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A Non-Invasive Approach for Elucidating the Spatial Distribution of In-Situ Stress in Deep Subsurface Geologic Formations Considered for CO 2 Storage (Final Report)

The primary objectives of this project were to: develop a new, non-invasive method to define the orientation and magnitude of in-situ stresses in deep geologic formations (depths that exceed 1500 meters) considered for carbon dioxide (CO 2 ) sequestration; to demonstrate the method at a real field site; and, to extend current technical capabilities and reduce costs of acquiring information about deep-stress fields. This investigation was segmented into five tasks, including Project Management (Task 1) and four technical tasks (Tasks 2 through 5). The results of the technical tasks are described in this document.

02 PETROLEUM↗

Stress engineering for crack and dendrite prevention in solid electrolytes via ion implantation

Solid-state batteries represent a promising technology that offers safer and more densely packed energy storage. A primary cause of failure in solid-state cells is the penetration of metal dendrites through the solid electrolyte. Here, we report that fluorine-ion implantation can enhance the mechanical resistance of solid electrolyte Li 6.5 La 3 Zr 1.5 Ta 0.5 O 12 to dendrite propagation by inducing residual compressive stress in the subsurface of the electrolyte. Ion implantation modifies subsurface residual stress and also alters the electrolyte’s surface, resulting in multifunctional enhancement. The combined chemical and mechanical effects of ion implantation enable reversible lithium metal stripping and plating at elevated current densities while enhancing air stability and mitigating the formation of a harmful carbonate layer at the surface. This study provides new insights into a scalable dendrite-suppression strategy for designing solid-state batteries suitable for cycling at room temperature and low stack pressures.

25 ENERGY STORAGE↗

A Bayesian Approach for In-Situ Stress Prediction and Uncertainty Quantification for Subsurface Engineering

Many subsurface engineering applications require accurate knowledge of the in-situ state of stress for their safe design and operation. Existing methods to meet this need primarily include field measurements for estimating one or more of the principal stresses from a borehole, or optimization methods for constructing a 3D geomechanical model in terms of geophysical measurements. These methods, however, often contain considerable uncertainty in estimating the state of stress. Here, in this paper, we build on a Bayesian approach to quantify uncertainty in stress estimations for subsurface engineering applications. This approach can provide an estimate of the 3D distribution of stress throughout the volume of interest and provide an estimate of the uncertainty arising from the stress measurement, the rheology parameters, and a paucity of measurements. The value of this approach is demonstrated using stress measurements from the In Salah carbon storage site, which was one of the world’s first industrial carbon capture and storage projects. This demonstration shows the application of this Bayesian approach for estimating the initial state of stress for In Salah and quantifying the uncertainty in the estimated stress. Also, an assessment of a maximum injection pressure to prevent geomechanical risks from CO 2 injection pressures is provided in terms of the probability distribution of the minimum principal stress quantified by the approach. With the In Salah case study, this paper demonstrates that using the Bayesian approach can provide additional insights for site explorations and/or project operations to make informed-site decisions for subsurface engineering applications.

58 GEOSCIENCES↗

Relation Between Residual and Hoop Stresses and Rolling Bearing Fatigue Life

Rolling-element bearings operated at high speed or high vibration may require a tight interference fit between the bore of the bearing and shaft to prevent rotation of the bearing bore around the shaft and fretting damage at the interfaces. Previous work showed that the hoop stresses resulting from tight interference fits can reduce bearing lives by as much as 65 percent. Where tight interference fits are required, case-carburized steel such as AISI 9310 or M50 NiL is often used because the compressive residual stresses inhibit subsurface crack formation and the ductile core inhibits inner-ring fracture. The presence of compressive residual stress and its combination with hoop stress also modifies the Hertz stress-life relation. This paper analyzes the beneficial effect of residual stresses on rolling-element bearing fatigue life in the presence of high hoop stresses for three bearing steels. These additional stresses were superimposed on Hertzian principal stresses to calculate the inner-race maximum shearing stress and the resulting fatigue life of the bearing. The load-life exponent p and Hertz stress-life exponent n increase in the presence of compressive residual stress, which yields increased life, particularly at lower stress levels. The Zaretsky life equation is described and is shown to predict longer bearing lives and greater load- and stress-life exponents, which better predicts observed life of bearings made from vacuum-processed steel.

