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DOE OSTI2024

Quarterly Research Performance Progress Report (Q8)

As part of Task 1, we have started by testing our modeling capabilities by reproducing isothermal DFIT simulations presented in the literature. Once satisfied with the results we have started by targeting the modeling of the DFITs at conducted at well 58-32. We have a identified a specific test (cycle 4 in zone 2) as the most interesting to be model with GEOS hydraulic fracturing module. Thus, we have first produced results with an isothermal model and adjusted model parameters to get a satisfying match with field pressure data. The, we have added thermal effects and compared the modeling results with and without thermal effects to estimate how thermal effects may influence test interpretation. Models seem to suggest that, for small volumes of fluid, thermal effects are moderate. In Task 2, we have adapted GEOS phase-field formulation to be able to simulate near-wellbore hydraulic fracture nucleation and propagation. We have devised a novel formulation that, compared to other existing ones, incorporates rock strengths. We have submitted a journal publication about our work. We are currently employing this phase-field formulation to model the experiments taking place at U Pitt and help us understand the effect of various parameters. In Task 3, we have built a model of the region surround well 16A and have started modeling stage 3 stimulation because of its simpler planar geometry. After calibrating simulation parameters using known analytical solutions, we have simulated the stage 3 stimulation using our isothermal hydraulic fracturing module, varying the permeability field, the stress conditions including different physics to get a better understanding of the numerical challenges and of the effects of varying these parameters on the simulation results. In Task 4 laboratory experimentation, a set of specialized drilling and injection tools has been customized and constructed to accommodate an inclined well with an orientation of up to 30 degrees relative to material anisotropy or principal stress axes. These inclined samples have also undergone thermal stress and hydraulic fracturing at a temperature of 190 degrees Celsius. Furthermore, both vertical and deviated sampling testing setups enable an extended analysis of post-peak pressure behaviors, facilitating post-test pressure analyses such as the G-function, step rate, and fracture reopening measurements. Thus, the key components of in-situ stress estimation can be extracted and validated through our experiment, providing a solid foundation for validating existing in-situ stress estimation theories or proposing new ones. Simultaneously, we are integrating computer vision techniques with traditional experimental fracture observation methods such as multi-overcore/slicing and water-penetration fracture observation. This combination will prove beneficial in populating the hydraulic fracture patterns database, generated under challenging EGS conditions. This approach aims to deepen our understanding of the complexities in EGS reservoirs and pave the way for future data-driven investigations. Additionally, PITT has also equipped the ELE International compression machine, which is now prepared for conducting indirect tensile and fracture toughness tests. These tests will aid in characterizing how rock fabrics influence the resulting fracture patterns. Additionally, we have completed the required personnel training and gained access to Scanning Electron Microscopy (SEM) and Energy Dispersive Spectroscopy (EDS) for conducting more detailed characterization and analysis of rock fabrics, as well as the examination of thermal and hydraulically induced fracture patterns. Thus, the PITT team has effectively demonstrated the capabilities of our experimental apparatuses in exploring the thermal effects, well deviation angles, material anisotropy, and operational choices (such as circulation rate, injection fluid viscosity, and injection rate) and their impact on pressure responses and fracture trajectories under the Utah FORGE conditions.

15 GEOTHERMAL ENERGY↗

DOE OSTI2020

Deep hybrid modeling of chemical process: Application to hydraulic fracturing

Not Available

Bangi, Mohammed Saad Faizan↗

DOE OSTI2021

Numerical and Analytical Modeling of Flow Partitioning in Partially Saturated Fracture Networks

