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At least 685 records · Page 38

Mineral Deposition on the Rough Walls of a Fracture

Modeling carbonate growth in fractures and pores is important for understanding carbon sequestration in the environment or when supersaturated solutions are injected into rocks. Here, we study the simple but nontrivial problem of calcite growth on fractures with rough walls of the same mineral using kinetic Monte Carlo simulations of attachment and detachment of molecules and scaling approaches. First, we consider wedge-shaped fracture walls whose upper terraces are in the same low-energy planes and show that the valleys are slowly filled by the propagation of parallel monolayer steps in the wedge sides. The growth ceases when the walls reach these low-energy configurations so that a gap between the walls may not be filled. Second, we consider fracture walls with equally separated monolayer steps (vicinal surfaces with roughness below 1 nm) and show that growth by step propagation will eventually clog the fracture gap. In both cases, scaling approaches predict the times to attain the final configurations as a function of the initial geometry and the step-propagation velocity, which is set by the saturation index. The same reasoning applied to a random wall geometry shows that step propagation leads to lateral filling of surface valleys until the wall reaches the low-energy crystalline plane that has the smallest initial density of molecules. Thus, the final configurations of the fracture walls are much more sensitive to the crystallography than to the roughness or the local curvature. The framework developed here may be used to determine those configurations, the times to reach them, and the mass of deposited mineral. Effects of transport limitations are discussed when the fracture gap is significantly narrowed.

calcite↗

A Numerical Study of Factors Affecting Fracture-Fluid Cleanup and Produced Gas/Water in Marcellus Shale: Part II

Horizontal wells combined with successful multi-stage hydraulic fracture treatments are currently the most established method for effectively stimulating and enabling economic development of gas bearing organic-rich shale formations. Fracture cleanup in the Stimulated Reservoir Volume (SRV) is critical to stimulation effectiveness and long-term well performance. However, fluid cleanup is often hampered by formation damage, and post-fracture well performance frequently falls below expectations. A systematic study of the factors that hinder fracture fluid cleanup in shale formations can help optimize fracture treatments and better quantify long term volumes of produced water and gas. Fracture fluid cleanup is a complex process influenced by multi-phase flow through porous media (relative permeability hysteresis, capillary pressure etc.), reservoir rock and fluid properties, fracture fluid properties, proppant placement, fracture treatment parameters, and subsequent flowback and field operations. Changing SRV and fracture conductivity as production progresses further adds to the complexity of this problem. Numerical simulation is the best, and most practical approach to investigate such a complicated blend of mechanisms, parameters, their interactions, and subsequent impact on fracture fluid cleanup and well deliverability. In this paper, a 3-dimensional, 2-phase, dual-porosity model was used to investigate the impact of multiphase flow, proppant crushing, proppant diagenesis, shut-in time, reservoir rock compaction, gas slippage, and gas desorption on fracture fluid cleanup, and well performance in Marcellus shale. The research findings have shed light on the factors that substantially constrains efficient fracture fluid cleanup in gas shales, and provided guidelines for improved fracture treatment designs and water management.

58 GEOSCIENCES↗

Demonstration of CFD to support the coupled analysis of a reactor pressure vessel subjected to pressurized thermal shock

The structural components that comprise nuclear reactors and their supporting structures are subjected to harsh operating environments that can challenge their integrity, especially after exposure for extended duration or under accident condition. As one of the most significant components of a reactor, the Reactor Pressure Vessel (RPV) is exposed to an aggressive environment during the operation time (e.g. more than 40 years). Aging degradation mechanisms (e.g. thermo-fatigue) could grow initial defects up to a critical size, increasing the susceptibility to failure in the RPV. The conventional methods are mostly based on simple crack and structure geometries. Very limited studies consider the real conditions of the RPV subjected to a thermal shock due to a Loss of Coolant Accident (LOCA). During a LOCA event, the most severe conditions take place when the emergency core cooling (ECC) water is injected inside the cold legs filled initially with hotter water and/or steam. The rapid cooling of the down-comer and the internal RPV surface followed probably by re-pressurization of the RPV causes large temperature gradients and variation of pressure which induces thermal-mechanical stresses. In order to develop the model for integrity assessment of a reactor pressure vessel (RPV) subjected to pressurized thermal shock (PTS), a multi-physics simulation, which includes the thermo-hydraulic, thermo-mechanical and fracture mechanics analyses is necessary. The prediction of the temperature field is achieved by using computational fluid dynamics (CFD) simulation. In this report, a demonstration CFD standalone simulation is performed to support coupled analysis for Reactor Pressure Vessel (RPV) subjected to Pressurized Thermal Shock (PTS). The study use a simplified computational domain to represents a real RPV. The purpose of the study is to demonstrate the transient temperature response of RPV to ECC injection. The CFD model is built in a robust and efficient way for further coupled calculation. The next steps of this work, including the coupled thermal and tensor mechanics capabilities using Cardinal are expected to be complete by the end of FY21 for the demo problem. After this, into FY22, the capability will be demonstrated for a realistic RPV.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Effects of HFIR neutron irradiation on fracture toughness properties of standard and Ni-doped F82H

