y3Al5O12, or YAG), magnesium oxide (MgO) and sapphire (Al2O3) are candidate refractive secondary concentrator materials for high temperature solar propulsion applications. However, thermo-mechanical reliability of these components in severe thermal environments during the space mission sun/shade transition is of great concern. Simulated mission tests are important for evaluating these candidate oxide materials under a variety of transient and steady-state heat flux conditions, and thus provide vital information for the component design. In this paper, a controlled heat flux thermal shock test approach is established for the single crystal oxide materials using a 3.0 kW continuous wave CO2 laser, with a wavelength 10.6 micron. Thermal fracture behavior and failure mechanisms of these oxide materials are investigated and critical temperature gradients are determined under various temperature and heating conditions. The test results show that single crystal sapphire is able to sustain the highest temperature gradient and heating-cooling rate, and thus exhibit the best thermal shock resistance, as compared to the yttria-stabilized zirconia, yttrium aluminum garnet, and magnesium oxide.
Thermal-Mechanical Stability of Single Crystal Oxide Refractive Concentrators for High-Temperature Solar Thermal Propulsion
Single crystal oxides such as yttria-stabilized zirconia (Y2O3-ZrO2), yttrium aluminum garnet (Y3Al5O12, or YAG), magnesium oxide (MgO) and sapphire (Al2O3) are candidate refractive secondary concentrator materials for high temperature solar propulsion applications. However, thermo-mechanical reliability of these components in severe thermal environments during the space mission sun/shade transition is of great concern. Simulated mission tests are important for evaluating these candidate oxide materials under a variety of transient and steady-state heat flux conditions, and thus provide vital information for the component design. In this paper, a controlled heat flux thermal shock test approach is established for the single crystal oxide materials using a 3.0 kW continuous wave CO2 laser, with a wavelength 10.6 micron. Thermal fracture behavior and failure mechanisms of these oxide materials are investigated and critical temperature gradients are determined under various temperature and heating conditions. The test results show that single crystal sapphire is able to sustain the highest temperature gradient and heating-cooling rate, and thus exhibit the best thermal shock resistance, as compared to the yttria-stabilized zirconia, yttrium aluminum garnet and magnesium oxide.
Computational Methods For Composite Structures
Selected methods of computation for simulation of mechanical behavior of fiber/matrix composite materials described in report. For each method, report describes significance of behavior to be simulated, procedure for simulation, and representative results. Following applications discussed: effects of progressive degradation of interply layers on responses of composite structures, dynamic responses of notched and unnotched specimens, interlaminar fracture toughness, progressive fracture, thermal distortions of sandwich composite structure, and metal-matrix composite structures for use at high temperatures. Methods demonstrate effectiveness of computational simulation as applied to complex composite structures in general and aerospace-propulsion structural components in particular.
Subsurface energy storage and transport for solar-powered geysers on Triton
The location of active geyser-like eruptions and related features close to the current subsolar latitude on Triton suggests a solar energy source for these phenomena. Solid-state greenhouse calculations have shown that sunlight can generate substantially elevated subsurface temperatures. A variety of models for the storage of solar energy in a subgreenhouse layer and for the supply of gas and energy to a geyser are examined. 'Leaky greenhouse' models with only vertical gas transport are inconsistent with the observed upper limit on geyser radius of about 1.5 km. However, lateral transport of energy by gas flow in a porous N2 layer with a block size on the order of a meter can supply the required amount of gas to a source region about 1 km in radius. The decline of gas output to steady state may occur over a period comparable with the inferred active geyser lifetime of 5 earth years. The required subsurface permeability may be maintained by thermal fracturing of the residual N2 polar cap. A lower limit on geyser source radius of about 50 to 100 m predicted by a theory of negatively buoyant jets is not readily attained.
