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Macro-scale Testing and Micromechanics Modeling of Fracture Behaviors for Boron Carbide Composites with Hierarchical Microstructures

With a unique combination of properties including high hardness, low density, wear and corrosion resistance, thermal stability, high neutron absorption, and semi-conductivity, boron carbide (B4C) is a candidate material for various engineering applications that involve extreme environment. The current applications of boron carbide, however, are limited by its intrinsic brittleness due to its strong covalent bonding. To toughen boron carbide, in this work hierarchical microstructure designs was used to provide multiple toughening mechanisms including crack deflection/bridging, micro-crack toughening, etc. Using field assisted sintering, B4C composites with hierarchical microstructure features including graphite platelets, micron and sub-micron sized TiB2 reinforcements were fabricated. The fracture toughness of fabricated B4C composites were previously measured at micro-scale using micro-indentation followed by post-testing microstructure inspection. However, questions including whether the fracture toughness enhancement measured at micro-scale can translate to macro-scale mechanical properties, and what are the fundamental mechanisms behind observed fracture toughness enhancement, remain to be answered. In this study, the fabricated B4C composites were tested using standardized four-point bending method to obtain fracture toughness at macro-scale. In addition, micromechanics modeling was conducted using MAC/GMC code and crack-band model to study the effect of residual stress and weak interphases on fracture behaviors of B4C composites reinforced with TiB2 particles. Through standardized four-point bending tests, fracture toughness enhancements up to 2.85, 3.32, and 3.65 MPa∙m(exp 1/2) (from 2.38 MPa∙m(exp 1/2)) were achieved for B4C composites with graphite platelets addition (micro/nano B4C), with TiB2 formation (micro B4C-TiB2), and with both graphite and TiB2 addition (micro/nano B4C-TiB2) respectively. Micromechanics modeling indicated that introduction of thermal residual stress and weak interphases caused enhanced micro-cracking behavior and resulted in the observed fracture toughness enhancement. These results furthered understanding about the mechanical behaviors at macro-scale and the mechanisms behind observed fracture toughness enhancement for B4C composites with hierarchical microstructures and can provide reference data for the future design of B4C composites with optimized microstructures for further fracture toughness enhancement.

Boron Carbide↗

DOE OSTI2022

LLNL 5-2428: Fracture Permeability and Seismic Slip Behavior

Our goal is to develop, apply and validate a holistic thermal, hydrologic, mechanical, and chemical (THMC) workflow that also includes evaluation of induced seismic slip in EGS reservoirs. We will integrate experimental and modelling approaches to reduce parameteruncertainty and better predict and mitigate seismic hazard at Utah FORGE and future EGS sites.We propose a novel approach that incorporates 3D physics-based Earthquake simulations in THMC models, herein referred to as “THMC+E” models. This capability will enable improvedengineering decisions at Utah FORGE and move EGS operations toward repeatable, robust, economically viable, and socially accepted development. Utah FORGE management and future EGS operators may employ results of THMC+E models for decision making purposes throughout the lifetime of the field operation. For example, before production well installation, our THMC+E models will predict circulation scenarios and related seismic hazard for a suite ofpossible well locations and flow rates, thus enabling evaluation of optimal production well placement. Such efforts will be conducted throughout the lifetime of the project, whereby additional laboratory experiments will constrain key model parameters and machine learning (ML) will reduce the size of the parameter space and the associated uncertainty. THMC+E simulations will enable exploration various circumstances that may hinder EGS success and develop mitigation strategies.