F82H is the Japanese reference reduced-activation ferritic-martensitic (RAFM) steel for fusion blanket applications. The harsh environment of a fusion reactor, such as neutron irradiation and He/H damage, can result in significant degradation of F82H fracture toughness. Therefore, understanding the fracture toughness behavior of F82H in the fusion environment is critical to ensure the long-term safe operation of the fusion reactor. Here, we summarize seven irradiation campaigns of the High Flux Isotope Reactor (HFIR) at Oak Ridge National Laboratory (ORNL) covering five variants of F82H steels, including F82H IEA, F82H Mod3, F82H doped with 1.4% natural Ni, F82H doped with 1.4% 58 Ni, and F82H doped with 1.4% 60 Ni. The irradiation temperatures covered the range from 220 °C to 530 °C and the neutron irradiation dose spanned 4 dpa to 70 dpa. The effects of neutron irradiation temperature, dose, materials composition, Ni doping, and He production on F82H fracture toughness are discussed. Our results showed that irradiation embrittlement monotonically decreased with increasing irradiation temperature until 400 °C for F82H IEA and F82H Mod3. F82H Mod3 showed better fracture toughness than F82H IEA both before and after neutron irradiation. We determined that 1.4% Ni alloying can be applied to F82H for simulating He effect in a fission reactor without jeopardizing the fracture toughness of the material. However, more studies are needed to understand the effect of high dose (>20 dpa) and He production on F82H fracture toughness.

36 MATERIALS SCIENCE↗

Validation Study of Unnotched Charpy and Taylor-Anvil Impact Experiments using Kayenta

Validation of a single computational model with multiple available strain-to-failure fracture theories is presented through experimental tests and numerical simulations of the standardized unnotched Charpy and Taylor-anvil impact tests, both run using the same material model (Kayenta). Unnotched Charpy tests are performed on rolled homogeneous armor steel. The fracture patterns using Kayenta’s various failure options that include aleatory uncertainty and scale effects are compared against the experiments. Other quantities of interest include the average value of the absorbed energy and bend angle of the specimen. Taylor-anvil impact tests are performed on Ti6Al4V titanium alloy. The impact speeds of the specimen are 321 m/s and 393 m/s. The goal of the numerical work is to reproduce the damage patterns observed in the laboratory. For the numerical study, the Johnson-Cook failure model is used as the ductile fracture criterion, and aleatory uncertainty is applied to rate-dependence parameters to explore its effect on the fracture patterns.

97 MATHEMATICS AND COMPUTING↗

Reduced-order modeling through machine learning and graph-theoretic approaches for brittle fracture applications

Typically, thousands of computationally expensive micro-scale simulations of brittle crack propagation are needed to upscale lower length scale phenomena to the macro-continuum scale. Running such a large number of crack propagation simulations presents a significant computational challenge, making reduced-order models (ROMs) attractive for this task. Here, the ultimate goal of this research is to develop ROMs that have sufficient accuracy and low computational cost so that these upscaling simulations can be readily performed. However, constructing ROMs for these complex simulations presents its own challenge. Here, we present and compare four different approaches for reduced-order modeling of brittle crack propagation in geomaterials. These methods rely on machine learning (ML) and graph-theoretic algorithms to approximate key aspects of the brittle crack problem. These methods also incorporate different physics-based assumptions in order to reduce the training requirements while maintaining accurate physics as much as possible. Results from the ROMs are directly compared against a high-fidelity model of brittle crack propagation. Further, the strengths and weaknesses of the ROMs are discussed, and we conclude that combining smart physics-informed feature engineering with highly trainable ML models provides the best performance. The ROMs considered here have computational costs that are orders-of-magnitude less than the cost associated with high-fidelity physical models while maintaining good accuracy.

