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All sourcesNASA NTRSDOE OSTI
NASA NTRS2020

Lunar Flashlight Propulsion System Fracture Control Plan

This document is intended to replace a previously approved Fracture Control Plan (VACCO X16029-10-FCP1) for the Lunar Flashlight Propulsion System (LFPS). The current LFPS is a new design and therefore requires a new plan; however, the spacecraft interfaces have remained the same. This document describes the elements of the Marshall Space Flight Center (MSFC)Fracture Control Program and the responsibilities for managing these elements for the LFPS for the Lunar Flashlight CubeSat mission that will launch as a secondary payload on the Space Launch System (SLS). The purpose of this document is to establish a plan for the fracture control activities for MSFC’s LFPS that will be used on the Lunar Flashlight CubeSat. This plan lists all the specific activities that will be performed to satisfy fracture control for this program. The provisions of this plan shall be met to demonstrate that the parts are in compliance with NASA’s fracture control requirements for space flight hardware.

Cubesat↗
NASA NTRSDate not supplied

Developing Approaches for Certification of Uninspectable Fracture Critical AM Components

Introduction - Human-rated spaceflight hardware is subject to the Fracture Control requirements in NASA-STD5019, which are intended to control the risk of component failure due to undetected cracks or defects. - All hardware in this mission class is classified for Fracture Control – Exempt, Non-fracture Critical, or Fracture Critical - Fracture Critical: A classification that identifies a part where failure due to the presence of a crack is a catastrophic hazard ➔ Pressure vessels, engine components, primary structure, etc. - Axiom 1: Material and manufacturing process produce structures and components with cracks or defects. - Axiom 2: The presence of a crack or defect of sufficient size reduces the strength and life of the structure. - Damage Tolerance: demonstration that a component can survive the service life (with a safety factor) in the presence of an undetected flaw or damage. - Components are manufactured from aerospace quality materials using controlled processes. - Components are inspected for damage (cracks, flaws, defects, etc.). - Components are shown by test or analysis to be tolerant to undetected flaws.

Will Tilson↗
DOE OSTI2018

APPLICATION OF THE FAVOR-OCI FRACTURE MECHANICS COMPUTER PROGRAM TO ASME CODE SECTION XI, IWB-3610 FLAW ACCEPTANCE CRITERIA EVALUATIONS

This paper presents an overview of added features in a new version of the FAVOR (Fracture Analysis of Vessels Oak Ridge) computer code called FAVOR-OCI. The original FAVOR code was developed at the US Department of Energy’s Oak Ridge National Laboratory (ORNL) under the sponsorship of the US Nuclear Regulatory Commission (NRC). FAVOR is applied by US and international nuclear power industries to perform deterministic and probabilistic fracture mechanics analyses of commercial nuclear reactor pressure vessels (RPVs). Appli-cations of FAVOR are focused on insuring that the structural integrity of aging, and increasingly embrittled, RPVs is main-tained throughout their licensed service life. Based on the final ORNL release of FAVOR, v16.1, FAVOR-OCI extends existing deterministic features of FAVOR while preserving all prev-iously-existing probabilistic capabilities of FAVOR.The objective of this paper is to describe new deterministic features in FAVOR-OCI that can be applied to analytical evaluations of planar flaws. These evaluations are consistent with the acceptance criteria of ASME Code, Section XI, Article IWB-3610, including Subarticles IWB-3611 (acceptance based on flaw size) and IWB-3612 (acceptance based on applied stress intensity factor). The linear elastic fracture mechanics (LEFM) capabilities of FAVOR-OCI also incorporate the analytical procedures presented in the Nonmandatory Appendix A, Analysis of Flaws, Article A-3000, Method of KI Determination, for both surface and subsurface (embedded) flaws.The paper describes a computational methodology for determining critical values of fracture-related parameters that satisfy ASME Code Section XI acceptance criteria for flaws exposed to multiple thermal-hydraulic transients. These com-pute-intensive analyses can be carried out with a single execution of FAVOR-OCI. The new methodology determines critical values by solving for either the point of tangency or point of intersection between applied KI versus time histories and a user-selected fracture toughness material property (e.g., ASME KIc, FAVOR Weibull KIc, or Master Curve Weibull KJc) for surface or subsurface flaws. Situations where warm prestress conditions apply can also be addressed. The paper highlights a need for this new capability via applications to a recent independent review of safety cases for RPVs in two Belgian nuclear power plants (NPPs). That review required ASME Section XI assessments of several thousand embedded, quasi-laminar flaws in the wall of each RPV. Analysis results provided by the new capability contributed to the technical bases compiled from several sources by the Belgian nuclear regulatory agency (FANC) and eventually used by FANC to justify the restart of these NPPs.