58 GEOSCIENCES↗

DOE OSTI2021

Hydraulic Response to Thermal Stimulation Efforts at Raft River Based on Stepped Rate Injection Testing

The injection well stimulation project at the Raft River geothermal field tests the effect of long-term cold water injection and high pressure injection on well injectivity, improvements to which could reduce operating costs. The primary data for analysis and interpretation of the injection test are step-rate flow tests run before each new phase of the injection. These tests were analyzed using a combination of standard pump-test analytical solution methods and methods developed expressly for the observed conditions. The stepped rate injection tests, combined with long-term flow and pressure response data suggest that the well is located within a fractured formation of low transmissivity but high storativity. These calculated parameters appeared to increase with pressure during the first injection test and the higher values were reproduced during the second stepped rate test. Calculated transmissivity and storativity are on the order of 4E-5 m cm 2 and 1E-4 m Pa -1 , respectively. The apparent pressure dependence of fitted hydraulic parameters may reflect near-well fracture compliance that increased the effective radius of the wellbore during the first test. While the type curve fit analysis also suggests that the reservoir behaves as a uniformly fractured reservoir with a radial flow regime, the hydraulic parameters indicate that condition may exist only a very limited distance (<10 m) from the well. Longer-term pressure response suggests that flow in the system effectively reaches steady state in a period of less than a day, which may reflect pressure stabilization resulting from pressure-dependent permeability or a region of much higher permeability located with a few meters of the well. The transmissivity estimates obtained from this analysis, converted to approximate fracture density and aperture, provide useful constraints on the distance to which the thermal front may migrate from the well during the cold water injection phase of the stimulation project. We estimate that the cooling front will migrate less than a tenth of a kilometer over an approximately one-year injection period. Here, the effects of that cooling, however, may be substantial, because increases in permeability have maximum effect nearest the well.

cold water injection↗

NASA NTRS2004

Searching for an Acidic Aquifer in the Rio Tinto Basin: First Geobiology Results of MARTE Project

Among the conceivable modern habitats to be explored for searching life on Mars are those potentially developed underground. Subsurface habitats are currently environments that, under certain physicochemical circumstances, have high thermal and hydrochemical stability [1, 2]. In planets like Mars lacking an atmospheric shield, such systems are obviously protected against radiation, which strongly alters the structure of biological macromolecules. Low porosity but fractured aquifers currently emplaced inside ancient volcano/sedimentary and hydrothermal systems act as excellent habitats [3] due to its thermal and geochemical properties. In these aquifers the temperature is controlled by a thermal balance between conduction and advection processes, which are driven by the rock composition, geological structure, water turnover of aquifers and heat generation from geothermal processes or chemical reactions [4]. Moreover, microbial communities based on chemolithotrophy can obtain energy by the oxidation of metallic ores that are currently associated to these environments. Such a community core may sustain a trophic web composed of non-autotrophic forms like heterotrophic bacteria, fungi and protozoa.

Fernandez-Remolar, D. C.↗

DOE OSTI2022

Mechanically-, Thermally, and Chemically-Robust High-Temperature Ceramic Composites

In an effort to lower the levelized cost of electricity generated by Concentrated Solar Power (CSP) plants, the heat-to-electricity conversion efficiency may be increased by operating such plants with higher turbine inlet temperatures using closed Brayton cycles with high-pressure, supercritical carbon dioxide (sCO 2 ) as the working fluid. For example, if the turbine inlet temperature is raised to ≥750°C, in combination with sCO2 closed Brayton cycles, the relative heat-to-electricity efficiency may be raised by more than 20% (compared to subcritical steam Rankine cycles operating with turbine inlet temperatures ≤550°C). The associated reduction in the cost of dispatchable electricity from such CSP plants (utilizing high-temperature thermal energy storage) would be an important breakthrough on the path towards direct competition with fossil-fuel-based plants. A key barrier to achieve such high-temperature efficient operation has been the limited thermomechanical performance of metal alloys used in compact, primary printed circuit- type heat exchangers (PCHEXs) for heat transfer to high-pressure sCO 2 . The maximum allowed stresses for the use of conventional stainless steels and nickel-based superalloys at high sCO 2 pressures (≥20 MPa) decline rapidly at temperatures ≥550°C. This project has been focused on demonstrating the desired high-temperature properties and attractive manufacturing characteristics of mechanically-, thermally-, and chemically-robust ceramic/metal composites (cermets), in order to allow for the use of such composites in primary PCHEXs for heat transfer to sCO 2 at ≥750°C and ≥20 MPa in CSP plants. Prior work with high-temperature, co-continuous carbide/refractory metal cermets, such as ZrC/W composites, has already demonstrated: i) the attractive combination of high-temperature properties exhibited by such materials (e.g., high values of stiffness, failure strength, and thermal conductivity at 800°C), and ii) cost-effective processes for manufacturing PCHEX plates comprised of such cermets with tailorable channel patterns. However, ZrC/W cermets were not found to be inherently corrosion resistant in sCO 2 at 750°C and 20 MPa. While the application of a Cu coating to ZrC/W surfaces, along with a modest addition (50 ppm) of CO to CO 2 , rendered such composites resistant to corrosion for 1000 h in such sCO 2 -based fluids at 750°C, such additional steps would increase the design complexity of such cermet-based components. An alternative approach (the focus of this project) is to develop mechanically-robust, cost- effective cermets that are inherently resistant to high-temperature oxidation in air and CO 2 . The overall goals of this project have been to demonstrate: i) the oxidation resistance of at least one cermet at 750°C in air and in CO 2 (i.e., with a projected annual corrosion ≤30 μm), ii) the mechanically robust nature of at least one cermet at 750°C (i.e., with an average failure strength ≥200 MPa), and iii) that the selected cermet can be manufactured via low-cost forming techniques.

