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DOE OSTI2015

Characterization of unsaturated hydraulic conductivity in fractured media using the multistep outflow method - 15461

The multistep outflow method is routinely used to characterize the unsaturated hydraulic conductivity of soils. The technique involves placing a soil sample in a pressure plate apparatus, subjecting the sample to multiple gas pressures in discrete steps through time, and measuring the transient volume of pore fluid extracted. Unsaturated hydraulic property values are estimated through inverse modeling of the experimental conditions. In this study the multistep outflow concept was applied to micro-cracked cementitious materials to assess the efficacy of the technique for these materials. The cementitious materials tested were salt-waste simulant grout samples artificially damaged through oven-drying. Compared to typical soils, fractured media exhibit higher saturated conductivity and lower air-entry pressure, and the volume of fluid extractable from fractures is much lower than soil porosity. To accommodate these material differences the standard test apparatus was modified to incorporate a higher conductivity ceramic pressure plate, a high-precision digital balance for logging outflow mass, a low volume (diameter) effluent line, multiple in-line high-precision gas regulators, and a high-precision low-range pressure gauge. Testing to date indicates that the modified apparatus can provide a viable means to measure the unsaturated hydraulic properties of micro-fractured cementitious materials. However the accuracy/uniqueness of inverse modeling is limited by the inherent characteristics of fractured media: high saturated conductivity, low air-entry pressure, and strong non-linearities. Hydraulic property results in the form of van Genuchten / Mualem curves are presented for three fractured grout specimens. DOE Performance Assessments often involve cementitious barriers and/or waste forms that are predicted or assumed to degrade over time due to various mechanisms such as carbonation-influenced reinforcing steel corrosion, external sulfate attack, differential settlement, and seismic activity. Physical degradation typically takes the form of small-scale cracking / fracturing, and the affected materials reside in unsaturated hydrogeologic zones. In these cases, unsaturated hydraulic properties are needed for fractured cementitious materials to simulate moisture movement and contaminant transport within and around the facility. The outflow extraction method, as implemented in the present study, provides a suitable method for estimating these material properties. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2017

Effect of water on critical and subcritical fracture properties of Woodford shale

Subcritical fracture behavior of shales under aqueous conditions is poorly characterized despite increased relevance to oil and gas resource development and seal integrity in waste disposal and subsurface carbon sequestration. In this paper, we measured subcritical fracture properties of Woodford shale in ambient air, dry CO 2 gas, and deionized water by using the double-torsion method. Compared to tests in ambient air, the presence of water reduces fracture toughness by 50%, subcritical index by 77%, and shear modulus by 27% and increases inelastic deformation. Comparison between test specimens coated with a hydrophobic agent and uncoated specimens demonstrates that the interaction of water with the bulk rock results in the reduction of fracture toughness and enhanced plastic effects, while water-rock interaction limited to the vicinity of the propagating fracture tip by a hydrophobic specimen coating lowers subcritical index and increases fracture velocity. Finally, the observed deviation of a rate-dependent subcritical index from the power law K-V relations for coated specimens tested in water is attributed to a time-dependent weakening process resulting from the interaction between water and clays in the vicinity of the fracture tip.

58 GEOSCIENCES↗

DOE OSTI2019

Statistical analyses of reservoir and fracturing parameters for a multifractured shale oil reservoir in Mississippi

The use of multifractured horizontal wells has improved the efficiency of hydrocarbon extraction from shale gas and oil plays. It is highly desirable to estimate the characteristics of the reservoir and well fracturing through production data analysis. Production rate transient data from 16 wells in the Mississippi sections were analyzed to estimate local reservoir permeability and hydraulic fracture parameters. Key factors affecting well productivity have been identified for optimizing future well completion. Based on the theory of distance of investigation during transient linear flow, the reservoir matrix permeability of TMS was estimated to be between 53 nd and 210 nd, averaging at 116 nd. The matrix permeability follows the lognormal distribution and is considered homogeneous according to the coefficient of variation. The fracture half-length was estimated using the matrix permeability data from the rate transient analysis. The fracture half-length was found to have a mean value of 234 ft with a standard deviation of 66 ft in a normal distribution. The fracture conductivity was back-calculated by matching pseudosteady production rate data to Guo et al's (SPE Reserve Eval Eng.12, 2009, 879) productivity model for boundary-dominated flow. The fracture conductivity was estimated to range from 0.4 md-ft to 3.2 md-ft, averaging at 1.4 md-ft. Based on Guo et al's (SPE Reserve Eval Eng.12, 2009, 879) well productivity model applied to TMS condition, well productivity can be improved significantly by increasing fracture length and conductivity. Future TMS wells should be completed with conductivity values of greater than 10 md-ft.

