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All sourcesNASA NTRSDOE OSTI
NASA NTRS2006

Mode I Toughness Measurements of Core/Facesheet Bonds in Honeycomb Sandwich Structures

Composite sandwich structures will be used in many future applications in aerospace, marine and offshore industries due to the fact that the strength and stiffness to mass ratios surpass any other structural type. Sandwich structure also offers advantages over traditional stiffened panels such as ease of manufacturing and repair. During the last three decades, sandwich structure has been used extensively for secondary structure in aircraft (fuselage floors, rudders and radome structure). Sandwich structure is also used as primary structure in rotorcraft, the most common example being the trailing edge of rotor blades. As with other types of composite construction, sandwich structure exhibits several types of failure mode such as facesheet wrinkling, core crushing and sandwich buckling. Facesheet/core debonding has also been observed in the marine and aerospace industry. During this failure mode, peel stresses applied to an existing facesheet/core debond or an interface low in toughness, results in the facesheet being peeled from the core material, possibly leading to a significant loss in structural integrity of the sandwich panel. In an incident during a test on a liquid hydrogen fuel tank of the X-33 prototype vehicle, the outer graphite/epoxy facesheet and honeycomb core became debonded from the inner facesheet along significant areas, leading to failure of the tank. As a consequence of the accident; significant efforts were made to characterize the toughness of the facesheet/core bond. Currently, the only standardized method available for assessing the quality of the facesheet/core interface is the climbing drum peel test (ASTM D1781). During this test a sandwich beam is removed from a panel and the lip of one of the facesheets is attached to a drum, as shown in Fig. 1. The drum is then rotated along the sandwich beam, causing the facesheet to peel from the core. This method has two major drawbacks. First, it is not possible to obtain quantitative fracture data from the test and so the results can only be used in a qualitative manner. Second, only sandwich structure with thin facesheets can be tested (to facilitate wrapping of the facesheet around the climbing drum). In recognition of the need for a more quantitative facesheet/core fracture test, several workers have devised experimental techniques for characterizing the toughness of the facesheet/core interface. In all of these cases, the tests are designed to yield a mode I-dominated fracture toughness of the facesheet/core interface in a manner similar to that used to determine mode I fracture toughness of composite laminates. In the current work, a modified double cantilever beam is used to measure the mode I-dominated fracture toughness of the interface in a sandwich consisting of glass/phenolic honeycomb core reinforced with graphite epoxy facesheets. Two specimen configurations were tested as shown in Fig 2. The first configuration consisted of reinforcing the facesheets with aluminum blocks (Fig. 2a). In the second configuration unreinforced specimens were tested (Fig. 2b). Climbing drum peel tests were also conducted to compare the fracture behavior observed between this test and the modified double cantilever beam. This paper outlines the test procedures and data reduction strategies used to compute fracture toughness values from the tests. The effect of specimen reinforcement on fracture toughness of the facesheet/core interface is discussed.

Nettles, Alan T.↗
NASA NTRS1994

Small-crack effects in high-strength aluminum alloys

The National Aeronautics and Space Administration and the Chinese Aeronautical Establishment participated in a Fatigue and Fracture Mechanics Cooperative Program. The program objectives were to identify and characterize crack initiation and growth of small cracks (10 microns to 2 mm long) in commonly used US and PRC aluminum alloys, to improve fracture mechanics analyses of surface- and corner-crack configurations, and to develop improved life-prediction methods. Fatigue and small-crack tests were performed on single-edgenotch tension (SENT) specimens and large-crack tests were conducted on center-crack tension specimens for constant-amplitude (stress ratios of -1, 0, and 0.5) and Mini-TWIST spectrum loading. The plastic replica method was used to monitor the initiation and growth of small fatigue cracks at the semicircular notch. Crack growth results from each laboratory on 7075-T6 bare and LC9cs clad aluminum alloys agreed well and showed that fatigue life was mostly crack propagation from a material defect (inclusion particles or void) or from the cladding layer. Finite-element and weight-function methods were used to determine stress intensity factors for surface and corner cracks in the SENT specimens. Equations were then developed and used in a crack growth and crack-closure model to correlate small- and large-crack data and to make life predictions for various load histories. The cooperative program produced useful experimental data and efficient analysis methods for improving life predictions. The results should ultimately improve aircraft structural reliability and safety.