Fatigue↗

Simplified solution for stresses and deformations

A shortcut is presented to the classical Hertzian solution for local stress and deformation of two elastic bodies in contact, which employs simplified forms for the ellipticity and for the complete elliptic integrals of the first and second kinds as a function of the geometry. Unlike previously proposed simplified formulas whose range of applicability was limited to ellipticities equal to, or greater than one, the present method extends the range of validity to include ellipticities less than one; in which the semimajor axis in the elliptical contact lies in a direction parallel to the rolling, rather than being perpendicular, as in previous studies. An auxiliary shear stress parameter is also expressed in simplified form as a function of the geometry, permitting a shortcut calculation to be made for the location and magnitude of the maximum subsurface shear stress.

Hamrock, B. J.↗

Experimental study of fracture slip due to stress perturbation in fractured geo-resources

Anthropogenic activities such as underground fluid injection/extraction, well stimulation, and dam impoundment will perturb the state-of-stress in the subsurface, which could activate critically stressed pre-existing fractures and faults. Fault and fracture activation can induce seismicity, change flow behavior, and damage asperities on the fracture surface to alter reservoir permeability. Here, in this study, triaxial shear tests were conducted on saw cut and rough fracture Barre granite specimens to better characterize how a decrease in normal stress and increase in shear stress will influence crystalline rock fracture hydromechanical properties. In a triaxial set up, confining pressure (CP) and differential stress (DS) were used to induce normal and shear stress on a 45° oriented fracture. Fracture slip and the corresponding stress relaxation was observed when the confining stress decreased. Fracture permeability increased when the fracture slipped. Moreover, new micro-cracks observed by x-ray images indicated the creation of new flow paths for fluid movement. The experimental outcomes of this study indicate that decrease in normal stress due to stress perturbations along the faults/fractures in the extensional stress regime can induce the slip along the fracture. This could have a significant influence on slope stability in quarries, stimulation and injection strategy in deep geo-resources, and potentially minimize the risk of induced seismicity. The observed stress dependency of hydraulic aperture in rough fracture during pre- and post-slip stages could provide key inputs for field-scale simulation of geo-resources.

58 GEOSCIENCES↗

Surface fatigue life of CBN and vitreous ground carburized and hardened AISI 9310 spur gears

Spur gear surface endurance tests were conducted to investigate CBN ground AISI 9310 spur gears for use in aircraft applications, to determine their endurance characteristics and to compare the results with the endurance of standard vitreous ground AISI 9310 spur gears. Tests were conducted with VIM-VAR AISI 9310 carburized and hardened gears that were finish ground with either CBN or vitreous grinding methods. Test conditions were an inlet oil temeprature of 320 K (116 F), an outlet oil temperature of 350 K (170 F), a maximum Hertz stress of 1.71 GPa (248 ksi), and a speed of 10,000 rpm. The CBN ground gears exhibited a surface fatigue life that was slightly better than the vitreous ground gears. The subsurface residual stress of the CBN ground gears was approximately the same as that for the standard vitreous ground gears for the CBN grinding method used.