Infiltration processes in fractured-porous media remain a crucial, yet not very well understood component of recharge and vulnerability assessment. Under partially-saturated conditions flows in fractures, percolating fracture networks, and fault zones contribute to the fastest spectrum of infiltration velocities via preferential pathways. Specifically, the partitioning dynamics at fracture intersections determine the magnitude of flow fragmentation into vertical and horizontal components and hence the bulk flow velocity and dispersion of fracture networks. In this work, we derive an approximate analytical solution for the partitioning process and validate it using smoothed particle hydrodynamics simulations. The developed transfer function is conceptually based on simulation results and laboratory experiments carried out in previous works. It allows to efficiently simulate flow through fracture networks with simple cubic structure and arbitrary number of fractures and aperture sizes via linear response theory and convolution of a given input signal. We derive a non-dimensional bulk flow velocity ($\widetilde{v}$) and dispersion coefficient ($\widetilde{D}$) to characterize fracture networks in terms of dimensionless horizontal and vertical time scales $\tau_m$ and $\tau_0$. The dispersion coefficient is shown to strongly depend on the horizontal time scale and converges towards a constant value of $0.08$ within reasonable fluid and geometrical parameter ranges, while the non-dimensional velocity exhibits a characteristic $\widetilde{v} \sim \tau_m^{-1/2}$ scaling. Given that hydraulic information is often only available at limited places within (fractured-porous) aquifer system, such as boreholes or springs, our study intends to provide a rudimentary analytical concept to potentially reconstruct internal fracture network geometries from external boundary information, e.g., the dispersive properties of discharge (groundwater level fluctuations).

42 ENGINEERING↗

NASA NTRS1982

Micromechanical predictions of crack propagation and fracture energy in a single fiber boron/aluminum model composite

The axisymmetric finite element model and associated computer program developed for the analysis of crack propagation in a composite consisting of a single broken fiber in an annular sheath of matrix material was extended to include a constant displacement boundary condition during an increment of crack propagation. The constant displacement condition permits the growth of a stable crack, as opposed to the catastropic failure in an earlier version. The finite element model was refined to respond more accurately to the high stresses and steep stress gradients near the broken fiber end. The accuracy and effectiveness of the conventional constant strain axisymmetric element for crack problems was established by solving the classical problem of a penny-shaped crack in a thick cylindrical rod under axial tension. The stress intensity factors predicted by the present finite element model are compared with existing continuum results.

Adams, D. F.↗

NASA NTRS2003

Modeling of High-Strain-Rate Deformation, Fracture, and Impact Behavior of Advanced Gas Turbine Engine Materials at Low and Elevated Temperatures

Gamma titanium aluminides have received considerable attention over the last decade. These alloys are known to have low density, good high temperature strength retention, and good oxidation and corrosion resistance. However, poor ductility and low fracture toughness have been the key limiting factors in the full utilization of these alloys. More recently, Gamma-met PX has been developed by GKSS, Germany. These alloys have been observed to have superior strengths at elevated temperatures and quasi-static deformation rates and good oxidation resistance at elevated temperatures when compared with other gamma titanium aluminides. The present paper discusses results of a study to understand dynamic response of gamma-met PX in uniaxial compression. The experiments were conducted by using a modified split Hopkinson pressure bar between room temperature and 900 C and strain rates of up to 3500 per second. The Gamma met PX alloy showed superior strength when compared to nickel based superalloys and other gamma titanium aluminides at all test temperatures. It also showed strain and strain-rate hardening at all levels of strain rates and temperatures and without yield anomaly up to 900 C. After approximately 600 C, thermal softening is observed at all strain rates with the rate of thermal softening increasing dramatically between 800 and 900 C. However, these flow stress levels are comparatively higher in Gamma met PX than those observed for other TiAl alloys.

