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At least 1,027 records · Page 57

Assessment of four strain energy decomposition methods for phase field fracture models using quasi-static and dynamic benchmark cases

Abstract Strain energy decomposition methods in phase field fracture models separate strain energy that contributes to fracture from that which does not. However, various decomposition methods have been proposed in the literature, and it can be difficult to determine an appropriate method for a given problem. The goal of this work is to facilitate the choice of strain decomposition method by assessing the performance of three existing methods (spectral decomposition of the stress or the strain and deviatoric decomposition of the strain) and one new method (deviatoric decomposition of the stress) with several benchmark problems. In each benchmark problem, we compare the performance of the four methods using both qualitative and quantitative metrics. In the first benchmark, we compare the predicted mechanical behavior of cracked material. We then use four quasi-static benchmark cases: a single edge notched tension test, a single edge notched shear test, a three-point bending test, and a L-shaped panel test. Finally, we use two dynamic benchmark cases: a dynamic tensile fracture test and a dynamic shear fracture test. All four methods perform well in tension, the two spectral methods perform better in compression and with mixed mode (though the stress spectral method performs the best), and all the methods show minor issues in at least one of the shear cases. In general, whether the strain or the stress is decomposed does not have a significant impact on the predicted behavior.

Zhang, Shuaifang↗

Interaction Between Proppant Compaction and Single-/Multiphase Flows in a Hydraulic Fracture

Understanding proppant-transport and -deposition patterns in a hydraulic fracture is vital for effective and economical production of petroleum hydrocarbons. In this research, a numerical-modeling approach, combining the discrete-element method (DEM) with single-/multiphase lattice Boltzmann (LB) simulation, was adopted to advance understanding of the interaction between reservoir depletion, proppant-particle compaction, and single-/multiphase flows in a hydraulic fracture. DEM was used to simulate effective-stress increase and the resultant proppant-particle movement and rearrangement during the process of reservoir depletion caused by hydrocarbon production. Simulated pore structure of the proppant pack was extracted and used as boundary conditions in the LB simulation to calculate the time-dependent permeability of the proppant pack. We first validated the DEM-LB numerical work flow, and the simulated proppant-pack permeabilities as functions of effective stress were in good agreement with laboratory measurements. Furthermore, three proppant packs with the same average particle diameter but different diameter distributions were generated to study the role of proppant-size heterogeneity (variation in particle diameter). Specifically, we used the coefficient of variation (COV) of diameter, defined as the ratio of standard deviation of diameter to mean diameter, to characterize the heterogeneity of particle size. We obtained proppant-pack porosity, permeability, and fracture-width reduction (closure distance) as functions of effective stress. Under the same effective stress, a proppant pack with a higher diameter COV had lower porosity and permeability and larger fracture-width reduction. This was because the high diameter COV gave rise to a wider diameter distribution of proppant particles; smaller particles were compressed into the pore space between larger particles with increasing stress, leading to larger closure distance and lower porosity and permeability. With multiphase LB simulation, relative permeability curves were obtained, which are critical for larger-scale reservoir simulations under various effective stresses. The relative permeability of the oil phase was more sensitive to changes in geometry and stress, compared with the wetting phase. This was because the oil phase occupied larger pores; compaction of the proppant pack affected the structure of the pores, because the pores were farther from the grain contacts and thus more susceptible to collapse. It is also interesting to note that when effective stress increased continuously, oil relative permeability increased first and then decreased. This nonmonotonic behavior was the result of the nonmonotonic development of pore structure and oil connectivity under increasing stress.

Fan, Ming↗

Determining the Role of Sost and Sostdc1 During Fracture Healing

The bone is a dynamic organ, often changing throughout the course of the human lifespan with its continuous remodeling, laying down new bone and resorbing old bone. With age, the bone becomes increasingly porous and mechanically unstable, leading to the development of osteoporosis in some individuals. Elderly patients with osteoporosis are at an increased risk of fracturing their bones which contributes to a higher mortality rate. Recent studies have revealed that type 1 diabetic mellitus (T1DM) patients also have an osteoporotic bone phenotype and impaired fracture healing, independent of age. Currently, there is a lack of available treatments that can improve impaired healing and directly enhance bone formation. Therefore, there is a great need for developing new therapies that can not only aid type 1 diabetic patients with osteoporosis to improve bone phenotype, but that could also aid patients with difficult or impaired fracture healing. In this thesis, I will be discussing the role of Wnt signaling and Sclerostin, a Wnt antagonist that negatively regulates bone formation, in the content of fracture repair.