Newman, J. C., Jr.↗
NASA NTRS2014

Diagenetic Features in Yellowknife Bay, Gale Crater, Mars: Implications for Substrate Rheology and Potential Gas Release

Multiple diagenetic features have been observed in clay­-bearing mudstone exposed within Yellowknife Bay, Gale Crater, Mars. These features occurred during at least two separate episodes: an early generation of spheroidal concretions that co-­occur with a dense networks of mineralized fractures, and a later generation of mineralized veins. Concretions consist of mm-sized spheroids (0.4 to 8.0 mm, mean diameter of 1.2 mm) that are distinctly more resistant than the encompassing mudstone. Dissected spheroids suggest an origin via compaction and incipient lithification of the substrate at the perimeter of syndepositional void space. Concretions are generally patchy in their distribution within clay-‐bearing mudstone, but in places can be the dominant fabric element. Locally dense networks of mineralized fractures occur in regions of low concretion abundance. These consist of short (< 50 cm), curvilinear to planar mineralized voids that occur across a range of orientations from vertical to subhorizontal. Fractures are filled by multi-phase cement consisting of two isopachous, erosionally resistant outer bands, and a central less resistant fill. Physical relationships suggests that original fractures may have formed as both interconnected voids and as discrete cross--cutting features. Co--occurrence of early diagenetic concretions and fracture networks suggests a common origin via gas release within a subaqueous, shallow substrate. We suggest that gas release within weakly cohesive subsurface sediments resulted in substrate dewatering and an increase in the cohesive strength of the substrate. Local differences in substrate strength and rate of gas production would have result in formation of either discrete voids or fracture networks. A second generation of mineralized veins is characterized by a regionally low spatial density, predominantly vertical or horizontal orientations, and a single phase of Ca-‐sulfate mineral fill. These veins cross-cut the early diagenetic elements and intersect a greater thickness of stratigraphy within Yellowknife Bay, suggesting a later-‐diagenetic origin via hydraulic fracturing.

Kah, L. C.↗
DOE OSTI2023

The hidden structure of hydrodynamic transport in random fracture networks

We study the large-scale dynamics and prediction of hydrodynamic transport in random fracture networks. The flow and transport behaviour is characterized by first passage times and displacement statistics, which show heavy tails and anomalous dispersion with a strong dependence on the injection condition. The origin of these behaviours is investigated in terms of Lagrangian velocities sampled equidistantly along particle trajectories, unlike classical sampling strategies at a constant rate. The velocity series are analysed by their copula density, the joint distribution of the velocity unit scores, which reveals a simple, albeit hidden, correlation structure that can be described by a Gaussian copula. Based on this insight, we derive a Langevin equation for the evolution of equidistant particle speeds. In this framework, particle motion is quantified by a stochastic time-domain random walk, the joint density of particle position, and speed satisfies a Klein–Kramers equation. The upscaled theory quantifies particle motion in terms of the characteristic fracture length scale and the distribution of Eulerian flow velocities. That is, it is predictive in the sense that it does not require the a priori knowledge of transport attributes. The upscaled model captures non-Fickian transport features, and their dependence on the injection conditions in terms of the velocity point statistics and average fracture length. It shows that the first passage times and displacement moments are dominated by extremes occurring at the first step. The presented approach integrates the interaction of flow and structure into a predictive model for large-scale transport in random fracture networks.

42 ENGINEERING↗
DOE OSTI2022

Utah FORGE Well 16A(78)-32 Stimulation DFN Fracture Plane Evaluation and Data

This dataset includes files used to fit planar fractures through the preliminary earthquake catalogs of the three stages of the April 2022 well 16A(78)-32 stimulation which is linked bellow. These planar features have been used to update the FORGE reference Discrete Fracture Network (DFN) model. The files are provided to encourage other modelers to use additional workflows to find additional/alternative features. To this end, the dataset includes the cleaned earthquake catalog data translated to the FORGE reference model global reference frame, the well trajectory of 16A(78)-32 in those same coordinates, the fit 15 planar features in csv format, and a pdf file with slides illustrating the process used to fit the features. A recorded presentation of this material is available from the October 2022 FORGE Modeling and Simulation Forum which is also linked below.

