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At least 433 records · Page 24

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NASA NTRS2000

Rotorcraft Damage Tolerance Evaluated by Computational Simulation

An integrally stiffened graphite/epoxy composite rotorcraft structure is evaluated via computational simulation. A computer code that scales up constituent micromechanics level material properties to the structure level and accounts for all possible failure modes is used for the simulation of composite degradation under loading. Damage initiation, growth, accumulation, and propagation to fracture are included in the simulation. Design implications with regard to defect and damage tolerance of integrally stiffened composite structures are examined. A procedure is outlined regarding the use of this type of information for setting quality acceptance criteria, design allowables, damage tolerance, and retirement-for-cause criteria.

Chamis, Christos C.↗

NASA NTRS2007

Progressive Fracture of Laminated Fiber-Reinforced Composite Stiffened Plate Under Pressure

S-Glass/epoxy laminated fiber-reinforced composite stiffened plate structure with laminate configuration (0/90)5 was simulated to investigate damage and fracture progression, under uniform pressure. For comparison reasons a simple plate was examined, in addition with the stiffened plate. An integrated computer code was used for the simulation. The damage initiation began with matrix failure in tension, continuous with damage and/or fracture progression as a result of additional matrix failure and fiber fracture and followed by additional interply delamination. Fracture through the thickness began when the damage accumulation was 90%. After that stage, the cracks propagate rapidly and the structures collapse. The collapse load for the simple plate is 21.57 MPa (3120 psi) and for the stiffened plate 25.24 MPa (3660 psi).

Gotsis, Pascalis K.↗

DOE OSTI2019

Matrix Diffusion in Fractured Media: New Insights Into Power Law Scaling of Breakthrough Curves

Here, we develop a theoretical model for power law tailing behavior of transport in fractured rock based on the relative dominance of the decay rate of the advective travel time distribution, modeled using a Pareto distribution (with tail decaying as ~ time -(1+α) ), versus matrix diffusion, modeled using a Lévy distribution. The theory predicts that when the advective travel time distribution decays sufficiently slowly (α<1), the late-time decay rate of the breakthrough curve is -(1+α/2) rather than the classical -3/2. Yet, if α>1, the -3/2 decay rate is recovered. For weak matrix diffusion or short advective first breakthrough times, we identify an early-time regime where the breakthrough curve follows the Pareto distribution, before transitioning to the late-time decay rate. The theoretical predictions are validated against particle tracking simulations in the three-dimensional discrete fracture network simulator dfnWorks, where matrix diffusion is incorporated using a time domain random walk.

58 GEOSCIENCES↗

DOE OSTI2025

Elucidating texture and grain morphology contributions to the micromechanical response of additively manufactured Inconel 625

Microstructural variation of additively manufactured (AM) metal components in comparison to wrought counterparts makes certification for critical applications a challenge. Microscale simulations leveraging modern computational tools may be used to supplement testing of AM microstructures, thus accelerating certification by reducing the number of experiments needed. However, as micromechanical response is closely tied to critical properties like fatigue-life and fracture, utilization of these simulations with macroscale experimental data alone is insufficient. One means to attain microscale experimental data is in situ diffraction data collected from synchrotron X-ray sources. In this work, such data were collected during in situ compression of AM Inconel 625 superalloy. Interpretation of experimental results was assisted by massive (8M element) complementary micromechanical simulations performed on sets of virtual microstructures generated using cellular automata. Together, micromechanical data from diffraction experiments and simulations were used to probe the effects of textured “track” microstructures generated during laser powder bed fusion and directional strength-to-stiffness on micromechanical response. Though fiber-averaged directional strength-to-stiffness ratios were expected to dominate given the high elastic anisotropy of the material, the combination of small variations in texture and specific grain configurations unique to AM microstructures lead to significant variability in micromechanical response after yield. The findings emphasize the importance of high-fidelity microstructural representation that captures key texture components and AM-specific morphology for property prediction of AM metals.