59 BASIC BIOLOGICAL SCIENCES↗

Modeling Dynamic Fracture of Cryogenic Pellets

This work is part of an investigation with the long-range objective of predicting the size distribution function and velocity dispersion of shattered pellet fragments after a large cryogenic pellet impacts a solid surface at high velocity. The study is vitally important for the shattered pellet injection (SPI) technique, one of the leading technologies being implemented at ORNL for the mitigation of disruption damage on current tokamaks and ITER. The report contains three parts that are somewhat interwoven. In Part I we formulated a self-similar model for the expansion dynamics and velocity dispersion of the debris cloud following pellet impact against a thick (rigid) target plate. Also presented in Part I is an analytical fracture model that predicts the nominal or mean size of the fragments in the debris cloud and agrees well with known SPI data. The aim of Part II is to gain an understanding of the pellet fracturing process when a pellet is shattered inside a miter tube with a sharp bend. Because miter tubes have a thin stainless steel (SS) wall a permanent deformation (dishing) of the wall is produced at the site of the impact. A review of the literature indicates that most projectile impact on thin plates are those for which the target is deformed and the projectile is perfectly rigid. Such impacts result in “projectile embedding” where the projectile speed is reduced to zero during the interaction so that all the kinetic energy (KE) of the projectile goes into the energy stored in plastic deformation. Much of the literature deals with perforation of the target. The problem here is quite different; the softer pellet easily undergoes complete material failure causing only a small transfer of KE to stored energy of wall deformation. For the real miter tube, we derived a strain energy function for the wall deflection using a non-linear (plastic) stress-strain relation for 304 SS. Using a dishing profile identical to the linear Kirchkoff-Love profile (for lack of a rigorously derived profile) we derived the strain energy associated with the deflection and applied a virtual work principle to find a relationship between the impact (load) pressure to the measured wall deflection depth. The inferred impact pressure was in good agreement with the expected pressure for oblique cryogenic pellet impacts where the pellet shear stress causing cleavage fracture is well above the yield stress for pure shear. The section is concluded with additional discussion on how this wall deformation data lends further support to the analytical fracture model presented in Part I. In Part III we present three different size distribution models. A summary, with a few brief suggestions for a follow on study, is provided at the end of this report.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

Development of Mini-Compact Tension Test Method for Determining Fracture Toughness Master Curves for Reactor Pressure Vessel Steels

Small specimens are playing the key role in evaluating properties of irradiated materials. The use of small specimens provides several advantages. Typically, only a small volume of material can be irradiated in a reactor at desirable conditions in terms of temperature, neutron flux, and neutron dose. A small volume of irradiated material may also allow for easier handling of specimens. Smaller specimens reduce the amount of radioactive material, minimizing personnel exposures and waste disposal. However, use of small specimens imposes a variety of challenges as well. These challenges are associated with proper accounting for size effects and transferability of small specimen data to the real structures of interest. Any fracture toughness specimen that can be made out of the broken halves of standard Charpy specimens may have exceptional utility for evaluation of reactor pressure vessels (RPVs) since it would allow one to determine and monitor directly actual fracture toughness instead of requiring indirect predictions using correlations established with impact data. The Charpy V-notch specimen is the most commonly used specimen geometry in surveillance programs. Validation of the mini compact tension specimen (mini-CT) geometry has been performed on previously well characterized Midland beltline Linde 80 (WF-70) weld in the unirradiated condition. It was shown that the fracture toughness transition temperature, To, measured by these Mini-CT specimens is almost the same as To value that was derived from various larger fracture toughness specimens. Moreover, an International collaborative program has been established to extend the assessment and validation efforts to irradiated Linde 80 weld metal. The program is underway and involves the Oak Ridge National Laboratory (ORNL), Central Research Institute for Electrical Power Industry (CRIEPI), and Electric Power Research Institute (EPRI). The irradiated Mini-CT specimens from broken halves of previously tested Charpy specimens of Midland beltline weld have been machined and just arrived to ORNL as part of this international collaboration. The ORNL will initiate tests of the irradiated Linde 80 weld in FY2017 and results of this international program will be reported in FY2018.