15 GEOTHERMAL ENERGY↗
NASA NTRS1993

Nondestructive Characterization of Composite Materials

Increasingly, composite materials are applied to fracture-critical structures of aircraft and spacecraft...Ultrasonics offer the most capable inspection technology and recently developed techniques appear to improve this technology significantly... Recent progress in ultrasonic NDE of composites will be reviewed.

composites composite materials ultrasonics fractur↗
NASA NTRS2013

Material Property Characterization of AS4/VRM-34 Textile Laminates

Several material properties (modulus, strengths, and fracture toughness) of a textile composite have been evaluated to provide input data to analytical models of Pultruded Rod Stiffened Efficient Unitized Structure (PRSEUS). The material system is based on warp-knitted preforms of AS4 carbon fibers and VRM-34 epoxy resin, which have been processed via resin infusion and oven curing. Tensile, compressive, shear, and fracture toughness properties have been measured at ambient and elevated temperatures. All specimens were tested in as-fabricated (dry) condition. Specimens were tested with and without through-thickness stitching.

Grenoble, Ray W.↗
DOE OSTI2021

Verification of Coupled Hydraulic Fracturing Simulators Using Laboratory-Scale Experiments

In this work, we aim to verify the predictions of the numerical simulators, which are used for designing field-scale hydraulic stimulation experiments. Although a strong theoretical understanding of this process has been gained over the past few decades, numerical predictions of fracture propagation in low-permeability rocks still remains a challenge. Against this background, we performed controlled laboratory-scale hydraulic fracturing experiments in granite samples, which not only provides high-quality experimental data but also a well-characterized experimental set-up. Using the experimental pressure responses and the final fracture sizes as benchmark, we compared the numerical predictions of two coupled hydraulic fracturing simulators—CSMP and GEOS. Both the simulators reproduced the experimental pressure behavior by implementing the physics of Linear Elastic Fracture Mechanics (LEFM) and lubrication theory within a reasonable degree of accuracy. The simulation results indicate that even in the very low-porosity (1–2 %) and low-permeability (10 -18 m 2 - 10 -19 m 2 ) crystalline rocks, which are usually the target of EGS, fluid-loss into the matrix and unsaturated flow impacts the formation breakdown pressure and the post-breakdown pressure trends. Therefore, underestimation of such parameters in numerical modeling can lead to significant underestimation of breakdown pressure. The simulation results also indicate the importance of implementing wellbore solvers for considering the effect of system compressibility and pressure drop due to friction in the injection line. The varying injection rate as a result of decompression at the instant of fracture initiation affects the fracture size, while the entry friction at the connection between the well and the initial notch may cause an increase in the measured breakdown pressure.

15 GEOTHERMAL ENERGY↗
NASA NTRS1990

Development of impact design methods for ceramic gas turbine components

Impact damage prediction methods are being developed to aid in the design of ceramic gas turbine engine components with improved impact resistance. Two impact damage modes were characterized: local, near the impact site, and structural, usually fast fracture away from the impact site. Local damage to Si3N4 impacted by Si3N4 spherical projectiles consists of ring and/or radial cracks around the impact point. In a mechanistic model being developed, impact damage is characterized as microcrack nucleation and propagation. The extent of damage is measured as volume fraction of microcracks. Model capability is demonstrated by simulating late impact tests. Structural failure is caused by tensile stress during impact exceeding material strength. The EPIC3 code was successfully used to predict blade structural failures in different size particle impacts on radial and axial blades.