Shazly, Mostafa↗

DOE OSTI2022

Sensitivity analysis applied to SiC failure probability in TRISO modeled with BISON

Here, a sensitivity analysis on the failure probability of the Silicon Carbide (SiC) layer in tristructural isotropic (TRISO) nuclear fuel during transient conditions predicted by the BISON fuel performance code is performed. The principal goal of the analysis is to understand the most important parameters dictating SiC failure behavior in BISON during Reactivity Initiated Accidents (RIAs). SiC brittle fracture probability is modeled using Weibull statistics. A total of seven inputs related to SiC failure has been selected for the analysis, including the Weibull statistics parameters, elastic moduli for SiC and Pyrolitic Carbon (PyC) and SiC stress-free temperature. A 1D TRISO BISON model has been established for various reactivity insertions performed at the Nuclear Safety Research Reactor (NSRR). The principal advantage associated with the 1D TRISO model developed in this work is its computational efficiency. The Sobol variance decomposition method is used, and the sensitivity indices are presented for eight different values of the energy deposition. The results show that the two most important parameters impacting the predicted SiC failure probability are the Weibull modulus and the characteristic stress, and a co-variance amongst these parameters is obtained for low reactivity insertions. An additional new finding of this work is that the relative importance of Weibull parameters depends on the energy deposition, and thus reactivity, regime. For low energy depositions, two parameters are of influence on SiC failure probability, while for high energy depositions only one parameter impacts failure probability results. Moreover, optimization of the Weibull modulus and characteristic stress is performed by minimizing the RMSE between BISON failure probability predictions and experimental failure fractions for each energy deposition. This work also demonstrates the validity of the NSRR tests BISON simulations and of the respective sensitivity analysis results as conservative, yet indicative for slower transients characterized by lower deposited energies. Such verification is achieved through the partial extension of the analysis to a group Control Rod Withdrawal reproduced from a previous study. Another novel result of this analysis is that no single set of Weibull parameters can reproduce all reactivity insertion experimental failure results, which is related to the intrinsic nature of SiC failure properties, and a new range for the parameters is proposed to produce a failure probability envelope that encompasses the experimental fractions. Additionaly, this work proposes a new approach for future failure analysis with BISON, consisting in the use of Weibull parameters ranges, rather than fixed sets, along with failure envelopes generation.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2020

Multi-Scale Microfluidics for Transport in Shale Fabric

We develop a microfluidic experimental platform to study solute transport in multi-scale fracture networks with a disparity of spatial scales ranging between two and five orders of magnitude. Using the experimental scaling relationship observed in Marcellus shales between fracture aperture and frequency, the microfluidic design of the fracture network spans all length scales from the micron (1 μ) to the dm (10 dm). This intentional `tyranny of scales’ in the design, a determining feature of shale fabric, introduces unique complexities during microchip fabrication, microfluidic flow-through experiments, imaging, data acquisition and interpretation. Here, we establish best practices to achieve a reliable experimental protocol, critical for reproducible studies involving multi-scale physical micromodels spanning from the Darcy- to the pore-scale (dm to μm). With this protocol, two fracture networks are created: a macrofracture network with fracture apertures between 5 and 500 μm and a microfracture network with fracture apertures between 1 and 500 μm. The latter includes the addition of 1 μm ‘microfractures’, at a bearing of 55°, to the backbone of the former. Comparative analysis of the breakthrough curves measured at corresponding locations along primary, secondary and tertiary fractures in both models allows one to assess the scale and the conditions at which microfractures may impact passive transport.

58 GEOSCIENCES↗

DOE OSTI2021

Fracture Sustainability in Enhanced Geothermal Systems: Experimental and Modeling Constraints

Enhanced geothermal systems (EGS) offer the potential for a much larger energy source than conventional hydrothermal systems. Hot, low-permeability rocks are prevalent at depth around the world, but the challenge of extracting thermal energy depends on the ability to create and sustain open fracture networks. Laboratory experiments were conducted using a suite of selected rock cores (granite, metasediment, rhyolite ash-flow tuff, and silicified rhyolitic tuff) at relevant pressures (uniaxial loading up to 20.7 MPa and fluid pressures up to 10.3 MPa) and temperatures (150–250 °C) to evaluate the potential impacts of circulating fluids through fractured rock by monitoring changes in fracture aperture, mineralogy, permeability, and fluid chemistry. Because a fluid in disequilibrium with the rocks (deionized water) was used for these experiments, there was net dissolution of the rock sample: this increased with increasing temperature and experiment duration. Thermal-hydrological-mechanical-chemical (THMC) modeling simulations were performed for the rhyolite ash-flow tuff experiment to test the ability to predict the observed changes. These simulations were performed in two steps: a thermal-hydrological-mechanical (THM) simulation to evaluate the effects of compression of the fracture, and a thermal-hydrological-chemical (THC) simulation to evaluate the effects of hydrothermal reactions on the fracture mineralogy, porosity, and permeability. Furthermore, these experiments and simulations point out how differences in rock mineralogy, fluid chemistry, and geomechanical properties influence how long asperity-propped fracture apertures may be sustained. Such core-scale experiments and simulations can be used to predict EGS reservoir behavior on the field scale.

