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DOE OSTI2023

Carbon nanofibers based carbon–carbon composite fibers

Textile grade polyacrylonitrile (PAN) was used as a precursor material for carbon fiber preparation. E-beam irradiated polyacrylonitrile grafted carbon nanofibers were dispersed in polyacrylonitrile solution (dissolved in dimethyl formamide). Carbon nanofibers (CNF) infused polyacrylonitrile solution was wet spun on a lab-scale wet-spinning setup to form 50 to 70 µm diameter fibers with 3.2 wt.% CNF-PAN, 6.4 wt.% CNF-PAN, and neat PAN. Precursor fibers were characterized for thermal, mechanical and morphological properties using various techniques. Drawing the precursor fibers further enhanced polymer chain orientation and coalesced the voids, enhancing tensile strength and modulus by more than 150% compared to those of the undrawn fibers. Precursor composite fibers on carbonization showed enhanced strength, compared to that of pristine PAN fibers, by four times and stiffness by 14 times. The carbon–carbon composite fibers were further characterized with SEM/FIB, XRD and tensile strength. The property improvements were dependent on the uniform distribution of carbon nanofibers, and surface modification of carbon nanofibers further enabled their dispersion in the composite fibers. Furthermore, 3.2 wt.% CNFs in PAN fibers showed maximum improvement in properties compared to 6.4 wt.% CNF in PAN fibers, indicating that the property enhancements go through a maximum and then drop off due to challenge in getting uniform distribution of nanofibers.

36 MATERIALS SCIENCE↗

DOE OSTI2022

An energy-based study of the embedded element method for explicit dynamics

Abstract The embedded finite element technique provides a unique approach for modeling of fiber-reinforced composites. Meshing fibers as distinct bundles represented by truss elements embedded in a matrix material mesh allows for the assignment of more specific material properties for each component rather than homogenization of all of the properties. However, the implementations of the embedded element technique available in commercial software do not replace the material of the matrix elements with the material of the embedded elements. This causes a redundancy in the volume calculation of the overlapping meshes leading to artificially increased stiffness and mass. This paper investigates the consequences in the energy calculations of an explicit dynamic model due to this redundancy. A method for the correction of the edundancy within a finite element code is suggested which removes extra energy and is shown to be effective at correcting the energy calculations for large amounts of redundant volume.

Martin, Valerie A.↗

DOE OSTI2025

Continuous surface-to-distributed acoustic sensor snapshots explain reactivation of individual natural fractures during an unconventional reservoir stimulation

ABSTRACT Fiber-optic sensing technologies allow petroleum engineering teams to detect hydraulic fracture interaction with boreholes during unconventional reservoir stimulation. In combination with high-repeatability seismic sources, the same distributed acoustic sensors (DASs) enable vertical seismic profiling (VSP) of the fracture evolution away from the boreholes. We discovered clear signatures of seismic scattering on activated fractures during nine days of continuous seismic monitoring of the fracturing stages at the Austin Chalk/Eagle Ford Field Laboratory. The present study applies a novel approach for quantitative analysis of the scattering events in terms of the evolution of the geometry and elastic stiffness of individual fractures. Our characterization strategy sequentially refines the fracture models: from a stack of 1D soft layers to 3D rectangular inclusions. First, we estimate the number of fracture locations and reflectivity using a modified sparse-spike deconvolution of the stacked VSP traces. The fracture set consists of five fractures spaced by 15–30 m with a reflectivity of approximately 1%. Then, we develop a scattering integral method to refine these estimates along with an inversion of the fracture top and bottom for each monitoring vintage. We find that, initially, some of the fractures are located above the monitoring fiber with the height of approximately 100 m. Then we integrate the seismic interpretation with the low-frequency DAS and pressure and microseismic monitoring to reconstruct the activation process of the fractures. Most likely, some of the natural fractures slowly grew downward to the monitoring fiber as a result of fluid injections in the stimulated well. This led to bright strain anomalies but did not trigger seismicity. The top of the fractures remained almost constant and were limited by a lithologic boundary/stress barrier. To our knowledge, this is the first time VSP data enabled tracking of the fracture evolution with such high spatial and temporal resolution, which was previously only available for crosswell surveys and at a much smaller scale.