42 ENGINEERING↗

Fracture Toughness Characterization of Highly irradiated Reactor Pressure Weld from the ATR-2 Experiment

The UCSB ATR-2 irradiation experiment is designed to generate a new database on a wide variety of irradiated reactor pressure vessel (RPV) steels to fill a critical gap in predicting high fluence embrittlement for extended plant operation up to 80 years. A major focus in this experiment is to characterize the effects of irradiation temperature, neutron flux and fluence, and alloy chemistry on MNSP evolution, and model how these features impact hardening and embrittlement, manifested as shifts in ductile-to-brittle transition temperature. As part of these efforts, disk compact tension (DCT) specimens of three representative materials were included in the ATR-2 experiment to have direct measurement of transition fracture toughness shift and, thus, to have some benchmark data to compare outcoming predictive models with actual fracture toughness shifts. In addition, the attempts would be made to use these fracture toughness data to address the potential effect of high dose irradiation on the shape of the Master Curve for highly embrittled RPV material.This report provides data for the fracture toughness characterization of highly embrittled weld from Palisades steam generator.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Final Report for LDRD: The Effect of Proppant Placement on Closure of Fractured Shale Gas Wells

The recent boom in the oil and natural gas industry of hydraulic fracture of source rocks has caused a new era in oil and gas production worldwide. However, there are many parts of this process that are poorly understood and thus hard to control. One of the few things that can be controlled is the process of injection to create the fractures in the subsurface and the subsequent injection of proppants to maintain the permeability of the fractured formation, allowing hydrocarbons to be extracted. The goal of this work was to better understand the injection process and resulting proppant distribution in the fracture through a combination of lab-scale experiments and computational models.

02 PETROLEUM↗

Post-Irradiation Fracture Toughness Characterization of Generation II FeCrAl Alloys

Currently, the handbook on FeCrAl material properties contains only limited data regarding the fracture toughness properties of any FeCrAl alloy, let alone alloys currently under investigation within the Advanced Fuels Campaign (AFC) such as the Oak Ridge National Laboratory (ORNL) derived FeCrAl alloys. Unirradiated datasets developed both by ORNL and previously within literature using Charpy V-notch specimens to determine the ductile to brittle transition temperature (DBTT) showed key findings including (i) increasing Al and/or Cr content can raise the DBTT of FeCrAl alloys, (ii) DBTT values can typically reside at or above room temperature for FeCrAl alloys, and (iii) grain size and residual strain can have an effect on the fracture properties. These results suggest that the fracture toughness of FeCrAl alloys may be a factor in its deployment for nuclear power applications, but no studies have been completed prior regarding the DBTT or fracture toughness of FeCrAl alloys after neutron irradiation, especially for the leaner Cr content alloys currently under investigation as candidate alloys for light water reactor (LWR) cladding. Taken in isolation, embrittlement of a cladding alloy during service has no bearing on possible licensure. Hydriding of zirconium cladding alloys is well understood to result in significant embrittlement. Furthermore, mechanical failure of irradiated cladding containing fuel pellets occurs at far higher stresses than defueled cladding samples because the presence of the fuel toughens the fuel rod. Despite this absence of direct relevance to licensure, radiation embrittlement is a fundamental structure-property evolution that should be understood to guide further development of FeCrAl alloys. Licensure of FeCrAl incorporates far more complex system behaviors that will not be possible until larger quantities of fueled irradiated rodlets are available.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Fracture Toughness of Microstructural Gradients