15 GEOTHERMAL ENERGY↗

NASA NTRS2018

Reactive Transport and Mass Balance Modeling of the Stimson Sedimentary Formation and Altered Fracture Zones Constrain Diagenetic Conditions at Gale Crater, Mars

On a planet as cold and dry as present-day Mars, evidence of multiple aqueous episodes offers an intriguing view into very different past environments. Fluvial, lacustrine, and eolian depositional environments are being investigated by the Mars Science Laboratory Curiosityin Gale crater, Mars. Geochemical and mineralogical observations of these sedimentary rocks suggest diagenetic processes affected the sediments. Here, we analyze diagenesis of the Stimson formation eolian parent material, which caused loss of olivine and formation of magnetite. Additional, later alteration in fracture zones resulted in preferential dissolution of pyroxene and precipitation of secondary amorphous silica and Ca sulfate. The ability to compare the unaltered parent material with the reacted material allows constraints to be placed on the characteristics of the altering solutions. In this work we use a combination of a mass balance approach calculating the fraction of a mobile element lost or gained, τ, with fundamental geochemical kinetics and thermodynamics in the reactive transport code CrunchFlow to examine the characteristics of multiple stages of aqueous alteration at Gale crater, Mars. Our model results indicate that early diagenesis of the Stimson sedimentary formation is consistent with leaching of an eolian deposit by a near-neutral solution, and that formation of the altered fracture zones is consistent with a very acidic, high sulfate solution containing Ca, P and Si. These results indicate a range of past aqueous conditions occurring at Gale crater, Mars, with important implications for past Martian climate and environments.

Gale crater↗

NASA NTRS1974

The surface geometry of inherited joint and fracture trace patterns resulting from active and passive deformation

Hypothetical models are considered for detecting subsurface structure from the fracture or joint pattern, which may be influenced by the structure and propagated to the surface. Various patterns of an initially orthogonal fracture grid are modeled according to active and passive deformation mechanisms. In the active periclinal structure with a vertical axis, fracture frequency increased both over the dome and basin, and remained constant with decreasing depth to the structure. For passive periclinal features such as a reef or sand body, fracture frequency is determined by the arc of curvature and showed a reduction over the reefmound and increased over the basin.

Podwysocki, M. H.↗

DOE OSTI2020

Optimal pumping schedule with high-viscosity gel for uniform distribution of proppant in unconventional reservoirs

Hydrocarbon recovery from a hydraulic-fractured unconventional reservoir can be enhanced by replacing slickwater with non-Newtonian high-viscosity gel as a fracturing fluid. However, in the literature, the role of gel rheology on hydrocarbon production from a fractured reservoir is not very well understood. This lack of understanding makes it difficult for the industry to choose appropriate viscosity parameters of fracturing gels. Motivated by these limitations, first, we have developed a high-fidelity model of non-Newtonian fluid flow to simulate fracture propagation, fluid leak-off, and gel flowback processes to predict the oil production from a hydraulic fractured reservoir. Simulation results of the high-fidelity model show how fracture geometry, formation damage, and gel cleanup process varies with the fracturing fluid rheology. Therefore, the developed model is used to understand the effect of gel rheology on hydrocarbon production via a sensitivity analysis, which provides a set of rheological parameters that maximize the cumulative amount of oil production. Finally, utilizing this optimal high-viscosity gel, a model predictive controller is designed to obtain an optimal pumping schedule necessary for producing a target fracture geometry and proppant concentration. The closed-loop simulation results demonstrate that the obtained pumping schedule successfully achieved the desired fracture geometry and proppant concentration at the end of pumping, leading to the maximum oil production from an unconventional reservoir.