04 OIL SHALES AND TAR SANDS↗

DOE OSTI2024

Arbitrary Order Virtual Element Methods for High‐Order Phase‐Field Modeling of Dynamic Fracture

ABSTRACT Accurate modeling of fracture nucleation and propagation in brittle and ductile materials subjected to dynamic loading is important in predicting material damage and failure under extreme conditions. Phase‐field fracture models have garnered a lot of attention in recent years due to their success in representing damage and fracture processes in a wide class of materials and under a variety of loading conditions. Second‐order phase‐field fracture models are by far the most popular among researchers (and increasingly, among practitioners), but fourth‐order models have started to gain broader acceptance since their more recent introduction. The exact solution corresponding to these high‐order phase‐field fracture models has higher regularity. Thus, numerical solutions of the model equations can achieve improved accuracy and higher spatial convergence rates. In this work, we develop a virtual element framework for the high‐order phase‐field model of dynamic fracture. The virtual element method (VEM) can be regarded as a generalization of the classical finite element method. In addition to many other desirable characteristics, the VEM allows computing on polytopal meshes. Here, we use ‐conforming virtual elements and the generalized‐ time integration method for the momentum balance equation, and adopt ‐conforming virtual elements for the high‐order phase‐field equation. We verify our virtual element framework using classical quasi‐static benchmark problems and demonstrate its capabilities with the aid of numerical simulations of dynamic fracture in brittle materials.

42 ENGINEERING↗

DOE OSTI2019

A Stochastic Study of Flow Anisotropy and Channelling in Open Rough Fractures

The quantification of fluid flow in rough fractures is of high interest for reservoir engineering, especially for deep geothermal applications. Herein, rough self-affine fractures are stochastically generated with incremental shear displacement and geometrically described by two aperture definitions, the vertical aperture a vert and the effective aperture a eff . In order to compare their effect on fracture flow, such as anisotropy and channelling, Local Cubic Law (LCL) model-based 2D fluid flow is simulated. The particularity of this approach is the combination of a stochastic generation of self-affine fractures with a statistical analysis (560 individual realizations) of the impact of the LCL’s aperture constraint on fracture flow. The results show that aperture definition affects the quantitative interpretation of flow anisotropy and channeling as well as the aperture distribution of the fractures with shearing. Higher values of mean aperture for a given fracture are found using a vert , whereas the aperture standard deviation is larger with a eff . In addition, flow anisotropy is significantly sensitive to aperture definition for small shear displacements and shows a relative higher dispersion with a eff . Thus, LCL prediction models based on a vert are expected to lead to higher dispersion of anisotropy results with a higher uncertainty (factor ~ 2). Realizations based on avert lead to an enhanced clustering of high flow rates for higher shearing displacements. This channeling development results in higher total flow rates for these simulations. Finally, these findings support the direct calibration of pre-existing LCL anisotropy simulations based on avert towards more representative results using a eff .

58 GEOSCIENCES↗

DOE OSTI2018

Immobile Pore-Water Storage Enhancement and Retardation of Gas Transport in Fractured Rock