Traditional singularity-based fracture mechanics theories rely on their ability to infer the crack tip driving force (local field) by surveying macroscopic physical magnitudes far from the crack tip (far field). This key capability allows engineers to employ nominal forces or displacements to estimate the potential for stable or unstable crack growth. In the case of heterogeneous or anisotropic materials, traditional fracture approaches are not fully theoretically sound and applications rely on extrapolating methodologies with ad-hoc corrections. This Express Laboratory Directed Research and Development (ELDRD) program employed mesoscale-sensitive finite element simulations to assess the impact of grain size and texture on the crack tip behavior. A dislocation-based crystal plasticity model conveys grain size effects by computing the constraint on dislocation cell structures. We assessed the effects of microstructural variability on multiple displacement-based measurements of the fracture driving forces for crack opening (Mode I) and sliding (Mode II). We also consider multiple microstructural realizations of single phase metals undergoing ductile failure. The results show that grain size and texture affect the applied fracture driving force and can induce a significant Mode II deformation under force and displacement control, which is completely neglected in homogeneous models. A large variability in driving forces upon identical far field applied conditions is attributed to a buffering effects of the microstructure. Furthermore, crack mouth opening displacement is almost insensitive to microstructure, which suggests that experimental measurements using such a magnitude (e.g., plastic hinge model) may underestimate local crack tip driving force variability.

42 ENGINEERING↗

Understanding Discrete Fracture Networks Through Spectral Graph Theory

Discrete Fracture Network models (DFNs) are used to simulate fluid flow and particle transport through fracture networks in low permeability rock. Understanding these processes are essential in many subsurface applications, such as environmental restoration of contaminated fractured media, CO 2 sequestration, detection of low-level nuclear tests, and hydrocarbon extraction. Compared with other models, DFNs allow for incorporation of a wider range of network characteristics but have substantially greater computation cost. These networks can be represented with graphs, allowing the use of graph theory tools to study the networks. I used Python to simulate flow and transport on a range of DFNs and analyzed these networks using methods from network analysis and spectral graph theory. My purpose was to find ways to gain insight about flow and transport on DFNs using these graph representations, bypassing the computationally intensive meshing typically required. My work is still in progress, but I have discovered several interesting trends and patterns that I believe could be useful towards my goal. If I am able to bring these results to fruition, they will aid subsurface geologists in extracting flow and transport information about fracture networks more efficiently.

54 ENVIRONMENTAL SCIENCES↗

Fracture Toughness Characterization of Generation II FeCrAl Alloys after ~18 dpa Irradiation

FeCrAl alloys are promising candidate materials for the accident tolerant fuel (ATF) cladding applications due to their excellent corrosion resistance to the elevated temperature steam environment. Currently, the handbook on FeCrAl material properties contains only limited data regarding the fracture toughness properties of any FeCrAl alloy. This includes alloys currently under investigation within the Advanced Fuels Campaign (AFC) at Oak Ridge National Laboratory (ORNL). In this project, a series of irradiation capsules have been irradiated in the High Flux Isotope Reactor (HFIR) at ORNL with two Generation II FeCrAl candidate alloys, i.e., C06M and C36M, to assess the fracture response of these alloys after neutron irradiation. These alloys represent the “book-end” compositions for C26M, the alloy currently being developed as the leading candidate for LWR cladding. A total of six irradiation capsules were irradiated in HFIR at target temperatures of 200°C, 330°C, and 500°C up to target damage doses of 8 displacements per atom (dpa) and 16 dpa. These damage doses represent the expected middle and end of life damage levels for typical LWR cladding while the irradiation temperature regimes will provide insight into the role of varying microstructural features on the fracture toughness properties of neutron irradiated FeCrAl alloys. To date, irradiation of all capsules has been completed in HFIR. This report summarizes the latest results of microhardness and fracture toughness PIE for the 16 dpa capsules (FCAB2, FCAB4, and FCAB6), for which the measured irradiation conditions were: 204°C/17.6dpa, 343°C/18.3dpa, and 507°C/18.6dpa. The main conclusions of this study can be summarized as follows: 1) After the 204°C/17.6dpa irradiation, both C06M and C36M exhibited significant irradiation hardening and embrittlement 2) After the 343°C/18.3dpa irradiation, both C06M and C36M exhibited small irradiation hardening without irradiation embrittlement 3) After the 507°C/18.6dpa irradiation, both C06M and C36M exhibited irradiation softening without irradiation embrittlement 4) Comparing the microhardness and Master Curve reference temperature T 0q before and after neutron irradiation, we did not observe a linear correlation between the two parameters for both C06M and C36M. This should be mainly due to a flat response of the Master Curve reference temperature T 0q to the irradiations at 166-204°C and 315-343°C ranges 5) C06M showed a lower T 0q , meaning better toughness, than C36M at the unirradiated condition and such trend was kept even after neutron irradiation except for the 166-204°C irradiation where both materials had similar T 0q . 6) In terms of hardening and embrittlement, the irradiation effect on both C06M and C36M appeared to saturate after an irradiation dose of 7 dpa.