Townsend, Dennis P.↗

Fretting Stresses in Single Crystal Superalloy Turbine Blade Attachments

Single crystal nickel base superalloy turbine blades are being utilized in rocket engine turbopumps and turbine engines because of their superior creep, stress rupture, melt resistance and thermomechanical fatigue capabilities over polycrystalline alloys. Currently the most widely used single crystal nickel base turbine blade superalloys are PWA 1480/1493 and PWA 1484. These alloys play an important role in commercial, military and space propulsion systems. High Cycle Fatigue (HCF) induced failures in aircraft gas turbine and rocket engine turbopump blades is a pervasive problem. Blade attachment regions are prone to fretting fatigue failures. Single crystal nickel base superalloy turbine blades are especially prone to fretting damage because the subsurface shear stresses induced by fretting action at the attachment regions can result in crystallographic initiation and crack growth along octahedral planes. Furthermore, crystallographic crack growth on octahedral planes under fretting induced mixed mode loading can be an order of magnitude faster than under pure mode I loading. This paper presents contact stress evaluation in the attachment region for single crystal turbine blades used in the NASA alternate Advanced High Pressure Fuel Turbo Pump (HPFTP/AT) for the Space Shuttle Main Engine (SSME). Single crystal materials have highly orthotropic properties making the position of the crystal lattice relative to the part geometry a significant factor in the overall analysis. Blades and the attachment region are modeled using a large-scale 3D finite element (FE) model capable of accounting for contact friction, material orthotrophy, and variation in primary and secondary crystal orientation. Contact stress analysis in the blade attachment regions is presented as a function of coefficient of friction and primary and secondary crystal orientation, Stress results are used to discuss fretting fatigue failure analysis of SSME blades. Attachment stresses are seen to reach peak values at locations where fretting cracks have been observed. Fretting stresses at the attachment region are seen to vary significantly as a function of crystal orientation. Attempts to adapt techniques used for estimating fatigue life in the airfoil region, for life calculations in the attachment region, are presented. An effective model for predicting crystallographic crack initiation under mixed mode loading is required for life prediction under fretting action.

Arakere, Nagaraj K.↗

Hawai‘i Play Fairway (Final Report)