The effect of immobile pore-water on gas transport in fractured rock has implications for numerical modeling of soil vapor extraction, methane leakage, gaseous CO 2 leakage from sequestration operations, radionuclide transport from underground nuclear explosions, and nuclear waste disposal. While the ability for immobile pore-water storage to effect gas transport has been recognized in the past, the details and specific scenarios leading to enhanced, retarded, or unaffected gas transport have not been explored. In this paper, we performed numerical investigations into the enhancement and retardation of gas transport due to immobile pore-water storage in order to identify implications for gas transport applications. To do this, we developed a numerical approach to model gas transport with a single-phase flow solution coupled to the advection–dispersion equation modified to account for immobile pore-water storage. Other than the immobility of pore water, the formulation contains all other physics included in two-phase formulations (advective and diffusive gas transport in fractures and rock matrix and dissolution in immobile pore water). The assumption of immobile pore water is valid here since for many applications involving transport of soluble gases in fractured rock, the rate of aqueous transport is insignificant compared to gas transport. We verify our modeling approach with analytical solutions of: (1) 1D gas diffusion, (2) 1D gas advection, (3) barometric pumping of a fracture, and (4) gas transport with uniform fracture flow and diffusion into the matrix. We account for pore-water storage in our model by implementing a kinetic formulation of gas dissolution wherein the dissolved (aqueous) phase is considered an immobile constituent. Using this formulation, we model the effect of dissolution rate and saturation on the retardation of gas transport during pure diffusion and pure advection. We also demonstrate that although it is commonly believed that pore-water storage will always enhance gas transport in fractures during oscillatory flow (e.g., during reversing pressure gradients such as barometric pumping cycles), our simulations indicate that this may not always be the case. Our numerical investigations indicate that scenarios with lower effective diffusion coefficients ( ⪅ 10 − 5  m 2 / s ) and lower dissolution coefficients (i.e., the dissolution diffusion coefficient) ( ⪅ 10 − 11  m 2 / s ) will result in enhanced gas transport. Other combinations of gaseous diffusion and dissolution coefficients result in delayed gas transport or insignificant effect on gas transport. Based on these results, and given the fact that the free-air diffusion coefficients for many gases are slightly above 10 − 5  m 2 / s (near the boundary of enhanced/non-enhanced gas transport), tortuosity would have to be significant for gas transport enhancement to occur. Similarly, if we consider the free-water diffusion coefficient of gases (around 10 − 9  m 2 / s for many gases of interest) to be a maximum bound for the effective dissolution coefficients (i.e., the rate of diffusion into the water away from the air/water interface will limit the dissolution rate), the effective dissolution coefficient would have to be at least 2 orders of magnitude less for enhanced gas transport to occur. Otherwise, pore-water storage will delay or have negligible effect on the gas transport. The results also indicate that the assumption of instantaneous equilibrium, often invoked in numerical codes for dissolution processes (i.e., dissolution coefficient is effectively infinite), will fail to accurately capture important details of soluble gas transport. Finally, the implication of our results is that gas breakthrough times in fractured rock during oscillatory flow may be highly dependent on the effective gaseous diffusion and dissolution coefficients.

58 GEOSCIENCES↗

DOE OSTI2023

Comparative Analysis of Imaging and Measurements of Micrometer-Scale Fracture Aperture Fields Within a Heterogeneous Rock Using PET and X-ray CT

Knowledge of the spatial distribution of fracture apertures is essential for reliable characterization of flow and transport processes in fractured systems and for better understanding of physicochemical matrix–fracture interactions. Here, we propose and test two image-based methods, thereby extending the current experimental capabilities to characterize aperture size distribution in structurally heterogeneous geologic porous media noninvasively. The first approach utilizes an inversion method based on the dataset acquired from positron emission tomography (PET) and the second approach considers an extension of the classic missing attenuation technique that relies on clinical X-ray computed tomography (X-ray CT). Independent sets of imaging experiments are conducted on a fractured basalt core with heterogeneous matrix properties and aperture distributions to compare the two methodologies. A repeat of each experiment is conducted to verify the proposed workflows. The performance of these two imaging techniques is systematically evaluated through the analysis of signal-to-noise ratio, minimum fracture size detectability, and measurement errors. While both approaches provide a reliable estimation of fracture aperture distributions, PET yields a signal-to-noise ratio that is substantially higher than the corresponding X-ray CT measurements. Furthermore, uncertainties of the aperture values for PET are considerably lower ($\bar {\sigma}_{\text {d}} = 15\%$) compared to those obtained from X-ray CT ($\bar {\sigma}_{\text {d}} = 29\%$), allowing for the detection of minimum aperture sizes of 20 $\mu$m with 70% confidence level. Finally, these approaches provide key experimental tools for better understanding dynamic hydromechanical fracture properties in geologic systems.

58 GEOSCIENCES↗

DOE OSTI2018

Investigation on Cracking Behavior and Development of a Fracture Model of Ti-47Al-2Nb-2Cr Alloy During Hot Deformation