36 MATERIALS SCIENCE↗

Integrated Multiphysics Modeling of Environmentally Assisted Brittle Fracture

Brittle materials, such as cement, compose major portions of built infrastructure and are vulnerable to degradation and fracture from chemo-mechanical effects. Currently, methods of modeling infrastructure do not account for the presence of a reactive environment, such as water, on the acceleration of failure. Here, we have developed methodologies and models of concrete and cement fracture that account for varying material properties, such as strength, shrinkage, and fracture toughness due to degradation or hydration. The models have been incorporated into peridynamics, non-local continuum mechanics methodology, that can model intersecting and branching brittle fracture that occurs in multicomponent brittle materials, such as concrete. Through development of new peridynamic capabilities, decalcification of cement and differential shrinkage in clay-cement composites have been evaluated, along with exemplar problems in nuclear waste cannisters and wellbores. We have developed methods to simulate multiphase phenomena in cement and cement-composite materials for energy and infrastructure applications.

36 MATERIALS SCIENCE↗

Physically rigorous reduced-order flow models of fractured subsurface environments without explosive computational cost

Fractured media models comprise discontinuities of multiple lengths (e.g. fracture lengths and apertures, wellbore area) that fall into the relatively insignificant length scales spanning millimeter-scale fractures to centimeter-scale wellbores in comparison to the extensions of the field of interest, and challenge the conventional discretization methods imposing highly-fine meshing and formidably large numerical cost. By utilizing the recent developments in the finite element analysis of electromagnetics that allow to represent material properties on a hierarchical geometry, this project develops computational capabilities to model fluid flow, heat conduction, transport and induced polarization in large-scale geologic environments that possess geometrically-complex fractures and man-made infrastructures without explosive computational cost. The computational efficiency and robustness of this multi-physics modeling tool are demonstrated by considering various highly-realistic complex geologic environments that are common in many energy and national security related engineering problems.

42 ENGINEERING↗

Closing the loop between in-situ stress complexity and EGS fracture complexity

The goal of the project is to employ a combination of high-fidelity simulations and true-triaxial block fracturing tests at high temperature to explore the intricate relationship between in-situ stress and hydraulic fracture patterns and better characterize the in-situ stress at Utah FORGE. Laboratory experiments are used to validate numerical models and better understand the impact of various parameters (e.g., temperature, well orientation, stress, etc) on the hydraulic fracture nucleation process in EGS. The project will have a significant impact as it will (1) improve the characterization of the in-situ stress field at FORGE; (2) demonstrate how high-fidelity modeling tools can be employed to analyze data for EGS; (3) provide a unique set of high-temperature hydraulic fracturing experimental results for EGS to help identifying the most important components for in-situ stress estimation and to validate the current in-situ stress estimation theory and establish a strong foundation for proposing a new one; (4) provide a validated set of numerical tools in an open source simulation framework (GEOS) that can be used to model EGS.

15 GEOTHERMAL ENERGY↗

Understanding Water Controls on Shale Gas/Oil Mobilization into Fractures (FY 2019-2021(FY2022, No Cost Extension), Final Report)

The large volumes of injected and produced water, and costs associated with both hydraulic fracturing fluids and produced water treatment motivate development of hydraulic fracturing strategies that use water more efficiently. The overall objective of this project is to improve understanding on how water is distributed within unconventional shales during and after hydraulic fracturing in order to provide a more rational basis for reservoir stimulation strategies that increase hydrocarbon recovery per unit of water used. The strong capillary imbibition of water into shale matrix pores and immiscibility with hydrocarbons makes it highly desirable to reduce water use during reservoir development. Given the importance, and competing influences of capillarity and gravity in controlling water in fractured porous media, this project also seeks to understand how these factors interact to obstruct or allow gas flow.