Dickson, Terry L.↗
DOE OSTI2023

Microscale drivers and mechanisms of fracture in post-processed additively manufactured Ti–6Al– 4 V

Herein, we focus on understanding the microstructure-fracture correlations in a Ti–6Al– 4 V alloy additively manufactured via electron beam melting (EBM) and subjected to various post-process heat-treatments. Specifically, the as fabricated material is subjected to a sub-transus heat-treatment followed by air-cooling and a super-transus heat-treatment followed by either air- or furnace-cooling. Next, a series of in-situ single edge notch tension (SENT) tests are carried out under a high-resolution digital optical microscope. The panoramic high-resolution images captured during the in-situ tests are then used to characterize the planar deformation on the specimen surface using microstructure-based digital image correlation (DIC). Additionally, the results of the in-situ SENT tests together with DIC and post-mortem fractographic analyses provided us with a better understanding of the microstructure-fracture correlations in these materials. Our results show that the fracture mechanism of the as fabricated and sub-transus heat-treated materials is essentially the same, while the changes in the microstructure following the super-transus heat-treatments significantly affects the fracture mechanism. In this case, several microcracks of hundreds of microns in length first nucleate away from the deformed notch following extreme plastic deformation at discrete locations. Furthermore, the location of these microcracks in the super-transus heat-treated materials is extremely sensitive to the details of the underlying microstructure.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Assessment and Response of Treated Cocos nucifera Reinforced Toughened Epoxy Composite Towards Fracture and Viscoelastic Properties

The current research work is dedicated to addressing the fibre orientation problem and environmental issues through the development of micron-sized coir particle reinforced epoxy composite with enhanced fracture toughness and viscoelastic properties. A ‘specific grade’ standard epoxy adhesive based polymer composite is produced with reinforcement of surface modified coir particle filler. The surface modification on raw coir filler is carried out by NaOH and confirmed by Fourier transform infrared spectroscopy (FTIR), X-ray diffractogram and thermogravimetric analysis (TGA). The reduced intensity of hydroxide functional group as well as the enhanced thermal stability of surface modified coir filler is observed by FTIR and TGA respectively. The properties of produced composite samples are investigated by tensile test with low to high strain rate, fracture toughness test and dynamic mechanical analysis. The investigation revealed an improvement in tensile strength, fracture toughness and storage modulus values of toughened coir–epoxy composite with filler loading. The maximum value of ultimate tensile strength, modulus of elasticity and fracture toughness were 27.58 MPa, 0.738 GPa and 1.792 MPa m{sup 1/2}. The constraints like strain rate and filler content demarcated some critical effects on tensile strength, Young’s modulus and modulus of rupture. The research work suggests the applicability of the developed material as household items, replacement of timber product for indoor and outdoor decorations.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2019

Computational Modeling of Fracture Toughness of Al-Si and Al-Zn-Mg-Cu Alloys with Detected Porosity

This article presents the results of an experimental and numerical analysis of the fracture resistance of cast aluminum alloys subjected to variable loads over time based on the fracture mechanics method. The subjects of the analysis were the AlSi9 and AlZn6MgCu alloys (usually used for plastic processing) in which the presence of porosities in the form of separate or dispersed voids was revealed experimentally. The material for the experimental procedures was obtained directly from a casting or from casting samples. Depending on the type of the defect detected, different numerical models were proposed. The results of the numerical calculations were verified experimentally. Static tensile tests, fatigue low-cycle tests, fracture mechanics tests, fatigue crack propagation tests, a microscopic examination of the sample fracture area, and an x-ray tomographic analysis were all performed. A correlation of the results between the numerical analysis and the experimental work has been found. On the basis of the proposed calculation models, the fatigue life of castings of the analyzed alloys can be predicted in the case of concentrated and dispersed defects.