13 HYDRO ENERGY↗

DOE OSTI2021

Characterizing Reactive Transport Behavior in a Three-Dimensional Discrete Fracture Network

While several studies have linked network and in-fracture scale properties to conservative transport behavior in subsurface fractured media, studies on reactive transport cases remain relatively underdeveloped. In this study, we explore the behavior of an irreversible kinetic reaction during the interaction of two solute plumes, one consisting of species A and the other species B. When the plumes converge, these species react kinetically to form a new species C via A+B→kC. This reactive system is studied using a three-dimensional discrete fracture network (DFN) model coupled with reactive Lagrangian particle tracking. We find that the interplay of network topology and chemical properties of the reactive solutes controls reactive transport processes. The network topology drives species A and B together, and the chemical properties dictate whether and how quickly a reaction occurs. Results demonstrate that reactions are most likely to occur in high-velocity fractures that make up the network backbone. The interplay between species’ chemical properties and transport is characterized by a non-dimensional Damköhler (Da) number. We show that the spatial distribution of reactions is sensitive to Da, which subsequently influences late-time tailing behavior in outlet breakthrough time distributions. The results of this study provide initial insights into how an irreversible reaction occurs during transport in a fracture network, using a methodology that can be applied to study reactive transport in a wide range of fractured media environments and contexts.

58 GEOSCIENCES↗

NASA NTRS2006

Impact Damage and Strain Rate Effects for Toughened Epoxy Composite Structures

Structural integrity of composite systems under dynamic impact loading is investigated herein. The GENOA virtual testing software environment is used to implement the effects of dynamic loading on fracture progression and damage tolerance. Combinations of graphite and glass fibers with a toughened epoxy matrix are investigated. The effect of a ceramic coating for the absorption of impact energy is also included. Impact and post impact simulations include verification and prediction of (1) Load and Impact Energy, (2) Impact Damage Size, (3) Maximum Impact Peak Load, (4) Residual Strength, (5) Maximum Displacement, (6) Contribution of Failure Modes to Failure Mechanisms, (7) Prediction of Impact Load Versus Time, and (8) Damage, and Fracture Pattern. A computer model is utilized for the assessment of structural response, progressive fracture, and defect/damage tolerance characteristics. Results show the damage progression sequence and the changes in the structural response characteristics due to dynamic impact. The fundamental premise of computational simulation is that the complete evaluation of composite fracture requires an assessment of ply and subply level damage/fracture processes as the structure is subjected to loads. Simulation results for the graphite/epoxy composite were compared with the impact and tension failure test data, correlation and verification was obtained that included: (1) impact energy, (2) damage size, (3) maximum impact peak load, (4) residual strength, (5) maximum displacement, and (6) failure mechanisms of the composite structure.

Chamis, Christos C.↗

NASA NTRS2004

Analysis of Europan Cycloid Morphology and Implications for Formation Mechanisms

Europa's highly fractured crust has been shown to contain features with a range of differing morphologies. Most lineaments on Europa are believed to have initiated as cracks, although the type of cracking (e.g. tensile vs. shear) remains unclear and may vary for different morphologies. Arcuate lineaments, called cycloids or flexi, have been observed in nearly all imaged regions of Europa and have been modeled as tensile fractures that were initiated in response to diurnal variations in tides. Despite this hypothesis about the formation mechanism, there have been no detailed analyses of the variable morphologies of cycloids. We have examined Galileo images of numerous locations on Europa to develop a catalog of the different morphologies of cycloids. This study focuses on variations in morphology along individual cycloid segments and differences in cusp styles between segments, while illustrating how morphologic evidence can help unravel formation mechanisms. In so doing, we present evidence for cycloid cusps forming due to secondary fracturing during strike-slip sliding on pre-existing cycloid segments.