When alloys are strained to a certain limit under the plastic deformation, ductile fracture occurs. Whether the required deformation can be put into effect before fracture appears has become a serious concern. A combination of compression tests, ductile fracture criteria as well as finite element simulation (FEM) were employed in this study to establish the fracture initiation prediction model of Ti-47Al-2Nb-2Cr alloy. To obtain the critical fracture strain, a technique was proposed to calculate the data for deformed cylindrical samples through isothermal compression tests in the temperature range between 1223 and 1423 K with strain rates ranging from 0.001 to 1 s{sup −1}. Five commonly used ductile fracture criteria were compared by FE simulation of compressing tests. It was found that the Brozzo criterion was found to be suitable and accordingly a failure criterion, considering temperature and strain ratio was established. Hot working parameters (critical fracture value and critical strain) in deformation could be obtained through the finite element simulation, revealing that this newly established failure criterion could accurately predict cracking initiation in compressing deformation of Ti-47Al-2Nb-2Cr alloy ingot.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Construction of occipital bone fracture using B-spline curves

Treating trauma to the cranio-maxillofacial region is a great challenge and requires expert clinical skills and sophisticated radiological imaging. The aim of reconstruction of the facial fractures is to rehabilitate the patient both functionally and aesthetically. In this article we employed B-spline curves to construct the occipital bone fracture using Digital Imaging and Communications in Medicine (DICOM) format data. The construction of occipital bone fracture starts with the boundary extraction followed by corner detection, construction of fractured part inner outer curve for each DICOM data using B-spline curves and finally the construction of fractured part in DICOM format. Method used in this article is based on DICOM data only and does not require any technique such as mirror imaging, technical help, reference skull, or to take average thickness of skull bone. Using the proposed method, the constructed fractured implant is custom made for every individual patient. At the end of this article we present a real case, in which we have constructed the occipital bone fracture using B-spline. The proposed method has been validated using post-operation DICOM data. For practical application, Graphical User Interface (GUI) has been developed.

62 RADIOLOGY AND NUCLEAR MEDICINE↗

DOE OSTI2015

A method to evaluate hydraulic fracture using proppant detection

Accurate determination of the proppant placement and propped fracture height are important for evaluating and optimizing stimulation strategies. A technology using non-radioactive proppant and a pulsed neutron gamma energy spectra logging tool to determine the placement and height of propped fractures is proposed in this paper. Gd 2 O 3 was incorporated into ceramic proppant and a Monte Carlo method was utilized to build the logging tools and formation models. Characteristic responses of the recorded information of different logging tools to fracture widths, proppant concentrations and influencing factors were studied. The results show that Gd capture gamma rays can be used to evaluate propped fractures and it has higher sensitivity to the change of fracture width and traceable proppant content compared with the exiting non-radioactive proppant evaluation techniques and only an after-fracture measurement is needed for the new method; The changes in gas saturation and borehole size have a great impact on determining propped fractures when compensated neutron and pulsed neutron capture tool are used. Finally, a field example is presented to validate the application of the new technique.

47 OTHER INSTRUMENTATION↗

DOE OSTI2025

Influence of Initial fabric and water-wetting on particle fracture and force chain evolution in natural silica sand

Particle fracture has a significant influence on the engineering behavior of granular materials. However, the combined influence of the initial fabric and wetting on particle fracture and force chain evolution in granular materials, particularly in sands, remains insufficiently explored in the current literature. Here, in this paper, one-dimensional (1D) confined compression experiments were conducted on dry and wet specimens, and particle-level fracture was captured using three-dimensional (3D) in-situ Synchrotron Micro-Computed Tomography (SMT). A quantitative assessment of particle fracture revealed that wet specimens, which have disturbed fabric, exhibited a higher fracture percentage in comparison to dry specimens. Complementary 3D finite element (FE) simulations were performed using dry and wet (only solid fabric was considered and the influence of pore water is not considered) sand assemblies to assess interparticle contact forces and particle-scale stress distributions within the specimens. Force chain analysis was subsequently conducted, encompassing quantification of interparticle forces, characterization of force network structures, and monitoring the dynamic evolution of force chains under different strain levels. The results show that the specimens with disturbed fabric led to a more dynamic and less persistent force network, more fabric instability, and thus more reorganization of force chain structures. In addition, the frequent rearrangement of the force network in the presence of water (with reduced inter-particle contact friction) likely exacerbates localized stress concentrations, promoting failure in previously unengaged or weakly connected particles. The results reported in this paper offer a new insight into how the initial fabric and wetting cause different fracture behavior. The findings can also pave the way for more in-depth future investigations into the mechanics governing particle fracture in granular assemblies.