04 OIL SHALES AND TAR SANDS↗

Fracture Network Prediction Using Physics-based Machine Learning Algorithms

In recent years, systematic CO2 injection into geological reservoirs across the U.S. has gained traction as a strategy to mitigate greenhouse gas emissions. This approach necessitates precise monitoring to ensure secure containment, minimize risks, and optimize storage management. Our study leverages machine learning (ML) techniques to advance the understanding of CO2 injection processes, focusing on the Illinois Basin. Over a three-year injection period, we analyzed microseismic data, identifying 19 temporal intervals with significant bottom-hole pressure changes. By partitioning microseismic events into these intervals and estimating b-values, we revealed over 100 clusters of events related to fracture initiation or reactivation. Advanced spatial analysis highlighted horizontally-oriented fractures along the NNW-SSE axis. This quantification of fracture networks informs dynamic injection scheduling, work-over strategies, and risk assessments, enhancing carbon capture, utilization, and storage (CCUS) operations. Additionally, our methodology offers valuable insights for oil and gas operations and geothermal development, supporting fracture-based monitoring and risk mitigation.

Kumar, Abhash↗

Characterizing Stress Roughness at Utah FORGE Through Simulation of Hydraulic Fracture Growth During 16A Stage 3 Stimulation

In most geologic formations, the vertical gradient of the minimum horizontal stress (𝜎 h ) exceeds the hydrostatic gradient, often driving hydraulic fractures to propagate upward. However, observations indicate that the upward growth of real hydraulic fractures is less pronounced than theoretical predictions based on smoothly varying 𝜎 h fields. In fact, the layered structure of sedimentary rocks hinders fracture propagation across layers, partially explaining the limited height growth observed in practice (Zoback et al., 2022). While crystalline rocks lack the pervasive layered fabric of sedimentary formations, they still possess structural fabric formed over their geologic history, resulting in inherently "rough" in situ stress fields. Recent studies have identified another key factor: the "roughness" of in situ stress, characterized by temporal, relatively short-wavelength fluctuations superimposed on the overall stress gradient. This stress roughness leads to apparent toughness anisotropy, where the vertical toughness appears significantly larger than the horizontal toughness (P. Fu et al., 2019; Dontsov & Suarez-Rivera, 2021). Neglecting the effects of rock fabric and stress roughness can yield inaccurate predictions of hydraulic fracture geometry and growth rates at larger length scales.

58 GEOSCIENCES↗

Analysis of Deformation and Fracture Mechanisms in the Harvested High-Dose Baffle-Former Bolt with Stress-Corrosion Cracks Formed While in Service

This report presents the results of advanced mechanical testing conducted on miniature tensile specimens excised from an irradiated baffle-former bolt, a commercial pressurized water reactor component. The specimens were extracted from the midsection of the bolt shank, where the estimated damage dose reached 23 displacements per atom. The mechanical testing included the following tests: (1) conventional tensile testing at room temperature, augmented by digital image correlation (DIC) to enable noncontact strain measurements, and (2) in situ tensile testing within a scanning electron microscopy (SEM) instrument equipped with energy-dispersive x-ray spectroscopy (EDS) and electron backscatter diffraction (EBSD) detectors to evaluate active deformation and fracture mechanisms. Additionally, SEM fractographic analysis revealed alterations in the fracture mechanism from a predominantly ductile fracture in nonirradiated steel to a mixed fracture mode (still dominating ductile and minor cleavage spots) in irradiated specimens derived from the baffle bolts. The findings indicate a complex strain localization behavior for in-service irradiated steel specimens. Beyond conventional necking at the macro scale and defect-free channel formation at the micro scale, DIC results identified the presence of deformation bands approximately 100 μm in width. These bands consist of chains of grains exhibiting elevated local strain levels and may be considered an intermediate or mesoscale level of strain localization. These bands become discernible near the yield stress as localized hot spots, areas of elevated strain, persisting throughout most of the experiment. The formation of mesoscale deformation bands as a strain localization mechanism may exacerbate the defect-free channel formation in irradiated materials, further promoting irradiation-assisted stress corrosion crack initiation.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