Glubokovskikh, Stanislav↗

DOE OSTI2020

Characterization of elastic mechanical properties of Tuscaloosa Marine Shale from well logs using the vertical transversely isotropic model

To avoid steep declines in the Tuscaloosa Marine Shale (TMS) production, wells are fracture-stimulated to release the hydrocarbons trapped in the matrix of the formation. An accurate estimation of Young’s modulus and Poisson’s ratio is essential for hydraulic fracture propagation. In addition, ignoring the highly heterogeneous and anisotropic character of TMS can lead to erroneous stress values, which subsequently affect hydraulic fracture width estimates and the overall hydraulic fracturing process. We have developed an empirical 1D geomechanical model that takes into account VTI anisotropy, and it is used to characterize the elastic mechanical properties of TMS in two wells. In the analyzed formation, the vertical Poisson’s ratio is less than the horizontal Poisson’s ratio, which suggests the necessity of an alternative to the ANNIE equations. The stiffness coefficients [Formula: see text] and [Formula: see text] were estimated using the relationships developed from the ultrasonic core data available for the two TMS. Further, correlations between the static and dynamic properties from laboratory tests were used to improve the minimum horizontal stress calculation. We compare VTI Young’s moduli, Poisson’s ratios, and minimum horizontal stress with the isotropic solution. VTI modeling improves the estimation of the elastic mechanical properties. The isotropic solution underestimates the minimum horizontal stress in the formation. Moreover, it was shown that the 20 ft shale interval below the TMS base is characterized by a low Young’s modulus (the vertical Young’s modulus is equal to 20 GPa, whereas the horizontal Young’s modulus is equal to 40 GPa) and may be a frac barrier.

Geochemistry & Geophysics↗

DOE OSTI2023

Effect of fiber reinforcement on the process parameters of injection molding manufacturing process

Use of fillers with the resin is common in injection molding manufacturing technique to enhance the stiffness and strength of the manufactured components. However, the addition of fillers changes the rheological and mechanical properties of the material, required adjustments in the process parameters used for the manufacturing. The present study aims to investigate this impact of fillers on the process parameters of the injection molding manufacturing process. Neat Acrylonitrile Butadiene Styrene (ABS) and ABS reinforced with short glass fibers are used as the materials to perform the comprehensive numerical analysis including complete process sequence, namely filling, packing, cooling and warpage. Parametric studies are conducted to optimize the manufacturing process for minimal warpage (or shrinkage) in the produced part. The selected process parameters for the parametric study include cooling time, packing pressure, and mold temperature, all of which directly impact the quality of the manufactured parts. The optimal values obtained for these parameters are compared to examine the effect fiber reinforcement has on the manufacturing process.

Garg, Nikhil↗

DOE OSTI2023

Low-velocity repeated impact behaviors of Polymer Fiber Reinforced Plastics (PFRPs)

Modern fiber-reinforced composites have become ubiquitous across multiple industries due to their excellent weight-to-strength ratio. Typically glass or carbon fibers are widely used. While Glass or Carbon Fiber-Reinforced Plastics (GFPRs or CFPRs) have good stiffness, strength, and fatigue life, they are expensive and difficult to recycle. Researchers are exploring Polymer Fiber-Reinforced Plastics (PFRPs) as an alternative solution. PFRPs utilize polymer fibers and a polymer matrix. A wide range of materials options is available, including low-cost thermoplastics such as polyethylene or polypropylene. These thermoplastics are easy to handle and recyclable without special methods. Manufacturing parts using thermoplastics are well-established as well. However, their mechanical performances have not been extensively studied compared to GFRPs or CFRPs. This study examines the low-velocity impact resistance of PFRPs made of different thermoplastics. The low-velocity impacts are applied through a drop-weight tower. The experiment is divided into two cases: a single perforation impact and low-energy repeated impacts. Energy absorption and the number of impacts to failure are measured. The results are compared to traditional CFRPs which have a thermoset matrix. The PFRPs demonstrate energy absorption capabilities comparable to or greater than those of CFRPs with respect to specimen thickness and density. Additionally, the PFRPs show significantly higher impacts-to-failure than the CFRPs in low-energy repeated impact tests. This is particularly noteworthy considering that the PFRPs are much simpler and more economical to manufacture than CFRPs. To further

Ko, Seunghyun↗

DOE OSTI2021

Advancing lightweight mirror design: a paradigm shift in mirror preforms by utilizing design for additive manufacturing

Additive manufacturing is a disruptive technology that can be leveraged by the redesign of components in most engineering fields. Fundamental engineering resources for lightweight mirrors were developed more than 30 years ago with a main design limitation, state of the art manufacturing. In this study, we present two design methodologies for the design of lightweight mirrors. The first method utilizes analytical expressions to design a traditional isogrid mirror, which provided the foundation for most lightweight mirrors to date. The second method employs a combination of topology optimization, lattice infill, and analytical estimation to develop an advanced lightweight mirror designed for additive manufacturing. The advanced mirror design outperforms the traditional design for each functional requirement, including a 94% reduction in predicted surface quilting and a higher specific stiffness. The manufacturing of the advanced mirror is only possible with an additive manufacturing process.