Thermal Experiments for Fractured Rock Characterization: Theoretical Analysis and Inverse Modeling
Abstract Field‐scale properties of fractured rocks play a crucial role in many subsurface applications, yet methodologies for identification of the statistical parameters of a discrete fracture network (DFN) are scarce. We present an inversion technique to infer two such parameters, fracture density and fractal dimension, from cross‐borehole thermal experiments data. It is based on a particle‐based heat‐transfer model, whose evaluation is accelerated with a deep neural network (DNN) surrogate that is integrated into a grid search. The DNN is trained on a small number of the heat‐transfer model runs and predicts the cumulative density function of the thermal field. The latter is used to compute fine posterior distributions of the (to be estimated) parameters. Our synthetic experiments reveal that fracture density is well constrained by data, while fractal dimension is harder to determine. Adding nonuniform prior information related to the DFN connectivity improves the inference of this parameter.
Modeling brittle fracture due to anisotropic thermal expansion in polycrystalline materials
Here, this work investigated brittle fracture of polycrystalline materials due to thermal stresses arising from anisotropic thermal expansion. We used phase-field fracture simulations with the properties of alpha-uranium (α-U) and assumed a linear elastic mechanical response. Three-dimensional simulations were used to predict fracture for various conditions and crystallographic textures. We found that fracture was more pronounced during cooling than during heating because the anisotropy increased with temperature. We also found that the total crack surface area increased with increasing average misorientation, while the net shape change of the material decreased with increasing misorientation. Two-dimensional simulations in which one crystallographic coefficient of thermal expansion (CTE) was set to zero indicated that the expansion behavior in the crystallographic direction with the smallest CTE was the primary cause of fracture.
Fracture‐Resistant and Thermally Insulating Ultrahigh‐Temperature Carbide Foams
Dense ultrahigh‐temperature ceramics (UHTCs) carbides are recognized as potential materials for thermal protection systems (TPS) owing to properties beyond existing structural materials’ capabilities. Recent advances in UHTCs have enabled the development of multiscale porous microstructures. Herein, it is highlighted that the porosity in UHTCs are no longer treated as a defect but as a functional property specifically tailored for thermal insulation. It is a promising solution to design and fabricate bulk UHTC foams via a freeze‐drying (FD) approach followed by calibrated pressureless spark plasma sintering. Herein, monolithic TaC and HfC UHTC foams and their composite show the partial solid–solution formation of (Ta, Hf)C with porosity ≥50%. TaC–HfC foam (≈80–92 N) shows an intermediate load‐bearing capability compared to monolithic TaC (≈120–135 N) and HfC (≈28–35 N) foams, with no evident cracking on the sample surface. The thermal conductivity of partial solid‐solution TaC–HfC foam increases up to fivefold compared to parent UHTC foams. In the results, solid solutions’ efficacy and pores’ unidirectionality in providing thermal insulation to TaC–HfC while maintaining its high‐load bearing capability are illustrated. In conclusion, the developed technique establishes a new paradigm shift in UHTCs, expanding their potential for TPS in extreme environments.
Multiscale Modeling of Fracture Strength in Fibrous Thermal Protection System Materials
This work presents a multiscale modeling approach to predict the fracture strength of fibrous Thermal Protection System (TPS) materials. The model assumes that system failure is initiated at the joints between individual fibers. We investigated three distinct TPS compositions: amorphous silica, alumina and aluminosilicate fibers. Molecular dynamics (MD) simulations were employed to determine the fracture strength values of these fiber joints for both material systems. These fracture strength values were then integrated into simulations of 3D randomly populated fiber structures, where tensile load transfer occurs through the fiber joints. These microscale properties are upscaled through a renormalization approach [1] to predict macroscale tensile strength of 3D random fiber networks, accounting for joint-dominated failure and effective load-bearing area. The study concludes by demonstrating the resulting strength variation as a function of material composition, fiber density, and morphology. We also show validation of results by comparing them against explicit fiber finite element (FE) modeling [2] where fiber joint fracture is represented by cohesive elements.