36 MATERIALS SCIENCE↗
DOE OSTI2019

A phase-field formulation for dynamic cohesive fracture

We extend a phase-field/gradient damage formulation for cohesive fracture to the dynamic case. The model is characterized by a regularized fracture energy that is linear in the damage field, as well as non-polynomial degradation functions. Two categories of degradation functions are examined, and a process to derive a given degradation function based on a local stress-strain response in the cohesive zone is presented. The resulting model is characterized by a linear elastic regime prior to the onset of damage, and controlled strain-softening thereafter. The governing equations are derived according to macro- and microforce balance theories, naturally accounting for the irreversible nature of the fracture process by introducing suitable constraints for the kinetics of the underlying microstructural changes. The model is complemented by an efficient staggered solution scheme based on an augmented Lagrangian method. Numerical examples demonstrate that the proposed model is a robust and effective method for simulating cohesive crack propagation, with particular emphasis on dynamic fracture.

42 ENGINEERING↗
DOE OSTI2022

A thermodynamically consistent finite strain phase field approach to ductile fracture considering multi-axial stress states

Phase field models for ductile fracture have gained significant attention in the last two decades due to their ability in implicitly tracking the nucleation and propagation of cracks. However, most crack phase field formulations for elastoplastic solids focus only on the effects of plastic deformation, and do not consider the different multi-axial stress states that may arise in practical designs. In this work, a thermodynamically consistent phase field approach coupled with finite strain plasticity, considering multi-axial stress states is presented. In order to account for the coupling between plasticity and stress states, the Stress-Weighted Ductile Fracture Model (SWDFM) is utilized. The SWDFM represents a criterion for predicting ductile crack initiation under both monotonic and cyclic loadings based on histories of an internal plastic variable, stress triaxiality, and the Lode angle parameter. The excellent performance of the SWDFM for predicting ductile crack initiation motivates for its incorporation into a phase field approach for predicting both crack initiation and propagation through degradation of the fracture toughness. Moreover, based on the second law of thermodynamics, exact requirements are imposed on the rate at which the fracture toughness can evolve. Here, a novel function for degrading the plastic yield surface during the evolution of damage is introduced. This function, in line with experimental observations, leads to an accumulation of plastic deformation in damaged regions of a solid, and avoids numerical instabilities arising from concentrations of large plastic deformations in severely damaged regions. For validating the proposed model, results of computational simulations are compared to data from selected tests considering different multi-axial stress states. Comparisons of the numerical results with data from laboratory experiments demonstrate the capabilities of the proposed framework.

42 ENGINEERING↗
DOE OSTI2023

Experimental flow-through a single fracture with monolayer proppant at reservoir conditions: A case study on Caney Shale, Southwest Oklahoma, USA

Global energy systems are undergoing a crucial transition to clean energy sources, thereby moving away from fossil-fuel based energy with the ultimate aim of reducing carbon dioxide emissions. It is essential to continue to advance in exploring and developing shale gas resources as this will underpin the global supply of natural gas that is needed to support the energy transition. The challenge hereby is that the slow fluid flow of the shale matrix due to its very low permeability requires large-scale volume fracturing to produce a conductive fracture network that enhances the connectivity between the shale formation and the wellbore. This work examines the influence of a thin proppant layer on a single fracture using a flow-through experiment, and also explores whether proppant embedment in the Caney shale is affected by the rock mineralogy, surface roughness, fluids, confining stress, time, temperature and bedding. The experiment was conducted for a duration of nine days (216 h), experimental temperature was varied from ambient temperature to reservoir temperature of 125 °C (257 °F) and confining stress was varied from 367 psi (2.53MPa) to a maximum of 4011.82 psi (27.66 MPa). Here, we find that the conductivity of the fracture is primarily influenced by the layer of proppant used, surface roughness, mineralogy, fluids, temperature and closure stress.

Caney shale↗
DOE OSTI2015

The effect of aging treatment on the fracture toughness and impact strength of injection molded Ni-625 superalloy parts

In this study, the effect of aging heat treatment on fracture toughness and impact strength of Ni-625 superalloy fabricated by using powder injection molding (PIM) method was examined. After a feedstock was prepared by mixing the prealloyed Ni-625 superalloy powder, which was fabricated by gas atomisation, with a polymeric binder system and then it was granulated, it was shaped through the use of injection. The molded specimens were sintered at 1300 °C for 3 h after a two-stage debinding process. Once the sintered specimens were treated in the solution at 1150 °C for 2 h, they were quenched. Aging treatment was performed by keeping specimens at 745 °C for 22 h. Fracture toughness and impact tests were performed on sintered and aged specimens. Microstructure examinations were performed by using optical microscope, scanning electron microscope, and transmission electron microscope. The results revealed that aging heat treatment led to the formation of some carbides and intermetallic phases in the microstructure. While the hardness of the aged specimens increased due to these phases, their fracture toughness and impact strength values decreased. - Highlights: • Ni-625 superalloy components were produced by means of powder injection molding. • The produced components were subjected to aging treatment. • Aging process provided approximately 50% increase in the hardness of components. • Intermetallic precipitates, carbides and TCP phases occurred within the aged parts. • Fracture toughness and impact strength values decreased due to the hard phases.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Microstructural characterization, formation mechanism and fracture behavior of the needle δ phase in Fe–Ni–Cr type superalloys with high Nb content