36 MATERIALS SCIENCE↗

DOE OSTI2013

Assessment of Alaska's North Slope Oil Field Capacity to Sequester CO{sub 2}

The capacity of 21 major fields containing more than 95% of the North Slope of Alaska's oil were investigated for CO{sub 2} storage by injecting CO{sub 2} as an enhanced oil recovery (EOR) agent. These fields meet the criteria for the application of miscible and immiscible CO{sub 2}-EOR methods and contain about 40 billion barrels of oil after primary and secondary recovery. Volumetric calculations from this study indicate that these fields have a static storage capacity of 3 billion metric tons of CO{sub 2}, assuming 100% oil recovery, re-pressurizing the fields to pre-fracturing pressure and applying a 50% capacity reduction to compensate for heterogeneity and for water invasion from the underlying aquifer. A ranking produced from this study, mainly controlled by field size and fracture gradient, identifies Prudhoe, Kuparuk, and West Sak as possessing the largest storage capacities under a 20% safety factor on pressures applied during storage to avoid over-pressurization, fracturing, and gas leakage. Simulation studies were conducted using CO{sub 2} Prophet to determine the amount of oil technically recoverable and CO{sub 2} gas storage possible during this process. Fields were categorized as miscible, partially miscible, and immiscible based on the miscibility of CO{sub 2} with their oil. Seven sample fields were selected across these categories for simulation studies comparing pure CO{sub 2} and water-alternating-gas injection. Results showed that the top two fields in each category for recovery and CO{sub 2} storage were Alpine and Point McIntyre (miscible), Prudhoe and Kuparuk (partially miscible), and West Sak and Lisburne (immiscible). The study concludes that 5 billion metric tons of CO{sub 2} can be stored while recovering 14.2 billion barrels of the remaining oil.

02 PETROLEUM↗

DOE OSTI2022

Impact of Concurrent Solubilization and Fines Migration on Fracture Aperture Growth in Shales during Acidized Brine Injection

Acidic hydraulic fracturing fluid chemically and physically alters shale rock fabric during injection and shut-in, creating a “reaction-altered zone” along the fracture faces. To better characterize the variable thickness and composition of this reaction-altered zone under advective flow, we take a coupled experimental and modeling approach. A fluidic cell, with six fiducial markers, is first fabricated to keep the rock sample in place during the core floods and to allow image alignment of acquired images. Then, we conduct a series of reactive core floods in a clay-rich siliceous Wolfcamp shale sample with 10 wt % carbonate, using a synthetic fracturing fluid under no confining stress and at room temperature. High-resolution computed tomography (CT) scans are periodically conducted to observe the spatial alteration of the fracture network. We then perform scanning electron microscopy (SEM-EDS) on the two orthogonal surfaces (fracture surface and freshly cut profile face) to generate high-resolution elemental maps that show the change in mineralogy, both with distance along a given flow path along a fracture surface and with depth from the fracture surface into the shale matrix. These results are contrasted against a two-dimensional (2D) advection-diffusion reaction model developed previously for batch reactions between shale and synthetic fracturing fluids. The model simulates the geochemical interaction occurring at the fracture/matrix interface and penetrating into the shale matrix during the reactive core flood. Both model and experimental results show that the acidic brine is neutralized during the core flood, corresponding to an increase in fracture aperture as a function of fluid volume injected with the greatest change near the inlet. SEM-EDS scans reveal significant dissolution of carbonates on the fracture surface without pyrite oxidation. The reactive transport model indicates that carbonate depletion into the shale interior should be observable, yet SEM-EDS shows no discernible loss of carbonate in the orthogonal profile face. The combination of these observations suggests an additional fracture evolution mechanism in the reactive system, i.e., fines migration. We show that fines migration enhances the access of fracturing fluid to the matrix resulting in a more pronounced fracture widening. Finally, we conclude that coupled mineral dissolution and fines migration govern fracture aperture growth during acidized brine injection. In this work, we effectively show the underlying risk of relying solely on models that do not include an important (transport) process that can alter the system significantly and propose a combined chemomechanical mechanism for fracture evolution appropriate for this shale mineralogy.

58 GEOSCIENCES↗

DOE OSTI2022

Statistical perspective on embrittling potency for intergranular fracture

Embrittling potency is a thermodynamic metric that assesses the influence of solute segregation to a grain boundary (GB) on intergranular fracture. Historically, authors of studies have reported embrittling potency as a single scalar value, assuming a single segregation site of importance at a GB and a particular cleavage plane. However, the topography of intergranular fracture surfaces is not generally known a priori. Accordingly, we, in this study, present a statistical ensemble approach to compute embrittling potency, where many free surface (FS) permutations are systematically considered to model fracture of a GB. The result is a statistical description of the thermodynamics of GB embrittlement. As a specific example, embrittling potency distributions are presented for Cr segregation to sites at two Ni $\langle 111 \rangle$ symmetric tilt GBs using atomistic simulations. We show that the average embrittling potency for a particular GB site, considering an ensemble of FS permutations, is not equal to the embrittling potency computed using the lowest energy pair of FSs. A mean GB embrittlement is proposed, considering both the likelihood of formation of a particular FS and the probability of solute occupancy at each GB site, to compare the relative embrittling behavior of two distinct GBs.