14 SOLAR ENERGY↗

DOE OSTI2025

Prediction and Analysis of Utah FORGE Injection Activities using a Coupled Thermo-hydro-mechanical and Earthquake (THM+E) Modeling Workflow

A coupled thermo-hydro-mechanical (THM) numerical workflow that is capable of modeling seismic slip is critical for the successful development of enhanced geothermal systems (EGS). By integrating key physical processes, this workflow enables accurate simulation of temperature and pressure diffusions, stress changes, and induced seismicity. As a result, it serves as a vital tool for predicting induced seismicity and optimizing reservoir stimulation strategies. The Utah FORGE (Frontier Observatory for Research in Geothermal Energy) project, located near Milford, Utah, is a U.S. Department of Energy initiative aimed at advancing EGS technology. In April 2024, eight new stimulation stages (Stages 3R-10) were conducted in well 16A (injection well) subsequent to the first series of stimulation (Stages 1-3) performed in April, 2022. To monitor the induced seismicity, geophones were deployed in wells 58-32, 56-32, and 78B-32, while fiber optic cables were also installed in wells 16B, 78-32, and 78B-32 to collect microseismic data and detect frac hits Preliminary analyses of microseismic catalogs and fiber optic data suggest that the stimulated fractures in Stages 3R–6 closely align with that generated during Stage 3, indicating that the new stimulations were likely reactivating the previously stimulated fracture. To better understand the underlying process, a comprehensive modeling approach that can accurately capture thermal, hydrological, mechanical, and seismic responses is essential. In this work, we propose and utilize a coupled thermo-hydro-mechanical and earthquake (THM+E) simulation workflow to numerically investigate the stimulation activities on well 16A. The specific objective is to confirm whether the new stimulation stages (Stages 3R–6) reactivated fractures previously stimulated during Stage 3. For this purpose, we perform THM+E simulations individually for Stages 3, 3R, 4, and 5, incorporating the discrete fracture networks (DFNs) created by the plane-fitting technique based on the microseismic catalogs. The simulation workflow consists of two separate models: a THM model and an earthquake model, coupled in a one-way manner. Detailed descriptions of the workflow are provided in Section 3. Simulation results are presented in terms of injection pressure, permeability evolution, and predicted seismic catalogs, which are then compared with field data for further analyses. This report is structured as follows. In Section 2, we present detailed analyses of the field data and propose the hypothesis that the new stimulation stages (Stages 3R–6) were probably reactivating the previously stimulated fractures in Stage 3. In Section 3, we introduce the coupled THM+E workflow and the problem setup to validate our hypothesis, followed by the simulation results for each stage in Section 4. Meanwhile, discussions are included to analyze the model predictions and their comparison with field data. Lastly, we conclude the report and outline future plans in Section 5.