Song, J.↗
DOE OSTI2020

Tritium Aging Effects on Fracture Toughness of Stainless Steel Weldments

The long-term embrittlement effects of tritium and decay helium on the structural properties of stainless steels have been studied for years at Savannah River to provide required data for establishing safe operating conditions and lifetimes of pressure vessels used to contain tritium gas. In this study, the fracture toughness properties of the longest-aged tritium-precharged stainless-steel base metals and weldments tested at Savannah River were measured and compared to earlier results. The fracture toughness values were the lowest recorded here for tritium-exposed stainless steel. As-forged and as-welded specimens were thermally precharging with tritium gas at 34.5 MPa and 623 K, then aged for up to 17 years to buildin decay helium prior to testing. ASTM J-Integral fracture mechanics analyses, transmission electron microscopy (TEM), and small angle neutron scattering (SANS) examinations were conducted to characterize the effects of tritium and its radioactive decay product, helium-3. Results show that the fracture toughness values were reduced to less than 2-4% of the as-forged values for specimens with more than 1300 appm helium from tritium decay. The trend of decreasing fracture toughness values with increasing helium content was consistent with earlier observations, and the data show that Type 304L stainless steel is more resistant to tritium-induced cracking than Type 21-6-9 stainless at similar decay helium levels. The fracture toughness properties of long-aged weldments were also affected, but the reductions were not as severe over time because weldments did not retain as much tritium as did the base metals. TEM observations were used to characterize the effects of decay helium bubbles on the deformation substructures, but nanometer-sized helium bubbles were not easily resolved because of high dislocation densities within the forged microstructures. SANS results are presented that suggest the technique can provide information on decay helium bubble size, spacing, and distribution in these steels.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Charpy Impact Characterization of Surveillance Specimens Harvested from Palisades High Fluence A-60 Capsule

Located on the shores of Lake Michigan, the Palisades Nuclear Generating Station (PNGS) was a nuclear power plant that operated in Covert Township, Michigan. The plant had a single pressurized water reactor that produced electricity for the region. The PNGS was shut down in 2022 after more than four decades of service. The PNGS included in its surveillance program a surveillance capsule, designated A-60, containing specimens of a weld metal with nickel content of about 1.36 wt% and copper content of about 0.25 wt%. The capsule was removed from its surveillance position in early 1995 and has been resident in the spent fuel pool since that time. This capsule was irradiated to a fluence of 1.96×10 20 n/cm 2 (E>1MeV) that is equivalent for more than 150 effective full power years (EFPYs) for the US reactor pressure vessel (RPV) fleet. The material is also of special interest because of its very high nickel content and potential for development of NiMnSi (nickel-manganese-silicon) precipitates. Combination of very high fluence and very high Ni and Cu content makes the material in this capsule of great interest as benchmark for currently developing embrittlement trend curves (ETC) aiming to predict embrittlement at high fluences. Multi-year efforts by the Light Water Reactor Sustainability (LWRS) Program personnel from the Materials Research Pathway (MRP) to harvest this capsule finally succeeded in 2023. As a result, the Westinghouse Electric Company (WEC) through contract with Oak Ridge National Laboratory (ORNL) came to PNGS site, retrieved the A-60 capsule, brought it to WEC Churchill hot cell facility, opened the capsule and sent all surveillance specimens in the capsule to ORNL for future characterization by July 2023. Total of 9 tensile and 48 Charpy specimens were inventoried in the ORNL hot cells. Testing plan has been developed based on available specimens. It includes hardness, tensile, Charpy impact, Mini-CT fracture toughness testing, in-situ thermal annealing, and microstructural characterization, including Atom Probe Tomography (APT). Charpy impact testing has been completed and results are presented in this report. Moreover, negotiations with Pressurized Water Reactors Owners Group (PWROG) and Westinghouse resulted in Westinghouse donating to ORNL a piece of archive weld and base metal such that unirradiated characterization of these materials can be performed as part of this project. Comparison of measured hardening and embrittlement has been performed and data are compared to available large database.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

Wintertime Brine Discharge at the Surface of a Cold Polar Glacier and the Unexpected Absence of Associated Seismicity