36 MATERIALS SCIENCE↗

The emergence of small-scale self-affine surface roughness from deformation

Most natural and man-made surfaces appear to be rough on many length scales. There is presently no unifying theory of the origin of roughness or the self-affine nature of surface topography. One likely contributor to the formation of roughness is deformation, which underlies many processes that shape surfaces such as machining, fracture, and wear. Using molecular dynamics, we simulate the biaxial compression of single-crystal Au, the high-entropy alloy Ni 36.67 Co 30 Fe 16.67 Ti 16.67 , and amorphous Cu 50 Zr 50 and show that even surfaces of homogeneous materials develop a self-affine structure. By characterizing subsurface deformation, we connect the self-affinity of the surface to the spatial correlation of deformation events occurring within the bulk and present scaling relations for the evolution of roughness with strain. These results open routes toward interpreting and engineering roughness profiles.

42 ENGINEERING↗

HOSS: Hybrid Optimization Software Suite

HOSS software, developed at LANL, is a powerful, flexible, and parallelized package that enables the user to predict deformation and failure of materials in a variety of situations. LANL’s HOSS software is an R&D 100 finalist that integrates solid mechanics and computational fluid dynamics into a multi-physics platform able to handle millions of interacting and fracturing solids and/or particle systems. This nextgeneration simulation software integrates solid mechanics and computational fluid dynamics into a multi-physics platform able to provide state-of-the-art simulation solutions for a wide field of applications including oil and gas, construction, mining, defense, material sciences, and biomechanics.

36 MATERIALS SCIENCE↗

OpenACC directive-based GPU acceleration of an implicit reconstructed discontinuous Galerkin method for compressible flows on 3D unstructured grids

In this study, we use a combination of modeling techniques to describe the relationship between fracture radius that might be accomplished in a hypothetical enhanced geothermal system (EGS) and drilling distance required to create and access those fractures. We use a combination of commonly applied analytical solutions for heat transport in parallel fractures and 3D finite-element method models of more realistic heat extraction geometries. For a conceptual model involving multiple parallel fractures developed perpendicular to an inclined or horizontal borehole, calculations demonstrate that EGS will likely require very large fractures, of greater than 300 m radius, to keep interfracture drilling distances to ~10 km or less. As drilling distances are generally inversely proportional to the square of fracture radius, drilling costs quickly escalate as the fracture radius decreases. It is important to know, however, whether fracture spacing will be dictated by thermal or mechanical considerations, as the relationship between drilling distance and number of fractures is quite different in each case. Information about the likelihood of hydraulically creating very large fractures comes primarily from petroleum recovery industry data describing hydraulic fractures in shale. Those data suggest that fractures with radii on the order of several hundred meters may, indeed, be possible. The results of this study demonstrate that relatively simple calculations can be used to estimate primary design constraints on a system, particularly regarding the relationship between generated fracture radius and the total length of drilling needed in the fracture creation zone. Comparison of the numerical simulations of more realistic geometries than addressed in the analytical solutions suggest that simple proportionalities can readily be derived to relate a particular flow field.

15 GEOTHERMAL ENERGY↗

Geothermal reservoir simulation

The prediction of long-term geothermal reservoir performance and the environmental impact of exploiting this resource are two important problems associated with the utilization of geothermal energy for power production. Our research effort addresses these problems through numerical simulation. Computer codes based on the solution of partial-differential equations using finite-element techniques are being prepared to simulate multiphase energy transport, energy transport in fractured porous reservoirs, well bore phenomena, and subsidence.