15 GEOTHERMAL ENERGY↗

NASA NTRS1984

Fracto-emission - The role of charge separation

Fracto-emission is the emission of particles (e.g., electrons, ions, ground state and excited neutrals, and photons) during and following fracture. It is found that during fracture in vacuum of adhesive bonds and crystalline materials involving large amounts of charge separation on the surface the emission of charged particles, excited neutrals, light, and radio waves occurs with unique and revealing time dependencies. Simultaneous fracto-emission measurements on several systems are reported. The results are interpreted in terms of a conceptual model involving the following steps: (1) charge separation due to fracture, (2) desorption of gases from the material into the crack tip, (3) a gas discharge in the crack, (4) energetic bombardment of the freshly created crack walls, and (5) thermally stimulated electron emission, accompanied by electron stimulated desorption of ions and excited neutrals. In addition to evidence from fracture experiments, results from studies of electron bombardment of a polymer surface are presented.

Dickinson, J. T.↗

DOE OSTI2020

Shatter Thresholds and Fragment Size Distributions of Deuterium–Neon Mixture Cryogenic Pellets for Tokamak Thermal Mitigation

Reliable mitigation is necessary to eliminate the detrimental effects of a disruption event in large high-current tokamaks such as ITER. To avoid serious damage to plasma-facing components during the thermal quench phase of a disruption, material is injected to radiate the plasma energy over the inner surface of the machine. The most promising method of material injection is a process known as shattered pellet injection (SPI). SPI utilizes cryogenic cooling to desublimate gas into the barrel of a pipe gun to form a solid pellet. High-pressure gas or a mechanical punch is used to dislodge the pellet and accelerate it into a bent tube to intentionally fracture it. Pellets made of a mixture of deuterium and neon are likely candidates for thermal mitigation. The survivability of these pellets throughout their flight path, before striking the shatter tube, is essential for reliable SPI operation. Experiments were conducted to determine intact speed limits for various mixtures. In this paper, we outline the details of brittle fracture theory and compare a theory-based model to experimental results from various mixtures of deuterium and neon pellets.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2021

Unveiling damage mechanisms of chromium-coated zirconium-based fuel claddings at LWR operating temperature by in-situ digital image correlation

Here, we investigate the coupled thermomechanical fracture mechanisms of coated nuclear fuel claddings at Light Water Reactor (LWR) operating temperatures. These coated claddings are a highly attractive, near-term solution, which addresses the demands for accident-tolerant fuel systems and provide greater oxidation resistance. However, the fracture mechanisms of these coatings, which may create channels for oxidation ingression, must be fully understood prior to implementation. Thus, high-temperature expanding plug experiments were conducted on coated cladding specimens at a temperature of 315 °C, consistent with the operating environment of LWRs. Furthermore, in-situ thermomechanical deformation was measured with stereo digital image correlation during heating and mechanical testing to separately resolve contributions of thermal and mechanical strain. Digital image correlation, supported by acoustic emissions (AE) detection, was also leveraged to track cracking activity during loading. Coating fracture was found to initiate at total hoop strains of 0.34%. The thermal deformation of the coated claddings was investigated via finite element simulations, revealing a bidirectional stress-state within the coating with axial and circumferential strains of 0.026 and 0.031%. This bidirectional stress-state was attributed with the generation of off-axis fracture pattern within the coating as identified via post-experiment scanning electron microscopy. Thus, this study unveiled critical, coupled thermomechanical mechanisms governing the coating fracture of coated claddings at LWR temperatures.