Most of Hawai'i's geothermal resources are blind—their manifestations, such as hot springs and steam vents, do not appear on the ground surface because the heated water flows far below. With the exception of $K\bar{i}lauea East Rift Zone$, in most areas of Hawai'i, high lateral permeability in the first kilometer below ground surface prevents surface thermal features from developing. As a methodology for discovering these blind resources, Play Fairway Analysis (PFA) involves finding potential locations of blind hydrothermal systems and describing potential geothermal sources in rift-zone settings. Using the PFA to find Hawai'i's geothermal resources, the University of Hawai'i (UH) conducted the Hawai‘i Play Fairway Project, Hawai'i's first statewide geothermal resource assessment since 1985. Sponsored by the U.S. Department of Energy, the Hawai'i Play Fairway Project provided an updated resource assessment, a roadmap for additional exploration activities, and the identification of areas for further exploration. Benefitting from UH's core competency in earth sciences and experienced geothermal researchers, the project comprised three phases. During the first phase, the team identified, compiled, and ranked existing geologic, groundwater, and geophysical datasets relevant to subsurface heat, fluid and permeability. Using a Bayesian statistical approach, the team developed a statistical methodology to integrate these data into a resource probability map. The team evaluated the confidence in the probability value and considered development viability of areas with geothermal resources. With these analyses, the team identified 10 locations in the Hawaiian Islands for exploration activities. For the second phase, the team collected new groundwater data in 10 locations across the state and new geophysical data on $L\bar{a}na‘i, Maui$, and central Hawai'i Island and modeled topographically induced stress to better characterize subsurface permeability. Analyzing the subsurface stresses, the team evaluated the potential for fracture-induced permeability. The team inverted the MT and gravity data to produce 3D models of resistivity and density, respectively, on $L\bar{a}na‘i$, across $Haleakal\bar{a}'s$ SW rift (Maui), and surrounding Mauna Kea (Hawai‘i Island). The team developed and applied a new method for incorporating depth information about resistivity, density, and potential for fracture-induced permeability into the statistical method for computing resource probability in these three focus areas. The team incorporated the new groundwater results with the new geophysical results and the calculations of potential for fracture-induced permeability to produce updated maps of resource probability and confidence. Through combining data from the first and second phases, the team determined locations for further exploration during the third phase. For MT and gravity surveys, the team recommended $Kaua'i's$ $L\bar{i}hu'e$ $Basin$, the east rift of $Maui's$ $Haleakal\bar{a}$ volcano, and the southwest rift of Hawai'i Island's Mauna Loa volcano. The MT and gravity surveys aimed to enable improved confidence in the resource potential in these locations. For drilling deep groundwater well(s), the team recommended Southeast Mauna Kea and $L\bar{a}na's$ $P\bar{a}l\bar{a}wai$ $Basin$. During the third phase, further exploration involved drilling a groundwater well in $L\bar{a}na's$ $P\bar{a}l\bar{a}wai$ $Basin$ and performing more geophysical surveys. We deepened an existing water well proximal to our target area on $L\bar{a}na'i$ due to funding constraints that precluded us from spudding a new well that would exceed 1km depth. Drilling was preceded by a number of substantial elements including: writing an Environmental Assessment and the subsequent legal process, performance of deviation logging, lowering a camera down the well, coordinating site preparation with $P\bar{u}lama$ $L\bar{a}na'i$, shipping the UH-owned rig interisland, procuring supplies, and leading 3 community meetings on $L\bar{a}na'i$. Drilling occurred 24/7 the entire month of June 2019 over which time $L\bar{a}na'i$ $Well$ 10 was deepened from 427 m to 1057 m, with continuous core collected. We measured a roughly linear temperature gradient averaging 42°C/km and a maximum bottom hole temperature of 66°C. This gradient is more than twice the background for Hawai'i and within a range of gradients measured in this depth range for some exploration wells within KERZ. We consider these results encouraging for $L\bar{a}na'i's$ resource potential and recommend following with a slim hole within $L\bar{a}na'i's$ caldera (our target zone) to ~ 2 km. Further, the positive implications such results have for the island of O‘ahu are substantial - the shield stage of O'ahu's volcanoes ended 1-2 My earlier. However, O'ahu uses more electricity than the rest of the islands combined, and the utility recently called for 500-700MW of firm, dispatchable renewable electricity on O'ahu by 2033. In Phase 3, we also collected limited new encouraging groundwater data, and updated our thoughts on the probabilities of fluid and permeability at resource depths (Pr F = 1; Pr P = mostly unconstrained). Ultimately, we advocate for using our final probability of heat, and confidence in this probability, to drive the next phase of exploration. We contend further development of geothermal in Hawai‘i will enable the state to achieve its 100% renewable policy objective and Hawai'i to transition off of fossil fuels through geothermal discovery and development. The project not only produced a large amount of data and expanded the existing knowledge of Hawai'i's geothermal resources, but also produced publications, theses, presentations, core photos, datasets, media reports, television interviews, community events, and a blog. Students and new professionals benefitted from the project's hands-on research experiences and educational opportunities and earned awards and recognition.

15 GEOTHERMAL ENERGY↗

Exploring Whether Subsurface Fluid Production Can Minimize Triggered Seismicity in Geothermal Fields

Fluid injection and production related to energy recovery and other industrial operations alter the pressure and stress state of subsurface reservoirs which can lead to induced seismicity. Here, the primary goal is to investigate the hypothesis that the modulation of stress state in subsurface reservoirs through fluid injection/production operations can reduce the likelihood of inducing seismicity. Validation of this mitigation strategy will provide an active operational method to control induced seismicity in subsurface reservoir exploitations such as geothermal energy recovery and carbon storage. In this project, we analyze the relationship between extensive fluid production and the paucity of aftershock activity at the Coso Geothermal plant (CGP) following the 2019 Ridgecrest earthquake sequence, where high rates of aftershock triggering were expected. We developed a high-fidelity multiphase coupled thermo-hydro-mechanical (THM) model to simulate fluid injection/production activities at the CGP between 1986 and 2020. THM results of surface subsidence due to high rates of fluid production agree well with field observations from global positioning system (GPS) and interferometric synthetic aperture radar (InSAR). Subsequently, the variations of pore pressure, temperature and stress state were used to drive numerical earthquake simulations of the aftershock response to the 2019 Ridgecrest earthquakes. The earthquake simulations show that seismic quiescence may occur following the Ridgecrest event, depending on the initial stress state at the time of the mainshock and at the initiation of geothermal energy production. Seismic quiescence occurs in 20% of the cases we explored, where rates are decreased by 50% of the background rate in the two years following the mainshock. In circumstances where aftershock rates increase near the CGP following Ridgecrest, the average rate change is a factor of two larger than background rates from simulations with no operations. These findings indicate that unlike many other operations that bring faults closer to failure, operations at the CGP are acting to stabilize faults such that triggering in the current stress state is minimal.