Mixed Mode Fracture of Plasma Sprayed Thermal Barrier Coatings: Effects of Anisotropy and Heterogeneity
The combined mode I-mode II fracture behavior of anisotropic ZrO2-8wt%Y2O3 thermal barrier coatings was determined in asymmetric flexure loading at both ambient and elevated temperatures. A fracture envelope of KI versus KII was determined for the coating material at ambient and elevated temperatures. Propagation angles of fracture as a function of KI/KII were also determined. The mixed-mode fracture behavior of the microsplat coating material was modeled using Finite Element approach to account for anisotropy and micro cracked structures, and predicted in terms of fracture envelope and propagation angle using mixed-mode fracture theories.
A comprehensive study of the effects of long-term thermal aging on the fracture resistance of cast austenitic stainless steels
Not Available
DCIF (Directional Cooling-Induced Fracturing) Westerly Granite AE Borehole Damage Effect Test (Task 3-0)
Directional Cooling-Induced Fracturing (DCIF) experiments were conducted on three rectangular Westerly granite blocks (width=depth=4.0", height=2.0") which were preheated to 200, 400, and 600 degree C to induce damage (microcracks) with varying degrees. Liquid nitrogen was poured in a small, 1"-diameter copper cup attached to the top of the sample, and the resulting acoustic emissions (AEs) and temperature changes on the surface of the sample were monitored. The experiments were conducted under one selected biaxial stress (5.8MPa). The obtained AEs were used to determine the microcracking source locations and amplitude, and the associated moment tensors. The onset time of the AEs was correlated with the cooling temperature, which was used to show that the temperature at the onset of microcracking is not affected significantly by the preexisting damage, compared to the impact of the stress in the sample. Included in this submission are the animations of the AE locations and graphics displaying the measured temperature-AE activity changes for samples with different degrees of microcrack damage.
Transformation toughened ceramics for the heavy duty diesel engine technology program
The objective of this program is to develop an advanced high temperature oxide structural ceramic for application to the heavy duty diesel engine. The approach is to employ transformation toughening by additions of ZrO.5HfO.5O2 solid solution to the oxide ceramics, mullite (2Al2O3S2SiO2) and alumina (Al2O3). The study is planned for three phases, each 12 months in duration. This report covers Phase 1. During this period, processing techniques were developed to incorporate the ZrO.5HfO.5O2 solid solution in the matrices while retaining the necessary metastable tetragonal phase. Modulus of rupture and of elasticity, coefficient of thermal expansion, fracture toughness by indent technique and thermal diffusivity of representative specimens were measured. In Phase 2, the process will be improved to provide higher mechanical strength and to define the techniques for scale up to component size. In Phase 3, full scale component prototypes will be fabri-]cated.
Mode I, Mode II, and Mixed-Mode Fracture of Plasma-sprayed Thermal Barrier Coatings at Ambient and Elevated Temperatures
The mixed-mode fracture behavior of plasma-sprayed ZrO2-8 wt% Y2O3 thermal barrier coatings was determined in air at 25 and 1316 C in asymmetric four-point flexure with single edge v-notched beam (SEVNB) test specimens. The mode I fracture toughness was found to be K(sub Ic) = 1.15 plus or minus 0.07 and 0.98 plus or minus 0.13 MPa the square root of m, respectively, at 25 and 1316 C. The respective mode II fracture toughness values were K(sub IIc) = 0.73 plus or minus 0.10 and 0.65 plus or minus 0.04 MPa the square root of m. Hence, there was an insignificant difference in either K(sub Ic or K(sub IIc) between 25 and 1316 C for the coating material, whereas there was a noticeable distinction between K(sub Ic) and K(sub IIc), resulting in K(sub IIc) per K(sub Ic) = 0.65 at both temperatures. The empirical mixed-mode fracture criterion best described the coatings' mixed-mode fracture behavior among the four mixed-mode fracture theories considered. The angle of crack propagation was in reasonable agreement with the minimum strain energy density criterion. The effect of the directionality of the coating material in on K(sub Ic) was observed to be insignificant, while its sintering effect at 1316 C on K(sub Ic) was significant.