Microstructural characterization, formation mechanism and fracture behavior of the needle δ phase in Fe–Ni–Cr type superalloys with high Nb content (GH4169, equivalent to Inconel 718) have been quantitatively investigated in this research. The typical microstructures of δ phases with the stick, mixed and needle shapes obviously present in Inconel 718 after the isothermal upsetting at the temperature of 980–1060 °C with the initial strain rate of 10{sup −3}–10{sup −1} s{sup −1}. It is found that the shape of the δ phase has a great effect on the mechanical properties of the alloy, viz., the stick δ phase behaves good plasticity and the needle δ phase has good strength. In addition, the needle δ phase can be used to control the grain size as it can prevent grain growth. The combined effect of the localized necking and microvoid coalescence leads to the final ductile fracture of the GH4169 components with the needle δ phase. Both dislocation motion and atom diffusion are the root-cause for the needle δ phase to be firstly separated at grain boundary and then at sub-boundary. The formation mechanism of the needle δ phase is the new finding in this research. Furthermore, it is the primary mechanism for controlling the needle δ phase in Fe–Ni–Cr type superalloys with high Nb content. - Highlights: • Shape of the δ phase takes great effect on mechanical property. • Needle δ phase plays a great role to prevent grain growth. • Needle δ phase can enhance the fracture strength. • Microstructure mechanism of the needle δ phase has been investigated. • Fracture behavior of the needle δ phase has been studied.

36 MATERIALS SCIENCE↗
DOE OSTI2018

The Development of Wormholes in Laboratory-Scale Fractures: Perspectives From Three-Dimensional Simulations

Here, we investigate the development of wormholes in laboratory–scale fractures using three–dimensional numerical simulations. Well–controlled initial conditions, involving a small perturbation near the inlet of an otherwise flat fracture aperture field, were used to make a systematic study of the effects of flow rate and reaction rate on the aperture evolution. We find at least two characteristic wormhole shapes, which can be grouped within a phase diagram in the space of Péclet and Damköhler numbers. We investigate how this phase diagram depends on fracture geometry, specifically the length ( L ) and width ( W ) in comparison to the initial aperture ( h 0 ). This information is used to determine an effective Damköhler number that leads to a Péclet and length–independent phase boundary between wormholes and uniform dissolution. We relate these observations to experimental studies of wormhole formation in dissolving fractures.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2018

Modelling DC responses of 3D complex fracture networks

Here, the determination of the geometrical properties of fractures plays a critical role in many engineering problems to assess the current hydrological and mechanical states of geological media and to predict their future states. However, numerical modeling of geoelectrical responses in realistic fractured media has been challenging due to the explosive computational cost imposed by the explicit discretizations of fractures at multiple length scales, which often brings about a tradeoff between computational efficiency and geologic realism. Here, we use the hierarchical finite element method to model electrostatic response of realistically complex 3D conductive fracture networks with minimal computational cost.

58 GEOSCIENCES↗
DOE OSTI2019

Rapid clay precipitation in explosion-induced fractures

Fractures within the earth control rock strength and fluid flow, but their dynamic nature is not well understood. As part of a series of underground chemical explosions in granite in Nevada, we collected and analyzed microfracture density data sets prior to, and following, individual explosions. Our work shows an ~4-fold increase in both open and filled microfractures following the explosions. Based on the timing of core retrieval, filling of some new fractures occurs in as little as 6 wk after fracture opening under shallow (<100 m) crustal conditions. These results suggest that near-surface fractures may fill quite rapidly, potentially changing permeability on time scales relevant to oil, gas, and geothermal energy production; carbon sequestration; seismic cycles; and radionuclide migration from nuclear waste storage and underground nuclear explosions.