36 MATERIALS SCIENCE↗

DOE OSTI2017

Off-fault deformations and shallow slip deficit from dynamic rupture simulations with fault zone plasticity

Kinematic source inversions of major (M≥7) strike-slip earthquakes show that the slip at depth exceeds surface displacements measured in the field, and it has been suggested that this shallow slip deficit (SSD) is caused by distributed plastic deformation near the surface. We perform dynamic rupture simulations of M 7.2–7.4 earthquakes in elastoplastic media and analyze the sensitivity of SSD and off-fault deformation (OFD) to rock quality parameters. While linear simulations clearly underpredict observed SSD and OFDs, nonlinear simulations for a moderately fractured fault damage zone predict a SSD of 44–53% and OFDs of 39–48%, consistent with the 30–60% SSD and 46 ± 10% (1σ) OFD reported for the 1992 M 7.3 Landers earthquake. Finally, both SSD and OFDs are sensitive to the quality of the fractured rock mass inside the fault damage zone, and surface rupture is almost entirely suppressed in poor quality material.

58 GEOSCIENCES↗

DOE OSTI2017

Predicting grid-size-dependent fracture strains of DP980 with a microstructure-based post-necking model

Ductile fracture is a local phenomenon, and it is well established that fracture strain levels depend on both stress triaxiality and the resolution (grid size) of strain measurements. Two-dimensional plane strain post-necking models with different representative volume element (RVE) sizes are used to predict the size-dependent fracture strain of a commercial dual-phase steel, DP980. The models are generated from the actual microstructures, and the individual phase flow properties and literature-based individual phase damage parameters for the Johnson-Cook model are used for ferrite and martensite. A monotonic relationship is predicted: the smaller the model size, the higher the fracture strain. Thus, a general framework is developed to quantify the size-dependent fracture strains for multiphase materials. In addition to the RVE sizes, the influences of intrinsic microstructure features, i.e., the flow curve and fracture strains of the two constituent phases, on the predicted fracture strains also are examined. Application of the derived fracture strain versus RVE size relationship is demonstrated with large clearance trimming simulations with different element sizes.

Cheng, G. (ORCID:0000000268604420)↗

DOE OSTI2023

Prediction and uncertainty quantification of shale well performance using multifidelity Monte Carlo

Uncertainty quantification is an integral component of reservoir management, especially considering the inherent uncertainty in subsurface systems. While a standard practice to estimate the uncertainty, Monte Carlo (MC) simulation is computationally intense when the sampling population comprises high-fidelity simulations. Alternatively, the Multi-fidelity Monte Carlo (MFMC) simulation overcomes this computational intensity by integrating low- and high-fidelity simulations. Our goal is to minimize the number of expensive high-fidelity simulations while maintaining accuracy and using numerous fast and cheap low-fidelity simulations to efficiently sample to input parameter space of interest. We selected gas production from unconventional wells to demonstrate the potential speedups and accuracy of the MFMC approach. The model fidelity usually determines the trade-off between accuracy and efficiency. While the high-fidelity model is more accurate, the low-fidelity model is more efficient. Our high-fidelity simulation includes reservoir simulations of a hydraulically fractured well. On the other hand, our low-fidelity model comprises the parallel-plate flow model. We used differential programming to efficiently solve the 1D flow model, where automatic differentiation is used to efficiently compute the gradients. We matched the production profile of high-fidelity simulations with our low-fidelity simulations. Then, we used a support vector regression to map the high- and low-fidelity input parameters. The mapping function is essential to tune the low-dimensional parameter space of the low-fidelity model to the high-dimensional parameter space of the high-fidelity model. We found that we can use a combination of 9 high fidelity and 10,000 low fidelity simulations to efficiently and accurately simulate pressure management. This method is at least two orders of magnitude faster than only using high-fidelity simulations. Finally, from a broader perspective, MFMC could efficiently estimate the uncertainty of various systems and models, integrating low- and high-fidelity models.