36 MATERIALS SCIENCE↗

DOE OSTI2026

On the roles of welding residual stresses in determination of fracture toughness in austenitic stainless steel SUS 304 pipeline girth welds

Welding residual stresses especially the high tensile stresses are proved to have negative impacts on the fatigue and fracture behaviors of welded structures. In this study, a virtual fabrication of test specimens from welding process to specimen preparation was carried out by numerical simulation. An austenitic stainless steel multi-pass pipe welding was simulated by transient thermal–mechanical finite element analysis, the residual stresses were then mapped into the test specimen to evaluate fracture toughness. The findings in this study confirmed that, residual stress can be high in a sub-sized compact tensile specimen, which may accelerate or hinder the crack propagation during actual fatigue and fracture tests as reported in recent years. The influence of the cutting location and orientation of the specimen on fracture performance was investigated systematically to provide a fundamental understanding of welding residual stress and necessary insights into the specimen preparation procedure. Considering the limitation of measuring techniques and the complexity of the stress distribution, the developed numerical model can be a very useful tool to elucidate the stress evolution and quantify the effect of remaining welding stress on fracture toughness.

Fracture behavior↗

DOE OSTI2020

Predictive Inverse Model for Advective Heat Transfer in a Short–Circuited Fracture: Dimensional Analysis, Machine Learning, and Field Demonstration

Identifying fluid flow maldistribution in planar geometries is a well–established problem in subsurface science/engineering. Of particular importance to the thermal performance of enhanced (or “engineered”) geothermal systems is identifying the existence of nonuniform (i.e., heterogeneous) permeability and subsequently predicting advective heat transfer. Here, machine learning via a genetic algorithm (GA) identifies the spatial distribution of an unknown permeability field in a two–dimensional Hele–Shaw geometry (i.e., parallel plates). The inverse problem is solved by minimizing the L2 norm between simulated residence time distribution (RTD) and measurements of an inert tracer breakthrough curve (BTC) (C–Dot nanoparticle). Principal component analysis (PCA) of spatially correlated permeability fields enabled reduction of the parameter space by more than a factor of 10 and restricted the inverse search to reservoir–scale permeability variations. Thermal experiments and tracer tests conducted at the mesoscale Altona Field Laboratory (AFL) demonstrate that the method accurately predicts the effects of extreme flow channeling on heat transfer in a single bedding–plane rock fracture. However, this is only true when the permeability distributions provide adequate matches to both tracer RTD and frictional pressure loss. Without good agreement to frictional pressure loss, it is still possible to match a simulated RTD to measurements, but subsequent predictions of heat transfer are grossly inaccurate. Here, the results of this study suggest that it is possible to anticipate the thermal effects of flow maldistribution, but only if both simulated RTDs and frictional pressure loss between fluid inlets and outlets are in good agreement with measurements.

42 ENGINEERING↗

DOE OSTI2024

5-2428: Fracture Permeability Impact on Seismic Slip Behavior

Our goal is to develop, apply and validate a holistic thermal, hydrologic, mechanical, and chemical (THMC) workflow that includes evaluation of induced seismic slip in EGS reservoirs. We will integrate experimental and modeling approaches to reduce parameter uncertainty and better predict/mitigate seismic hazard at EGS sites. Our novel approach couples 3D physics-based earthquake simulations with THMC models (THMc+E). This capability will enable improve engineering decisions at Utah-FORGE and move EGS operations toward repeatable, robust, economically viable, and socially accepted development. For example, our THMC+E models will predict circulation scenarios and related seismic hazard for a suite of flow rates and under uncertainty, thus enabling evaluation of optimal circulation strategy. Laboratory experiments will be performed to constrain key model parameters and Bayesian techniques will provide a probabilistic evaluation of parameters used in models. THMC+E simulations will enable exploration various circumstances that may hinder EGS success and develop mitigation strategies.

58 GEOSCIENCES↗

NASA NTRS1992

Tempered glass and thermal shock of ceramic materials

A laboratory experiment is described that shows students the different strengths and fracture toughnesses between tempered and untempered glass. This paper also describes how glass is tempered and the materials science aspects of the process.

Bunnell, L. Roy↗

NASA NTRS1983

Hygrothermomechanical fracture stress criteria for fiber composites with sense-parity

Hygrothermomechanical fracture stress criteria are developed and evaluated for unidirectional composites (plies) with sense-parity. These criteria explicity quantify the individual contributions of applied, hygral and thermal stresses as well as couplings among these stresses. The criteria are for maximum stress, maximum strain, internal friction, work-to-fracture and combined-stress fracture. Predicted results obtained indicate that first ply failure will occur at stress levels lower than those predicted using criteria currently available in the literature. Also, the contribution of the various stress couplings (predictable only by fracture criteria with sense-parity) is significant to first ply failure and attendant fracture modes.