Finite element analysis↗

DOE OSTI2019

Effect of alkali-silica reaction on the fracture properties of confined concrete

Alkali-silica reaction (ASR), which was recently discovered in nuclear power plant structures commonly without shear reinforcement, has previously been shown to induce anisotropic expansion in confined concrete. The fracture properties (strength, stiffness, and specific fracture energy) of ASR-induced anisotropically-damaged concrete specimens were quantified by varying both the damage level and relative direction of the ASR-induced cracking orientation against the loading direction corresponding to the fracture propagation. Here, the effect of different orientations (0, 45, and 90° relative to the notch of the specimen) of expected ASR-induced cracks on the fracture properties was investigated using a wedge-splitting test (WST). Specimens without ASR expansion generally showed the highest fracture properties; however, the specific fracture energy was highest for ASR-affected specimens in which the expected orientation of ASR-induced cracks was perpendicular to the WST specimen notch. Specimens in which the ASR-induced cracks were parallel to the notch exhibited the lowest strength and fracture energy.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Joint state-parameter estimation for the reduced fracture model via the united filter

Here, in this paper, we introduce an effective United Filter method for jointly estimating the solution state and physical parameters in flow and transport problems within fractured porous media. Fluid flow and transport in fractured porous media are critical in subsurface hydrology, geophysics, and reservoir geomechanics. Reduced fracture models, which represent fractures as lower-dimensional interfaces, enable efficient multi-scale simulations. However, reduced fracture models also face accuracy challenges due to modeling errors and uncertainties in physical parameters such as permeability and fracture geometry. To address these challenges, we propose a United Filter method, which integrates the Ensemble Score Filter (EnSF) for state estimation with the Direct Filter for parameter estimation. EnSF, based on a score-based diffusion model framework, produces ensemble representations of the state distribution without deep learning. Meanwhile, the Direct Filter, a recursive Bayesian inference method, estimates parameters directly from state observations. The United Filter combines these methods iteratively: EnSF estimates are used to refine parameter values, which are then fed back to improve state estimation. Numerical experiments demonstrate that the United Filter method surpasses the state-of-the-art Augmented Ensemble Kalman Filter, delivering more accurate state and parameter estimation for reduced fracture models. This framework also provides a robust and efficient solution for PDE-constrained inverse problems with uncertainties and sparse observations.

Bayesian inference↗

DOE OSTI2017

Lamellae spatial distribution modulates fracture behavior and toughness of african pangolin scales

Pangolin scales form a durable armor whose hierarchical structure offers an avenue towards high performance bio-inspired materials design. In this paper, the fracture resistance of African pangolin scales is examined using single edge crack three-point bend fracture testing in order to understand toughening mechanisms arising from the structures of natural mammalian armors. In these mechanical tests, the influence of material orientation and hydration level are examined. The fracture experiments reveal an exceptional fracture resistance due to crack deflection induced by the internal spatial orientation of lamellae. An order of magnitude increase in the measured fracture resistance due to scale hydration, reaching up to ~ 25 kJ/m 2 was measured. Post-mortem analysis of the fracture samples was performed using a combination of optical and electron microscopy, and X-ray computerized tomography. Interestingly, the crack profile morphologies are observed to follow paths outlined by the keratinous lamellae structure of the pangolin scale. Most notably, the inherent structure of pangolin scales offers a pathway for crack deflection and fracture toughening. Finally, the results of this study are expected to be useful as design principles for high performance biomimetic applications.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2020

Microstructure and fracture toughness characterization of three 9Cr ODS EUROFER steels with different thermo-mechanical treatments

Ferritic martensitic ODS steels are one of the candidate structural materials for future Gen-IV nuclear fission and fusion reactors. Here, the dependence of fracture toughness on microstructure was investigated by comparing three 9Cr ODS EUROFER steels manufactured through different thermo-mechanical processing routes. Quasi-static fracture toughness testing was performed with sub-sized C(T) specimens and microstructural characterization was carried out using scanning electron microscopy, electron backscatter diffraction, and transmission electron microscopy. It was found that at lower test temperatures (-100 – 22 °C), the fracture toughness was primarily controlled by crack initiation at sub-micron particles and by production of secondary cracks during fracture. At higher temperatures (above 100 °C), fracture toughness was predominantly controlled by the matrix ductility and the grain boundary strength with a relatively ductile coarse-grained alloy demonstrating higher fracture toughness compared to high-strength fine-grained alloys. These results and discussion show that variations in thermomechanical treatments can produce significant differences in microstructure and fracture toughness behavior of ferritic martensitic ODS steels.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Fracture behavior of irradiation induced nanocrystalline UO 2 studied by in-situ mechanical testing in transmission electron microscopy