58 GEOSCIENCES↗

Residual Stress Measurements After Proof and Flight: ETP-0403

The intent of this testing was to evaluate the residual stresses that occur in and around the attachment details of a case stiffener segment that has been subjected to flight/recovery followed by proof loading. Not measured in this test were stresses relieved at joint disassembly due to out-of-round and interference effects, and those released by cutting the specimens out of the case segment. The test article was lightweight case stiffener segment 1U50715, S/N L023 which was flown in the forward stiffener position on flight SRM 14A and in the aft position on flight SRM24A. Both of these flights were flown with the 3 stiffener ring configuration. Stiffener L023 had a stiffener ring installed only on the aft stub in its first flight, and it had both rings installed on its second flight. No significant post flight damage was found on either flight. Finally, the segment was used on the DM-8 static test motor in the forward position. No stiffener rings were installed. It had only one proof pressurization prior to assignment to its first use, and it was cleaned and proof tested after each flight. Thus, the segment had seen 3 proof tests, two flight pressurizations, and two low intensity water impacts prior to manufacturing for use on DM-8. On DM-8 it received one static firing pressurization in the horizontal configuration. Residual stresses at the surface and in depth were evaluated by both the x-ray diffraction and neutron beam diffraction methods. The x-ray diffraction evaluations were conducted by Technology for Energy Corporation (TEC) at their facilities in Knoxville, TN. The neutron beam evaluations were done by Atomic Energy of Canada Limited (AECL) at the Chalk River Nuclear Laboratories in Ontario. The results showed general agreement with relatively high compressive residual stresses on the surface and moderate to low subsurface tensile residual stresses.

Webster, Ronald L..↗

Advanced Gear Alloys for Ultra High Strength Applications

Single tooth bending fatigue (STBF) test data of UHS Ferrium C61 and C64 alloys are presented in comparison with historical test data of conventional gear steels (9310 and Pyrowear 53) with comparable statistical analysis methods. Pitting and scoring tests of C61 and C64 are works in progress. Boeing statistical analysis of STBF test data for the four gear steels (C61, C64, 9310 and Pyrowear 53) indicates that the UHS grades exhibit increases in fatigue strength in the low cycle fatigue (LCF) regime. In the high cycle fatigue (HCF) regime, the UHS steels exhibit better mean fatigue strength endurance limit behavior (particularly as compared to Pyrowear 53). However, due to considerable scatter in the UHS test data, the anticipated overall benefits of the UHS grades in bending fatigue have not been fully demonstrated. Based on all the test data and on Boeing s analysis, C61 has been selected by Boeing as the gear steel for the final ERDS demonstrator test gearboxes. In terms of potential follow-up work, detailed physics-based, micromechanical analysis and modeling of the fatigue data would allow for a better understanding of the causes of the experimental scatter, and of the transition from high-stress LCF (surface-dominated) to low-stress HCF (subsurface-dominated) fatigue failure. Additional STBF test data and failure analysis work, particularly in the HCF regime and around the endurance limit stress, could allow for better statistical confidence and could reduce the observed effects of experimental test scatter. Finally, the need for further optimization of the residual compressive stress profiles of the UHS steels (resulting from carburization and peening) is noted, particularly for the case of the higher hardness C64 material.