36 MATERIALS SCIENCE↗

DOE OSTI2024

The hypernuclear physics program at Jefferson Lab

Missing mass spectroscopy of Λ hypernuclei using the (e, e' K⁺) re action has been performed in the past at the Thomas Jefferson National Accelerator Facility (Jefferson Lab) by several experiments in Halls A and C. A new experimen tal campaign is expected to start running in 2026 in Hall C and to provide the first study of the isospin dependence in medium-mass hyperisotopes by populating $^{40}_Λ{K}$ and $^{48}_Λ{K}$ using isotopically enriched calcium targets [E12-15-008]. During this cam paign, it will be possible to study Λ interactions in nuclear matter using a lead target [E12-20-013]. Solid-state targets made of lithium, beryllium, boron [LOI12-23-013], and aluminum [LOI12-23-016] are considered to be included in the campaign. The use of the HKS and HES spectrometers together with thin target foils and high beam currents leads to a sub-MeV energy resolution, significantly better than in hadron beam experiments. Valuable information on few-body hyperon systems would be gained if helium targets were used [E12-19-002]. Using an additional spectrometer for measuring the decay-pion spectra could give access to the binding energies of light hyperfragments [LOI12-23-011]. The measurement of precise and accurate en ergy spectra of different hyperisotopes probes the Λ-N interaction in nuclei including the Λ-N-N interaction. The latter is assumed to play a key role for the stiffness of the nuclear equation of state relevant for the stability of neutron stars.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2021

Experimental Investigation of Concrete Fatigue in Axial Compression

The use of concrete in fatigue critical structures, such as wind turbine towers, has necessitated the replacement of simplistic (and therefore insufficient) fatigue design recommendations with more accurate and advanced fatigue models that can consider a greater complexity of stress states and materials. As the first part of a multistage test series, an experimental investigation was conducted to determine the fatigue life of concrete subjected to axial compressive fatigue loading, focusing on the relatively high-cycle fatigue domain. Here, a wide range of values for maximum stress levels and stress ratios were considered. The experimental results were compared against existing predictive models, and the most applicable model was identified. Concrete strain and stiffness behavior during fatigue loading were also investigated and reported. Based on the observed behavior, a hypothesis for identifying the impending occurrence of fatigue failure, based on the monotonic stress-strain curve, is examined.

17 WIND ENERGY↗

DOE OSTI2024

Utah FORGE: Fluid Injection Induced Shearing Experiments on Fractured Granitoid at Elevated Temperatures

This repository contains experimental data from a series of fluid injection-induced shearing tests conducted on Utah FORGE granitoid. The experiments were performed using an aluminum triaxial pressure vessel (TEMCO) apparatus at Pennsylvania State University. The primary aim was to investigate the impact of temperature on fault seismicity and to explore how different pre-stress ratios influence shearing behavior. The data includes results from experiments conducted under varying conditions of temperature, pre-stress ratios, and pore pressure increments. The rock samples used in these experiments were 60-grit granitoid with a single inclined fracture oriented at 60 degrees with respect to the horizontal cross-section. The dataset also includes measurements of normal stiffness at different temperatures and images of the experimental apparatus. The included README file details each experiential setup and outlines which data files represent which experimental conditions.

15 GEOTHERMAL ENERGY↗

DOE OSTI2024

TEAMER: Pitching Foil Crossflow Turbine Efficiency Data

This dataset documents the efficiency testing of a pitching foil crossflow turbine, conducted at the University of New Hampshire's (UNH) Chase Ocean Engineering Laboratory tow tank facility. The tests explored various pitch phases and amplitudes, ranging from 0 to 18 degrees, across different flow speeds and turbine RPMs. Specifically, testing was performed at pitch amplitudes of 0,3,6,9,12,15 and 18 degrees. The results indicate that turbine efficiency improves with increased pitch amplitude, reaching optimal performance at 12 degrees. Modifications were made to the test frame by UNH to enhance the stiffness of the support structure. The testing specifically mapped the efficiency of a single quadrant of the Ocean Renewable Power Company (ORPC) Autonomous Turbine Generator Unit (ATGU), covering the full range of allowable pitching amplitudes and phases. The dataset provides both raw and processed data, including drag and torque measurements, and contains Python scripts used for data processing and visualization. This research was supported by funding from TEAMER RFTS 1 (Request for Technical Support).