Uranium Dioxide (UO 2 ) is widely used as a fuel in current light water reactors (LWRs). Upon accumulation of radiation damage, LWR UO 2 fuel pellets start to develop a different microstructure at the pellet periphery when fuel burnup exceeds 45–50 GWd/tHM. The resulting porous, nanocrystalline microstructure is one of the most prominent microstructural changes occurring in such fuel. Its fracture mechanisms, which causes fuel fine fragmentation, could impact safety limits when the cladding breaches. Direct measurements of these properties are challenging, therefore a surrogate obtained via ion irradiation can be used. In this study, multiple microcantilevers were fabricated by focused ion beam from both fresh UO 2 and UO 2 irradiated with 84 MeV Xe 26+ ions to a peak dose of 1357 displacements per atom (dpa). Further, the irradiation produced a pseudo high burnup structure approximately 2 µm below the surface. In-situ nano-mechanical bending tests were conducted to investigate the fracture behavior and the effect of the surrogate UO 2 high burnup structure on local fracture properties. Fresh UO 2 fuel was observed to fracture in transgranular mode without nucleation or movement of dislocations. However, the Xe-irradiated nanocrystalline microcantilevers fractured along the grain boundaries, with no influence from the pre-existing micro-cracks in the microcantilever. Fracture toughness for this type of surrogate high burnup UO 2 structure is reported for the first time in literature. Both the fracture stress and toughness show degradation for UO 2 as a result of Xe-irradiation.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Statistical fracture behavior of doped UO 2 using a ball-on-ring equibiaxial flexure test method

Metal oxide dopants, such as titanium and chromium oxides, have garnered considerable attention for their potential to increase grain size (≥ 30 µm) in UO 2 fuel, purportedly enhancing fission gas retention during reactor operation. Fuel performance is significantly impacted by fuel fracture behavior, so it is important to understand the effects of enhanced grain size and dopant content on UO 2 fuel fracture. UO 2 pellets were doped with 0.1 wt% TiO 2 and 0.3 wt% Cr 2 O 3 to alter density and grain size. Inductively coupled plasma mass spectroscopy measured dopant levels pre- and post-sintering. X-ray diffraction revealed lattice changes and microstrain via Rietveld refinement. Field emission scanning electron microscopy determined grain sizes of approximately 30 µm for TiO 2 doping and 7 µm for Cr 2 O 3 doping. Transverse rupture strength tests were performed on over 30 samples per dataset to obtain characteristic strength and Weibull modulus. Results indicate no statistical difference in fracture strength between 0.1 wt% TiO 2 doped UO 2 and undoped UO 2 , while 0.3 wt% Cr 2 O 3 doped UO 2 exhibited a 20% decrease in fracture strength. Doped UO 2 samples also showed reduced Weibull modulus compared to undoped UO 2 , suggesting increased scatter in fracture strength. This study's findings suggest that titanium and chromium oxide doping in UO 2 , regardless of grain size, induce residual stresses, decreasing fracture strength and increasing variability in fracture behavior.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2023

Fabric controls on fracture surface roughness of an architected rock material

Fluid flow through fractures is intimately linked to the fracture surfaces that define the void geometry through which fluids flow. Thus, an understanding of what controls fracture surface roughness is essential to the development of models for predicting fluid transport through fractured rock. The difficulty in predicting surface roughness arises from the complexity of rock which is inherently heterogeneous and nonuniform in composition, fabric, and structural components, even when samples are acquired from the same rock mass. Here, a benchmarked-simulation approach motivated from geo-architected 3D printed synthetic gypsum rocks is used to provide insight into the competing contributions from fabric and layering on fracture roughness formation. Simulation results from a discrete element model (Particle Flow Code, Itasca Consulting Group, Inc.) clearly indicate that the relative orientation between mineral layers and in-layer mineral fabric, and the variability in mineral bonding strengths determine whether anisotropic corrugated surfaces or isotropic surfaces are formed. Weak mineral layers oriented perpendicular to the applied load resulted in strong roughness anisotropy. Peak failure loads were found to vary up to 30% depending on the strength of the mineral fabric at the location of fracture initiation, which provides insight into the observed high variability in strength values of natural rock. The uniqueness of induced fracture roughness and peak failure load is intimately linked to layering, mineral fabric, and their distribution in the rock. These findings have important implications for any architected material fabricated through serial printing of layers with local compositional heterogeneity.

3D printed rock↗