04 OIL SHALES AND TAR SANDS↗

DOE OSTI2023

Using Homogenized Models to Explore the Effect of Fracture Densities on Weathering

Despite its importance, only a few researchers have incorporated the effects of fracturing into models of reactive transport for rock weathering. Here we explore 2D simulations that describe weathering under conditions of diffusive and advective transport within heterogeneous media consisting of rocky blocks and fractures. In our simulations, the Darcy velocities vary in space and time and depend on weathering processes within the rock matrix. We explore simulations with saturated and unsaturated flow for weathering bedrock that consists of blocks separated by inert or weathered material. The simulations show that a simplified homogenized model can approximate exact solutions for some of the simulated columns and hills and can allow exploration of coupling between flow and reaction in fractured rock. These hillslope simulations document that, even in the presence of 2D water flow, i) an increase in fracture density results in faster weathering advance rates; and ii) the water table locates deeper for a rock system that is weathered and fractured rather than weathered and unfractured. Some of these patterns have also been observed for natural systems. But these simulations also highlight how simplified models that do not use appropriate averaging of heterogeneities can be inaccurate in predicting weathering rate for natural systems. For example, if water flows both vertically and laterally through the vadose zone of a hill, then a prediction of the depth of regolith that is based on modeling strictly unidirectional downward infiltration will be unrealistically large. Likewise, if the fracture density observed near the land surface is used in a model to predict depth of weathering for a system where the fracture density decreases downward, the model will overestimate regolith depth. Learning how to develop accurately homogenized models could thus enable better conceptual models and predictions of weathering advance in natural systems.

58 GEOSCIENCES↗

DOE OSTI2016

Experimental studies of Micro- and Nano-grained UO 2 : Grain Growth Behavior, Sufrace Morphology, and Fracture Toughness

This activity is supported by the US Nuclear Energy Advanced Modeling and Simulation (NEAMS) Fuels Product Line (FPL) and aims at providing experimental data for the validation of the mesoscale simulation code MARMOT. MARMOT is a mesoscale multiphysics code that predicts the coevolution of microstructure and properties within reactor fuel during its lifetime in the reactor. It is an important component of the Moose-Bison-Marmot (MBM) code suite that has been developed by Idaho National Laboratory (INL) to enable next generation fuel performance modeling capability as part of the NEAMS Program FPL. In order to ensure the accuracy of the microstructure-based materials models being developed within the MARMOT code, extensive validation efforts must be carried out. In this report, we summarize the experimental efforts in FY16 including the following important experiments: (1) in-situ grain growth measurement of nano-grained UO 2 ; (2) investigation of surface morphology in micrograined UO 2 ; (3) Nano-indentation experiments on nano- and micro-grained UO 2 . The highlight of this year is: we have successfully demonstrated our capability to in-situ measure grain size development while maintaining the stoichiometry of nano-grained UO 2 materials; the experiment is, for the first time, using synchrotron X-ray diffraction to in-situ measure grain growth behavior of UO 2 .

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1996

Progressive Fracture of Fiber Composite Builtup Structures

The damage progression and fracture of builtup composite structures was evaluated by using computational simulation to examine the behavior and response of a stiffened composite (0 +/- 45/90)(sub s6) laminate panel subjected to a bending load. The damage initiation, growth, accumulation, progression, and propagation to structural collapse were simulated. An integrated computer code (CODSTRAN) was augmented for the simulation of the progressive damage and fracture of builtup composite structures under mechanical loading. Results showed that damage initiation and progression have a significant effect on the structural response. Also investigated was the influence of different types of bending load on the damage initiation, propagation, and final fracture of the builtup composite panel.

Gotsis, Pascal K.↗

NASA NTRS2005

Computational Simulation of Damage Propagation in Three-Dimensional Woven Composites

Three dimensional (3D) woven composites have demonstrated multi-directional properties and improved transverse strength, impact resistance, and shear characteristics. The objective of this research is to develop a new model for predicting the elastic constants, hygrothermal effects, thermomechanical response, and stress limits of 3D woven composites; and to develop a computational tool to facilitate the evaluation of 3D woven composite structures with regard to damage tolerance and durability. Fiber orientations of weave and braid patterns are defined with reference to composite structural coordinates. Orthotropic ply properties and stress limits computed via micromechanics are transformed to composite structural coordinates and integrated to obtain the 3D properties. The various stages of degradation, from damage initiation to collapse of structures, in the 3D woven structures are simulated for the first time. Three dimensional woven composite specimens with various woven patterns under different loading conditions, such as tension, compression, bending, and shear are simulated in the validation process of this research. Damage initiation, growth, accumulation, and propagation to fracture are included in these simulations.