Mercer, J. W., Jr.↗

Time-temperature-stress capabilities of composite materials for advanced supersonic technology application

Advanced composites will play a key role in the development of the technology for the design and fabrication of future supersonic vehicles. However, incorporating the material into vehicle usage is contingent on accelerating the demonstration of service capacity and design technology. Because of the added material complexity and lack of extensive data, laboratory replication of the flight service will provide the most rapid method to document the airworthiness of advanced composite systems. Consequently, a laboratory program was conducted to determine the time-temperature-stress capabilities of several high temperature composites. Tests included were thermal aging, environmental aging, fatigue, creep, fracture, tensile, and real-time flight simulation exposure. The program had two phases. The first included all the material property determinations and aging and simulation exposures up through 10,000 hours. The second continued these tests up to 50,000 cumulative hours. This report presents the results of the Phase 1 baseline and 10,000-hr aging and flight simulation studies, the Phase 2 50,000-hr aging studies, and the Phase 2 flight simulation tests, some of which extended to almost 40,000 hours.

Kerr, James R.↗

Experimental Characterization of Non-Associative Plasticity Flow Rule Coefficients and Post-Peak Stress Degradation for the LS-DYNA MAT213 Model

This project is focused on developing an experimental framework for characterizing non-associative plasticity flow rule coefficients through coupon-scale tests for the LS-DYNA MAT213 model. The main objective is to characterize these coefficients based on the multi-scale (i.e., both microscopic and macroscopic) full-field measurement of the evolution of strain and stress fields. This paper focuses on presenting the experimental work on characterizing the full-scale stress-strain curves of T700/LM-PAEK composites under tension, compression, and shear loads. The experimental data set was intended to build a deformation sub-model in the MAT213 model for the material. The strain data were collected using both microscopic and macroscopic digital image correlation techniques. The microscopic technique was particularly useful for fracture cases under small strains. A preliminary simulation result obtained from the MAT213 model is also presented in the paper. The experimental framework herein will be extended to characterize post-peak stress degradation in the composite material and to develop a damage sub-model for the material. This project will contribute to developing a simulation tool based on the MAT213 model for simulating the rate-dependent impact damage in composites under multi-axial loading.

MAT213↗

Extending ISS Life Beyond 2030

This paper presents an overview of the International Space Station life extension project, focusing on the analytical approach used to assess its primary structure. Also addressed are life extension approaches for other affected sub-systems, including secondary structure, materials, Environmental Control and Life Support Systems (ECLSS), Electrical Power Systems (EPS), and Logistics and Maintenance (L&M). The United States On-orbit Segment (USOS) of the International Space Station (ISS) was initially designed for a 15-year on-orbit life, but with the realization of its continued importance, efforts were made to extend its operations through 2030. The paper discusses the various analyses conducted, including future operations planning, load simulation, material degradation studies, thermal analyses, and fracture analyses. The results demonstrate the feasibility and achievability of extending the ISS's life, ensuring its on-going role as a hub for scientific research, international cooperation, and educational endeavors. With the life extension process in place, continuous operations beyond 2030 are possible to maintain an uninterrupted human presence in Low Earth Orbit, facilitating the testing of new technologies, and allow for a seamless transition to new commercially owned and operated destinations.

design life↗

The EGS Collab Project: Status and Accomplishments

The EGS Collab project, supported by the US Department of Energy, is addressing challenges in implementing enhanced geothermal systems (EGS). This includes improving understanding of the stimulation of crystalline rock to create appropriate flow pathways, and the ability to effectively simulate both the stimulation and the flow and transport processes in the resulting fracture network. The project is performing intensively monitored rock stimulation and flow tests at the 10-m scale in an underground research laboratory. Data and observations from the field test are compared to simulations to understand processes and to build confidence in numerical modeling of the processes. In Experiment 1, we examined hydraulic fracturing an underground test bed at the Sanford Underground Research Facility (SURF) in Lead, South Dakota, at a depth of approximately 1.5 km. We drilled eight sub-horizontal boreholes in a well-characterized phyllite. Six of the boreholes were instrumented with many sensor types to allow careful monitoring of stimulation events and flow tests, and the other two boreholes were used for water injection and production. We performed a number of stimulations and flow tests in the testbed. Our monitoring systems allowed detailed observations and collection of numerous data sets of processes occurring during stimulation and during dynamic flow tests. Long-term ambient temperature and chilled water flow tests were performed in addition to many tracer tests to examine system behavior. Data were rapidly analyzed, allowing adaptive control of the tests. Numerical simulation was used to answer key experimental design questions, to forecast fracture propagation trajectories and extents, and to analyze and evaluate results. Many simulations were performed in near-real-time in conjunction with the field experiments, with more detailed process study simulations performed on a longer timeframe. Experiment 2 will examine hydraulic shearing in a test bed being built at the SURF at a depth of about 1.25 km in amphibolite under a different set of stress and fracture conditions than Experiment 1. Five sets of fracture orientations were considered in design, and three orientations seem to be consistently observed.