58 GEOSCIENCES↗
DOE OSTI2023

Utah FORGE 3-2418: Wellbore Fracture Imaging Using Inflow Detection Measurements - Workshop Presentation

This is a presentation on the Wellbore Fracture Imaging Using Inflow Detection Measurements project by Stanford University, presented by Dr. Roland N. Horne. The project's objective was to make measurements in the Utah FORGE wells, both before and after fracturing experiments, to map the fractures and estimate their flow magnitude. The approach utilizes a ion-specific electrode that will measure chloride in the well. The idea is that water flowing into the well from the fractures will have a different concentration of chloride than the surrounding water. This presentation was featured in the Utah FORGE R&D Annual Workshop on September 8, 2023. The workshop provided a valuable opportunity to explore the progress made in each of the 17 Research and Development projects funded under Solicitation 2020-1 which aim to enhance our understanding of the crucial factors influencing the development of Enhanced Geothermal Systems (EGS) reservoirs and resources.

15 GEOTHERMAL ENERGY↗
DOE OSTI2023

Utah FORGE 3-2535: Joint EM-Seismic-InSAR Imaging of Fracture Properties - Workshop Presentation

This is a presentation on the Joint Electromagnetic/Seismic/InSAR Imaging of Spatial-Temporal Fracture Growth and Estimation of Physical Fracture Properties During EGS Resource Development project by Lawrence Berkeley National Laboratory, presented by Dr. David Alumbaugh, Staff Scientist. The project's objective was to develop a set of technologies and workflow to image induced fracture generation and growth for an Enhanced Geothermal System (EGS). The project anticipates imaging of the fracture generation and growth at FORGE using a combination of passive seismic, active source borehole EM, and INSAR technology. This presentation was featured in the Utah FORGE R&D Annual Workshop on September 8, 2023. The workshop provided a valuable opportunity to explore the progress made in each of the 17 Research and Development projects funded under Solicitation 2020-1 which aim to enhance our understanding of the crucial factors influencing the development of Enhanced Geothermal Systems (EGS) reservoirs and resources.

15 GEOTHERMAL ENERGY↗
DOE OSTI2023

Coupling Thermal-Hydraulics with Reactor Pressure Vessel Fracture Models

Because of the importance of maintaining the integrity of the reactor pressure vessel (RPV) in light-water reactors, significant effort has been devoted over the last several decades to understand the potential failure mechanisms, characterize how material properties evolve due to environmental conditions, and develop tools to assess the probability of fracture in aged RPVs during potential transient events. One important aspect of this problem that has not yet been fully addressed is the effects of nonuniform cooling on the RPV inner wall due to the way low-temperature water injected into the primary coolant system is distributed within the RPV during potential loss-of-coolant accident transients. Colder temperatures are expected in the regions near the inlets, causing a “cold-plume” effect. Rapid cooling of the RPV wall increases the likelihood of fracture initiation, and localized cooling due to cold-plume effects could potentially exacerbate this problem. The Grizzly code can perform a three-dimensional simulation of the RPV thermomechanical response as well as the probabilistic assessment of fracture for a population of pre-existing flaws, which is necessary to account for spatial variations in coolant temperature. This report documents a first effort to couple Grizzly RPV fracture models with computational fluid dynamics models performed using the Cardinal code, which allows for a realistic representation of the temperature distribution. This report demonstrates this coupling approach on two test cases: a simplified proof-of-concept scenario and a realistic small-break loss-of-coolant accident scenario. In both cases, the effects of the spatially varying temperature are evident; although, because the small-break loss-of-coolant accident scenario was far from challenging the RPV’s margins, it is still inconclusive how important cold-plume effects are in realistic accident scenarios. However, this effort represents an important step toward performing realistic analyses to determine to what extent spatially nonuniform cooling might affect RPV integrity under more aggressive accident scenarios.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Utah FORGE 2-2446: Closing the Loop Between In-Situ Stress Complexity and EGS Fracture Complexity - 2024 Annual Workshop Presentation

This is a presentation on Closing the Loop Between In-Situ Stress Complexity and EGS Fracture Complexity by Lawrence Livermore National Laboratory, presented by Matteo Cusini. The video discusses the combination of high-fidelity simulations and true-triaxial block fracturing tests to explore the intricate relationship between in-situ stress and hydraulic fracture patterns. This presentation was featured in the Utah FORGE R&D Annual Workshop on August 14, 2024.

15 GEOTHERMAL ENERGY↗