Marshall, S. T.↗

NASA NTRS1985

SCARE: A post-processor program to MSC/NASTRAN for the reliability analysis of structural ceramic components

A computer program was developed for calculating the statistical fast fracture reliability and failure probability of ceramic components. The program includes the two-parameter Weibull material fracture strength distribution model, using the principle of independent action for polyaxial stress states and Batdorf's shear-sensitive as well as shear-insensitive crack theories, all for volume distributed flaws in macroscopically isotropic solids. Both penny-shaped cracks and Griffith cracks are included in the Batdorf shear-sensitive crack response calculations, using Griffith's maximum tensile stress or critical coplanar strain energy release rate criteria to predict mixed mode fracture. Weibull material parameters can also be calculated from modulus of rupture bar tests, using the least squares method with known specimen geometry and fracture data. The reliability prediction analysis uses MSC/NASTRAN stress, temperature and volume output, obtained from the use of three-dimensional, quadratic, isoparametric, or axisymmetric finite elements. The statistical fast fracture theories employed, along with selected input and output formats and options, are summarized. An example problem to demonstrate various features of the program is included.

Gyekenyesi, J. P.↗

NASA NTRS1986

SCARE - A postprocessor program to MSC/NASTRAN for reliability analysis of structural ceramic components

Gyekenyesi, J. P.↗

DOE OSTI2020

Hydraulic fracturing to enhance injectivity and storage capacity of CO 2 storage reservoirs: Benefits and risks

Several potential CO 2 storage reservoirs have been found to have insufficient porosity and permeability to support cost effective commercial-scale injection. As a result, the use of hydraulic fracturing to enhance injectivity and storage capacity of CO 2 storage reservoirs was explored. Previous modeling studies indicate that fracturing can increase storage capacity by modest to significant amounts (10%–35%), depending on model assumptions. Simulations completed as part of this study confirm that for a range of horizontal well lengths, number of fractures, fracture geometries, and fracture properties, injectivity is improved and capacity increases by 13%–71% over the base case unfractured vertical well. Intuitively, increasing the well length and number of fractures had a corresponding impact on increased capacity. Here, fracture area (i.e., the fracture height multiplied by its width) was an important parameter for increasing capacity but the specific geometry (e.g., the ratio of height-to-width) was unimportant. The most important aspect that affected capacity was the ability of a fracture to connect high permeability horizontal zones in the reservoir. This would allow a single well to access both layers, thereby maximizing total storage capacity of the reservoir while likely leading to an overall increase of the CO 2 footprint, which is an important consideration for Class VI UIC permitting. The results of this work demonstrate that hydraulic fracturing is an attractive option to consider when faced with an underperforming geologic carbon storage site that is at risk of causing a project to fail.

03 NATURAL GAS↗

DOE OSTI2020

Investigation of Failure Modes, Mechanisms and Driving Forces for Electrically Conductive Adhesives as Interconnects in PV Modules

In this work we describe our current progress into investigating the reliability of ECA interconnects for PV modules. Preliminary thermal cycling experiments demonstrated that both cohesive and adhesive failure of the ECA joint are relevant failure modes that result in an increase of the joints electrical resistance. A thorough viscoelastic characterization of the candidate ECA was conducted to enable accurate numerical modeling of the joint’s response to thermal cycling. Combined with critical and subcritical fracture measurements, the numerical model elucidates that an additional fatigue mechanism exists which can result in fracture well below subcritical debonding threshold values. It is also demonstrated that fracture of the ECA is more sensitive to humidity than temperature and subcritical debonding mechanisms do exist which are again more sensitive to humidity.

41 EE - Solar Energy Technologies Office (EE-4S)↗