Chamis, C. C.↗

DOE OSTI2020

Coupled Thermo–Hydro–Mechanical Modeling of Hydro-Shearing Stimulation in an Enhanced Geothermal System in the Raft River Geothermal Field, USA

The Raft River Enhanced Geothermal System (EGS) demonstration project aims to improve the geothermal production by enhancing the reservoir permeability via shear stimulation in well RRG-9. In this paper, we performed a series of 3D thermo– hydro–mechanical (THM) simulations to investigate the influence of hydraulic and thermal effects on the development of this EGS. The model includes synthetic fracture populations based on borehole televiewer images and in-situ stress measurements from well RRG-9. Fracture permeability evolution is determined using an empirical permeability law developed from laboratory experiments. The model was calibrated by comparing the hydraulic response to field observations, including wellhead pressure, injection rate, and well injectivity. Particularly, we analyzed the enhancement of reservoir permeability and the spatial extent of the stimulation zone for the given injection schedule. Our results indicate that the permeability enhancement of fractured geothermal reservoir is caused by the combined effects of injection-induced cooling and fluid pressure increase. The decrease of temperature plays a dominant role in reactivation of natural fractures under the hydro-shearing mechanism, while the higher injection pressure promotes shear failure and enlarges the stimulation zone. Finally, for the specified extensional stress state, the model favors greatest permeability enhancement along the maximum horizontal principal stress, a moderate vertical enhancement, and a smaller gain along the minimum horizontal principal stress.

58 GEOSCIENCES↗

NASA NTRS1985

Residual thermal and moisture influences on the strain energy release rate analysis of edge delamination

A laminated plate theory analysis is developed to calculate the strain energy release rate associated with edge delamination growth in a composite laminate. The analysis includes the contribution of residual thermal and moisture stresses to the strain energy released. The strain energy release rate, G, increased when residual thermal effects were combined with applied mechanical strains, but then decreased when increasing moisture content was included. A quasi-three-dimensional finite element analysis indicated identical trends and demonstrated these same trends for the individual strain energy release rate components, G sub I and G sub II, associated with interlaminar tension and shear. An experimental study indicated that for T300/5208 graphite-epoxy composites, the inclusion of residual thermal and moisture stresses did not significantly alter the calculation of interlaminar fracture toughness from strain energy release rate analysis of edge delamination data taken at room temperature, ambient conditions.

Obrien, T. K.↗

NASA NTRS1986

Residual thermal and moisture influences on the strain energy release rate analysis of edge delamination

Obrien, T. K.↗

NASA NTRS1993

Interface considerations in Al2O3/NiAl composite

The fiber-matrix interface requirements in an Al2O3/NiAl composite were examined from theoretical considerations. Several factors that influence the interface bonding requirements were analyzed. These include: (1) residual stresses due to fiber-matrix coefficient of thermal expansion (CTE) mismatch; (2) matrix cracking stress at room temperature; (3) fracture toughness at room temperature; (4) load transfer from the matrix to the fiber and ultimate tensile strength at the use temperature; and (5) creep resistance at high temperature. A relatively weak fiber-matrix bond, with an interfacial shear strength of approximately 15-20 MPa, might be sufficient for attaining the desired mechanical properties in the fiber direction at the use temperature. A weak fiber-matrix bond is also beneficial for increasing the fracture toughness of the composite at room temperature. In contrast, a strong fiber-matrix bond is required to withstand some of the residual stresses resulting from the fiber-matrix CTE mismatch, which are not likely to be reduced significantly by interface coatings. A relatively strong bond is also beneficial in increasing the matrix cracking stress at room temperature. Various interface coating options to accommodate the conflicting bonding requirements were reviewed. One viable coating option is to incorporate a thick, ductile interface layer well bonded to both the fiber and the matrix.

Misra, Ajay K.↗