A subglacial groundwater system beneath Taylor Glacier, Antarctica, discharges hypersaline, iron-rich brine episodically at the glacier surface to create Blood Falls. However, the triggering mechanism for these brine release events is not yet understood. Identifying which fracture processes are observed seismically can help us better characterize the hydrological system at Taylor Glacier, and more generally, provide us with a broader understanding of englacial hydrologic activity in cold glaciers. We document wintertime brine discharge using time-lapse photography. Subfreezing air temperatures during the brine discharge indicate that surface melt-induced hydrofracture is an unlikely trigger for brine release. Further, we analyze local seismic data to test a hypothesis that fracturing generates elevated surface wave energy preceding and/or coinciding with brine release events. Our results show no discernible elevated Rayleigh wave activity prior to or during Blood Falls brine release. Instead, we find a pattern of seismic events dominated by a seasonal signal, with more Rayleigh events occurring in the summer than the winter from the Blood Falls source area. We calculate that the volumetric opening of cracks that would generate Rayleigh waves at our detection limits are of similar size to myriad cracks in glacier ice, lake ice, and frozen sediment in the terminus area. We therefore propose that any fracturing coincident with brine release activity likely consists of a series of smaller opening events that are masked by other seismicity in the local environment.

58 GEOSCIENCES↗
NASA NTRS2015

Iron-Manganese Redox Reactions in Endeavour Crater Rim Apron Rocks

The Mars Exploration Rover Opportunity has been exploring Noachian age rocks and outcrops on the rim of the 22 km diameter Endeavour crater since August 2011. The Cape York area is a low-lying rim of Endeavour that contains 3 distinct lithologies: 1) the stratigraphically lowest Matijevic fm of pre-impact lithology, 2) Shoemaker fm of impact breccias, and 3) the stratigraphically highest rim lithology Grasberg fm of post-impact sediments that drape the lower slopes of the rim. The sulfate-rich sediment of the Burns fm lies unconformably over the Grasberg fm. Ca-sulfate veins were discovered in Grasberg fm sediments; the sulfates precipitated from aqueous fluids flowing upward through these materials. Opportunity investigated the chemistry and morphology of outcrops in the Matijevic fm that have Fe(sup 3+)-rich smectite detected by orbital signatures returned by CRISM on MRO. Matijevic fm also contains "boxwork" fractures with chemistry consistent with an Al-rich smectite and veins that appear to be rich in Ca-sulfate. More recently on Cape Tribulation, Opportunity has characterized two S-, Mg- and Mn-rich rich rocks overturned and fractured by the rover's wheels on Cook Haven. Those rocks have been dubbed "Pinnacle Island" and "Stuart Island" and will be referred to as the "Island" rocks. The objectives of this study are to characterize the Fe and Mn contents in the Cape York materials, including the two Island rocks, and to provide a model for Mn mobilization and precipitation. Detailed geochemistry of Endeavour rim rocks is presented in a companion paper. Geochemical trends and elemental associations were obtained from data returned by the Alpha Particle X-ray Spectrometer (APXS) on Opportunity.

Ming, D. W.↗
DOE OSTI2021

Evaluation of Energy Storage Potential of Unconventional Shale Reservoirs Using Numerical Simulation of Cyclic Gas Injection

Compressed air energy storage (CAES) stores energy as compressed air in underground formations, typically salt dome caverns. When electricity demand grows, the compressed air is released through a turbine to produce electricity. CAES in the US is limited to one plant built in 1991, due in part to the inherent risk and uncertainty of developing subsurface storage reservoirs. As an alternative to CAES, we propose using some of the hundreds of thousands of hydraulically fractured horizontal wells to store energy as compressed natural gas in unconventional shale reservoirs. To store energy, produced or “sales” natural gas is injected back into the formation using excess electricity and is later produced through an expander to generate electricity. To evaluate this concept, we performed numerical simulations of cyclic natural gas injection into unconventional shale reservoirs using cmg-gem commercial reservoir modeling software. We tested short-term (diurnal) and long-term (seasonal) energy storage potential by modeling well injection and production gas flowrates as a function of bottom-hole pressure. First, we developed a conceptual model of a single fracture stage in an unconventional shale reservoir to characterize reservoir behavior during cyclic injection and production. Next, we modeled cyclic injection in the Marcellus shale gas play using published data. Results indicate that Marcellus unconventional shale reservoirs could support both short- and long-term energy storage at capacities of 100–1000 kWe per well. The results indicate that energy storage in unconventional shale gas wells may be feasible and warrants further investigation.