EGS Collab↗

Design and implementation of a shearing apparatus for the experimental study of shear displacement in rocks

Fluid flow in the subsurface is not well understood in the context of “impermeable” geologic media. This is especially true of formations that have undergone significant stress fluctuations due to injection or withdrawal of fluids that alters the localized pressure regime. When the pressure regime is altered, these formations, which are often already fractured, move via shear to reduce the imbalance in the stress state. While this process is known to happen, the evolution of these fractures and their effects on fluid transport are still relatively unknown. Numerous simulation and several experimental studies have been performed that characterize the relationship between shearing and permeability in fractures; while many of these studies utilize measurements of fluid flow or the starting and ending geometries of the fracture to characterize shear, they do not characterize the intermediate stages during shear. We present an experimental apparatus based on slight modifications to a commonly available Hassler core holder that allows for shearing of rocks, while measuring the hydraulic and mechanical changes to geomaterials during intermediate steps. The core holder modification employs the use of semi-circular end caps and structural supports for the confining membrane that allow for free movement of the sheared material while preventing membrane collapse. By integrating this modified core holder with a computed tomography scanner, we show a new methodology for understanding the interdependent behavior between fracture structure and flow properties during intermediate steps in shearing. Here, we include a case study of this device function which is shown here through shearing of a fractured shale core and simultaneous observation of the mechanical changes and evolution of the hydraulic properties during shearing.

58 GEOSCIENCES↗

Three-Dimensional Gear Crack Propagation Studies

Three-dimensional crack growth simulation was performed on a split-tooth gear design using boundary element modeling and linear elastic fracture mechanics. Initial cracks in the fillet of the teeth produced stress intensity factors of greater magnitude (and thus, greater crack growth rates) than those in the root or groove areas of the teeth. Crack growth simulation was performed on a case study to evaluate crack propagation paths. Tooth fracture was predicted from the crack growth simulation for an initial crack in the tooth fillet region. Tooth loads on the uncracked mesh of the split-tooth design were up to five times greater than those on the cracked mesh if equal deflections of the cracked and uncracked teeth were considered. Predicted crack shapes as well as crack propagation life are presented based on calculated stress intensity factors, mixed-mode crack propagation trajectory theories, and fatigue crack growth theories.

Lewicki, David G.↗

FRACTURE RESISTANCE OF CAST AUSTENITIC STAINLESS STEELS

Cast austenitic stainless steels (CASS) possess excellent corrosion resistance and mechanical properties and are used alongside with wrought stainless steels (SS) in light water reactors for primary pressure boundaries and reactor core internal components. In contrast to an austenitic microstructure of wrought SS, CASS alloys consist of a dual-phase microstructure of delta ferrite and austenite. While the delta ferrite is critical for the service performance of CASS alloys, it is also vulnerable to embrittlement when exposed to reactor service temperatures and fast neutron irradiations. In this study, the combined effect of thermal aging and neutron irradiation on the degradation of CASS alloys was investigated. Static casts of CF-3 and CF-8 grades with > 23% delta ferrite were selected for the study, and specimens with and without prior thermal aging were irradiated at ~320°C to about 0.08 dpa. Crack growth rate and fracture toughness J-integral resistance curve tests were performed in simulated light water reactor environments with low corrosion potential. While no elevated crack propagation rates were detected, significant reductions in fracture toughness were observed after either thermal aging or neutron irradiation. The loss of fracture toughness due to neutron irradiation seemed more evident in the samples without prior thermal aging. Transmission electron microscope (TEM) examination showed that both neutron irradiation and thermal aging affect the microstructural evolution of delta ferrite. A high density of G-phase precipitates was observed in both thermally aged and irradiated specimens The evolution of the precipitate microstructure is more extensive in the samples subjected to both thermal aging and neutron irradiation. The similarity of precipitate microstructures resulting from thermal aging and neutron irradiation are consistent with the fracture toughness results, suggesting a common microstructural origin of the observed embrittlement among the tested specimens.

cast austenitic stainless steels↗