Huang, Dade↗

NASA NTRS1992

Design for progressive fracture in composite shell structures

The load carrying capability and structural behavior of composite shell structures and stiffened curved panels are investigated to provide accurate early design loads. An integrated computer code is utilized for the computational simulation of composite structural degradation under practical loading for realistic design. Damage initiation, growth, accumulation, and propagation to structural fracture are included in the simulation. Progressive fracture investigations providing design insight for several classes of composite shells are presented. Results demonstrate the significance of local defects, interfacial regions, and stress concentrations on the structural durability of composite shells.

Minnetyan, Levon↗

NASA NTRS2023

Modeling of Response of Thermoplastic Composites Under High Energy Impact

This work investigates the response of a thermoplastic panel under high energy ballistic impact. The composite material system is a carbon fiber reinforced low melt semi-crystalline resin TC1225 LMPAEK T700G (T700/LMPAEK3). Several high energy dynamic impact tests were performed where an aluminum projectile impacted various panels at different impact velocities. For this work, the test performed at an impact velocity of 73.2 m/s was investigated. The projectile rebounded upon impact, and the damage to the panel was characterized through ultrasonic and CT-scanning. Response of the panel under impact and the associated damage is discussed. Numerical simulation of the impact process was performed using the LS-DYNA® computer code [1] with a new material model MAT_COMPOSITE_DAMAGE_DGD (MAT 299), a modification over MAT 261 material model in terms of an improved representation of damage coupling and additional capability for strain rate effects. Delaminations were modeled using cohesive zone contact formulation in LS-DYNA®, wherein the mixed-mode fracture is captured via the Benzegaggh-Kenane (B-K) mode-dependent fracture energy interpolation law. Simulation of this impact test demonstrates a good match of results in terms of panel deflection and panel-projectile interactions. The overall extent of delaminations was under-predicted by the simulation. This work forms the basis to model tests performed at higher velocities, involving projectile penetration of panel.

Composite Materials↗

DOE OSTI2018

Connecting Pressure-Saturation and Relative Permeability Models to Fracture Properties: The Case of Capillary-Dominated Flow of Supercritical CO 2 and Brine

Fractures are potential pathways for subsurface fluids. In the context of geologic CO 2 sequestration, fractures could threaten the security of reservoirs since they are pathways for leakage. However, the constitutive equations describing the pressure-saturation and relative permeability-saturation, key inputs for flow modeling and prediction, are poorly understood for two-phase fracture flow at the field scale where each fracture might be an element of a complex fracture network or dual-porosity domain. This knowledge is required for the safe storage of CO 2 under potentially fractured caprocks. To address this, we numerically simulated two-phase viscous flow through horizontal heterogeneous fractures across a broad range of roughness and aperture correlation length. The numerical experiments, which solved the modified local cubic law, showed a weak to strong phase interference during the drainage process; that is, supercritical CO 2 displaces brine if the imposed pressure + local viscous force > local capillary force. The drainage process ended when no new brine cells can be further invaded by CO 2 . Afterward, we froze the saturation field for each individual phase and calculated the relative permeability by single-phase flow modeling. Thousands of simulated pressure-saturation and relative permeability curves enabled us to estimate and connect the parameters of the Van-Genuchten model and of the generalized ν-type model to fracture roughness and aperture correlation length. In conclusion, this empirical connection will be useful for assessing and predicting immiscible two-phase flow in horizontal rough fractures at the large scale.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS2007

Progressive Fracture of Laminated Composite Stiffened Plate

Laminated fiber-reinforced composite stiffened plate with [0/90/plus or minus 45]s plies made of S-Glass/epoxy are evaluated via computational simulation to study damage and fracture progression. The loads are pressure and temperature which varies from 21 to 65.5 C (case I) and from 143.3 to 21 C (case II). An integrated computer code is used for the simulation of the damage progression. Results show that damage initiation begins at low load level, with matrix cracking at the 0 deg. (bottom and top) plies, fiber fracture at the bottom (0 deg.) ply and interply delamination at the top (0 deg. ) ply. Increasing the applied pressure, the damage growth is expended resulting in fracture through the thickness of the structure. At this stage, 90 percent of the plies damage at applied pressure 15.306 MPa for the case I and 15.036 MPa for the case II. After this stage the cracks propagate rapidly and the structure collapses.

Gotsis, Pascalis K.↗