25 ENERGY STORAGE↗
DOE OSTI2022

High-fidelity micromechanical modeling of the effects of defects on damage and creep behavior in single tow ceramic matrix composite

Despite the superior properties of ceramic matrix composites (CMCs), their fabrication process generates inevitable defects with high density that significantly influence material integrity and residual useful life. Recent efforts have focused on CMC property prediction and investigation of their different inelastic mechanisms, but very limited work exists on understanding the influence of defects on inelastic responses of CMCs. Here, we introduce a three-dimensional micromechanics computational framework that includes experimentally informed material microstructure and architectural variabilities to investigate CMC response in the presence of manufacturing-induced defects. A developed microstructure generation algorithm is used to generate the representative volume elements in the micromechanics models from complex material morphology information obtained from extensive characterization studies of C/SiNC and SiC/SiNC CMCs. A fracture mechanics-informed matrix damage model is reformulated, in which the model considers the growth of porosity and microcracks in the as-received material. A progressive fiber damage model as well as Orthotropic viscoplasticity creep formulation are also utilized for the study. This methodology is implemented within the micromechanics framework to investigate the complex temperature- and time-dependent load transfer and damage mechanisms of CMCs under operation loading conditions. The developed framework explores the influence of as-received defects on the damage and creep behavior in service conditions. It also provides new insights into the effect of size, shape, distribution, and location of these defects on material response. The framework is then calibrated with unidirectional CMC minicomposite results available in the literature.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Machine Learning Application to Assess Occurrence and Saturations of Methane Hydrate in Marine Deposits Offshore India

Artificial Neural Networks (ANN) were used to assess methane hydrate occurrence and saturation in marine sediments offshore India. The ANN analysis classifies the gas hydrate occurrence into three types: methane hydrate in pore space, methane hydrate in fractures, or no methane hydrate. Further, predicted saturation characterizes the volume of gas hydrate with respect to the available void volume. Log data collected at six wells, which were drilled during the India National Gas Hydrate Program Expedition 02 (NGHP-02), provided a combination of well log measurements that were used as input for machine learning (ML) models. Well log measurements included density, porosity, electrical resistivity, natural gamma radiation, and acoustic wave velocity. Combinations of well logs used in the ML models provide good overall balanced accuracy (0.79 to 0.86) for the prediction of the gas hydrate occurrence and good accuracy (0.68 to 0.92) for methane hydrate saturation prediction in the marine accumulations against reference data. The accuracy scores indicate that the ML models can successfully predict reservoir characteristics for marine methane hydrate deposits. In conclusion, the results indicate that the ML models can either augment physics-driven methods for assessing the occurrence and saturation of methane hydrate deposits or serve as an independent predictive tool for those characteristics.

58 GEOSCIENCES↗
DOE OSTI2021

Wabash CarbonSAFE (Subtask 3.1 - Application of the NRAP Tools to the Wabash CarbonSAFE Site for Risk Assessment Associated with Geologic Carbon Storage Activities)

This report documents a risk assessment of CO 2 containment loss and induced shear failure due to geologic carbon storage at the Wabash CarbonSAFE site. The operator, Wabash Valley Resources, has proposed adapting the onsite integrated gasification combined cycle (IGCC) facilities to produce hydrogen and injecting the byproduct CO 2 stream into the subsurface Potosi dolomite formation. The purpose of this study is to assess (1) CO 2 sequestration performance relative to the CarbonSAFE goals of storing 50 Mt over 30 years, (2) the risk of containment loss due to leakage along a wellbore and into an overlying aquifer, and (3) the state of stress and risk of reactivating existing fractures. This study relied upon the initial site characterization work performed by the Illinois State Geologic Survey (ISGS) along with analogue data collected from other carbon sequestration projects in the region.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