16 TIDAL AND WAVE POWER↗

DOE OSTI2025

Order conditions for nonlinearly partitioned Runge-Kutta methods

Recently, a new class of nonlinearly partitioned Runge–Kutta (NPRK) methods was proposed for nonlinearly partitioned systems of autonomous ordinary differential equations y' = F(y, y). The target class of problems are those in which different scales, stiffnesses, or physics are coupled in a nonlinear way, wherein the desired partition cannot be written in a classical additive or component-wise fashion. Here we use a rooted-tree analysis to derive full-order conditions for NPRKM methods, where M denotes the number of nonlinear partitions. Due to the nonlinear coupling and thereby the mixed product differentials, it turns out that the standard node-colored rooted tree analysis used in analyzing ODE integrators does not naturally apply. Instead we develop a new edge-colored rooted-tree framework to address the nonlinear coupling. The resulting order conditions are enumerated, are provided directly for up to fourth order with M = 2 and third order with M = 3, and are related to existing order conditions of additive and partitioned RK methods. We conclude with an example that shows how the nonlinear order conditions can be used to obtain an embedded estimate of the state-dependent nonlinear coupling strength in a dynamical system.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2020

Extending the range of constant strain rate nanoindentation testing

Constant strain rate nanoindentation hardness measurements at high sustained strain rates cannot be made in conventional nanoindentation testing systems using the commonly employed continuous stiffness measurement technique (CSM) because of the “plasticity error” recently reported by Merle et al. [Acta Mater.134, 167 (2017)]. To circumvent this problem, here we explore an alternative testing and analysis procedure based on quasi-static loading and an independent knowledge of the Young's modulus, which is easily obtained by standard nanoindentation testing. In theory, the method applies to any indentation strain rate, but in practice, an upper limit on the rate arises from hardware limitations in the testing system. The new methodology is developed and applied to measurements made with an iMicro nanoindenter (KLA, Inc.), in which strain rates up to 100 s -1 were successfully achieved. The origins of the hardware limitations are documented and discussed.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Regional-Scale 3D Ground-Motion Simulations of M w 7 Earthquakes on the Hayward Fault, Northern California Resolving Frequencies 0–10 Hz and Including Site-Response Corrections

Large earthquake ground-motion simulations in 3D Earth models provide constraints on site-specific shaking intensities but have suffered from limited frequency resolution and ignored site response in soft soils. In this work we report new regional-scale 3D simulations for moment magnitude 7.0 scenario earthquakes on the Hayward Fault, northern California with SW4. Simulations resolved significantly broader band frequencies (0–10 Hz) than previous studies and represent the highest resolution simulations for any such earthquake to date. Seismic waves were excited by a kinematic rupture following Graves and Pitarka (2016) and obeyed wave propagation in a 3D Earth model with topography from the U.S. Geological Survey (USGS) assuming a minimum shear wavespeed, VSmin, of 500 m/s. We corrected motions for linear and nonlinear site response for the shear wavespeed, VS, from the USGS 3D model, using a recently developed ground-motion model (GMM) for Fourier amplitude spectra . At soft soil locations subjected to strong shaking, the site-corrected intensities reflect the competing effects of linear amplification by low V S material, reduction of stiffness during nonlinear deformation, and damping of high frequencies. Sites with near-surface V S of 500 m/s or greater require no linear site correction but can experience amplitude reduction due to nonlinear response. Averaged over all sites, we obtained reasonable agreement with empirical ergodic median GMMs currently used for seismic hazard and design ground motions (epsilon less than 1), with marked improvement at soft sedimentary sites. At specific locations, the simulated shaking intensities show systematic differences from the GMMs that reveal path and site effects not captured in these ergodic models. Results suggest how next generation regional-scale earthquake simulations can provide higher spatial and frequency resolution while including effects of soft soils that are commonly ignored in scenario earthquake ground-motion simulations.