Shen, Tony↗

Geothermal Deep Direct-Use for Low-Carbon Heating: A Case Study at Cornell University

Cornell University is developing a geothermal deep direct-use system to provide reliable, low carbon, and cost-competitive heating for its main campus in Ithaca, New York. This geothermal system, also referred to as Earth Source Heat, would provide the majority of the campus heating load and represents a key pillar for the university to become carbon neutral by 2035. Over the last 10 years, numerous desktop, seismic, and geophysical studies have been undertaken at Cornell to characterize the local subsurface, predict long-term reservoir performance, design the integration into the existing district heating network, and estimate capital and levelized costs. Recently, the university received funding for drilling an observatory well to obtain in-situ subsurface data (e.g., reservoir temperatures, pressures, fluid chemistry, stress field), significantly lowering subsurface uncertainty and de-risking the project. Drilling of the test well is planned for fall 2021. This paper provides an overview and status of the project, including a summary of past studies and a description of the proposed well and planned testing activities.

Cornell University↗

Modeling Validation of Mechanical and Thermal Borehole Breakouts From Polyaxial Laboratory Tests to Determine Maximum Horizontal in Situ Stress

To accurately assess rock behavior in the deep subsurface, it is necessary to measure the in situ stress directions and magnitudes. The current methods for measuring the in situ stress state in the deep subsurface primarily include hydraulic fracturing tests (i.e., the minimum horizontal stress) or occasionally observing existing compressive borehole breakouts (i.e., the maximum horizontal stress) that have occurred naturally from drilling. If there are no existing compressive breakouts in a borehole, the maximum horizontal in situ stress cannot be estimated with much confidence. In response to this data gap, a new thermal breakout technology is being developed that will provide a method for thermally inducing borehole breakouts and obtaining consistent measurements of the maximum horizontal stress magnitude. This thermal breakout technology involves heating the borehole and increasing the thermoelastic compressive stress in the rock until a breakout develops, which is directly correlated to the maximum horizontal stress magnitude. In support of developing the thermal breakout technology, polyaxial laboratory tests have been performed on small-scale boreholes within rock blocks where mechanically- and thermally-induced borehole breakouts have been created. Numerical models along with the principal of superposition were created and used to analyze the polyaxial laboratory tests to predict the maximum horizontal stress, given the same data that would be obtained in an actual subsurface borehole thermal breakout test. Multiple failure criteria were used to evaluate the best prediction of the breakout onset and maximum horizontal stress. The maximum horizontal stress predictions were compared to the actual maximum horizontal stress applied at breakout using acoustic events recorded from emission sensors in the polyaxial tests. The results showed consistent results that could be used to refine the modeling approach and failure criterion that are used to make the maximum horizontal stress predictions. This study provided insight and validation for the thermal breakout stress measurement concept.

Jones, Matt↗

Subsurface Cooling and Sea Surface Temperature Pattern Formation Over the Equatorial Pacific

Abstract The equatorial cold tongue region has not warmed up in response to historical radiative forcing in the real world, contrary to the strong warming often simulated by climate models. Here we demonstrate that climate models fail to represent one or both of the key processes driving observed sea surface temperature (SST) pattern formation: a realistic surface wind stress pattern shaping subsurface cooling through wind‐driven circulation changes, and effective connectivity between subsurface and surface temperatures via upwelling and mixing. Consequently, none of the models approximate the observed lack of cold tongue SST warming and strengthening of zonal SST gradient across the equatorial Pacific. Furthermore, those that come closest achieve this due to interhemispheric warming differences rather than equatorial dynamics as observed. Addressing different origins of subsurface cooling in observations and simulations, and how they connect to SST, will lead to improved understanding of tropical Pacific SST changes to date and how they will evolve in the future.

Jiang, Feng [Lamont‐Doherty Earth Observatory Colu↗