58 GEOSCIENCES↗

DOE OSTI2022

Variable Daily Autocorrelation Functions of High-Frequency Seismic Data on Mars

Abstract High-frequency seismic data on Mars are dominated by wind-generated lander vibrations, which are radiated partially to the subsurface. Autocorrelation functions (ACFs) of seismic data on Mars filtered between 1 and 5 Hz show clear phases at ∼1.3, ∼2.6, and ∼3.9 s. Daily temporal changes of their arrival times (dt/t) correlate well with the daily changes of ground temperature, with ∼5% daily variation and ∼50 min apparent phase delay. The following two mechanisms could explain the observations: (1) the interference of two predominant spectral peaks at ∼3.3 and ∼4.1 Hz, assumed to be both lander resonance modes, generate the apparent arrivals in the ACFs; (2) the interference of the lander vibration and its reflection from an interface ∼200 m below the lander generate the 3.3 Hz spectral peak and ∼1.3 s arrival in the ACFs. The driving mechanism of the resolved dt/t that most likely explains the ∼50 min delay is thermoelastic strain at a near-surface layer, affecting the lander–ground coupling and subsurface structures. The two outlined mechanisms suggest, respectively, up to ∼10% changes in ground stiffness at 1–5 Hz and ∼15% velocity changes in the top ∼20 m layer. These are upper bound values considering also other possible contributions. The presented methodology and results contribute to analysis of ACFs with limited data and the understanding of subsurface materials on Mars.

Geochemistry & Geophysics↗

DOE OSTI2022

Design of a Transport System for the PIP-II HB650 Cryomodule

The PIP-II Project at FNAL requires the assembly of 3 high-beta 650MHz cryomodules at STFC Daresbury (DL) in the UK. These modules must be safely transported from DL to FNAL in the USA. Previous experience with cryomodule transport was leveraged at both labs to design a transport system to protect the cryomodules during transit. Requirements for the system included mitigation of shocks, drops, and vibrations, and acting as a lifting fixture. It is comprised of a tessellated steel frame which encompasses the module with a wire rope isolator arrangement which the module mounts to. The frame was designed to withstand the weight of the 12.5 tonne cryomodule in various load cases. Details of shock and vibration profiles were obtained from MIL-STD-810H and were used to guide the sizing of the isolators. The frame and the isolation system were analysed via FEA using the shock and vibration profiles as an input. The transport system was found to be suitable for the given isolation, frame stiffness, and lifting code requirements. The frame has been fabricated and successfully load tested at FNAL. It will now be road tested with a dummy cryomodule before undergoing a trial run to DL.

43 PARTICLE ACCELERATORS↗

DOE OSTI2025

Compaction and Morphology of Lost Circulation Materials

Lost circulation material (LCM) selection is critical to effectively and efficiently treating wellbore fluid losses in geothermal drilling where costs of treatment can be as much as 30% of the total drilling cost. We conducted several uniaxial compaction experiments on 10 different materials and several material mixtures to identify critical mechanical parameters of each. Materials degraded at 200°C were also investigated to understand how elevated temperatures in geothermal wells would degrade their compaction behavior. Granular materials tended to have lower compressibility and higher compression resistance, while more elongated and softer materials had less mechanical stiffness. Mixing materials tended to moderate the mechanical behaviors while heating universally increased the compaction of materials. Microscopy showed that particle strength tended to correlate positively with roundness and circularity and negatively with elongation of a material. Convexity of the degraded and undegraded materials showed heating may have increased the convexity or roughness of the individual particles. In conclusion, we concluded that granular materials are likely to provide the best seals in wells but that a mixture of size distribution, mechanical rigidity, and elongation is more likely to form a better seal for geothermal wells.

annular pressure drilling↗

DOE OSTI2019

Mesoscale Design of Magnetoelectric Heterostructures and Nanocomposites

Multiferroic materials have a coexistence of at least two ferroic orders. The coupling interaction between the different order parameters can produce new phenomena, such as the magnetoelectric (ME) effect. The ME response is the appearance of an electric polarization P upon applying a magnetic field H, and/or vice versa. Magnetoelectricity has been observed as an intrinsic effect in some natural materials at low temperature; however, such single phase materials suffer from extremely weak ME exchange. Better alternatives are two-phase composites consisting of magnetostrictive and piezoelectric phases, which have been shown to have large ME coefficients. Said composites exploit a unique product ME tensor property that depends upon the individual strictions of the piezoelectric and magnetostrictive phases, the elastic stiffness and integrity of the interphase interfaces, the phase distribution and the dimensionality of its connectivity, and any elastic constraint; amongst other things. This research program between D. Viehland PI and S.Priya at Virginia Tech investigated the mesoscale physics and chemistry of such two-phase ME heterostructures. The results of the proposed research are relevant to new generations of multifunctional materials involving heterogeneous components. How the product ME property be optimized? The answers lies with the interphase-interfaces, where the atomic layers coordinate stress transfer from one phase to another. It was the primary goal of this research program to discover such fundamental relationship for two phase ME heterostructures and nanocomposites. This research program integrated all the components required to fully investigate the ME phenomenon: starting from synthesis of nanomaterials with diversified interfacial characteristics; to full electrical, magnetic, and structural characterizations.

36 MATERIALS SCIENCE↗