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At least 1,243 records · Page 69
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Complex Fracture Nucleation and Evolution with Nonlocal Elastodynamics

A mechanical model is introduced for predicting the initiation and evolution of complex fracture patterns without the need for a damage variable or law. The model, a continuum variant of Newton’s second law, uses integral rather than partial differential operators where the region of integration is over finite domain. The force interaction is derived from a novel nonconvex strain energy density function, resulting in a nonmonotonic material model. The resulting equation of motion is proved to be mathematically well-posed. The model has the capacity to simulate nucleation and growth of multiple, mutually interacting dynamic fractures. In the limit of zero region of integration, the model reproduces the classic Griffith model of brittle fracture. As a result, the simplicity of the formulation avoids the need for supplemental kinetic relations that dictate crack growth or the need for an explicit damage evolution law.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Chemical and isotope compositions of shallow groundwater in areas impacted by hydraulic fracturing and surface mining in the Central Appalachian Basin, Eastern United States

Here, hydraulic fracturing of shale deposits has greatly increased the productivity of the natural gas industry by allowing it to exploit previously inaccessible reservoirs. Previous research has demonstrated that this practice has the potential to contaminate shallow aquifers with methane (CH 4 ) from deeper formations. This study compares concentrations and isotopic compositions of CH 4 sampled from domestic groundwater wells in Letcher County, Eastern Kentucky in order to characterize its occurrence and origins in relation to both neighboring hydraulically fractured natural gas wells and surface coal mines. The studied groundwater showed concentrations of CH 4 ranging from 0.05 mg/L to 10 mg/L, thus, no immediate remediation is required. The δ 13 C values of CH 4 ranged from 66‰ to 16‰, and δ 2 H values ranged from –286‰ to –86‰, suggesting an immature thermogenic and mixed biogenic/thermogenic origin. The occurrence of CH 4 was not correlated with proximity to hydraulically fractured natural gas wells. Generally, CH 4 occurrence corresponded with groundwater abundant in Na + , Cl – , and HCO 3 – , and with low concentrations of SO 4 –2 . The CH 4 and SO 4 –2 concentrations were best predicted by the oxidation/reduction potential of the studied groundwater. CH 4 was abundant in more reducing waters, and SO 4 –2 was abundant in more oxidizing waters. Additionally, groundwater in greater proximity to surface mining was more likely to be oxidized. This, in turn, might have increased the likelihood of CH 4 oxidation in shallow groundwater.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2015

The shear fracture toughness, K IIc , of graphite

In this study, the critical shear stress intensity factor, K IIc , here-in referred to as the shear fracture toughness, K IIc (MPa m), of two grades of graphite are reported. The range of specimen volumes was selected to elucidate any specimen size effect, but smaller volume specimen tests were largely unsuccessful, shear failure did not occur between the notches as expected. This was probably due to the specimen geometry causing the shear fracture stress to exceed the compressive failure stress. In subsequent testing the specimen geometry was altered to reduce the compressive footprint and the notches (slits) made deeper to reduce the specimen's ligament length. Additionally, we added the collection of Acoustic Emission (AE) during testing to assist with the identification of the shear fracture load. The means of K IIc from large specimens for PCEA and NBG-18 are 2.26 MPa m with an SD of 0.37 MPa m and 2.20 MPa m with an SD of 0.53 MPa m, respectively. The value of K IIc for both graphite grades was similar, although the scatter was large. In this work we found the ratio of K IIc / K Ic ≈ 1.6. .

36 MATERIALS SCIENCE↗
DOE OSTI2016

Pressure and fluid-driven fracture propagation in porous media using an adaptive finite element phase field model

This work presents phase field fracture modeling in heterogeneous porous media. We develop robust and efficient numerical algorithms for pressure-driven and fluid-driven settings in which the focus relies on mesh adaptivity in order to save computational cost for large-scale 3D applications. In the fluid-driven framework, we solve for three unknowns pressure, displacements and phase field that are treated with a fixed-stress iteration in which the pressure and the displacement–phase-field system are decoupled. The latter subsystem is solved with a combined Newton approach employing a primal–dual active set method in order to account for crack irreversibility. Numerical examples for pressurized fractures and fluid filled fracture propagation in heterogeneous porous media demonstrate our developments. Finally in particular, mesh refinement allows us to perform systematic studies with respect to the spatial discretization parameter.

42 ENGINEERING↗
DOE OSTI2018

Predictive modeling of dynamic fracture growth in brittle materials with machine learning

We use simulation data from a high delity Finite-Discrete Element Model to build an e cient Machine Learning (ML) approach to predict fracture growth and coalescence. Our goal is for the ML approach to be used as an emulator in place of the computationally intensive high delity models in an uncertainty quanti cation framework where thousands of forward runs are required. The failure of materials with various fracture con gurations (size, orientation and the number of initial cracks) are explored and used as data to train our ML model. This novel approach has shown promise in predicting spatial (path to failure) and temporal (time to failure) aspects of brittle material failure. Predictions of where dominant fracture paths formed within a material were ~85% accurate and the time of material failure deviated from the actual failure time by an average of ~16%. Additionally, the ML model achieves a reduction in computational cost by multiple orders of magnitude.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Fracture, failure and compression behaviour of a 3D interconnected carbon aerogel (Aerographite) epoxy composite

Aerographite (AG) is a mechanically robust, lightweight synthetic cellular material, which consists of a 3D interconnected network of tubular carbon [1]. The presence of open channels in AG aids to infiltrate them with polymer matrices, thereby yielding an electrical conducting and lightweight composite. Aerographite produced with densities in the range of 7–15 mg/cm 3 was infiltrated with a low viscous epoxy resin by means of vacuum infiltration technique. Detailed morphological and structural investigations on synthesized AG and AG/epoxy composite were performed by scanning electron microscopic techniques. Our present study investigates the fracture and failure of AG/epoxy composites and its energy absorption capacity under compression. The composites displayed an extended plateau region when uni-axially compressed, which led to an increase in energy absorption of ~133% per unit volume for 1.5 wt% of AG, when compared to pure epoxy. Preliminary results on fracture toughness showed an enhancement of ~19% in K IC for AG/epoxy composites with 0.45 wt% of AG. Furthermore, our observations of fractured surfaces under scanning electron microscope gives evidence of pull-out of arms of AG tetrapod, interface and inter-graphite failure as the dominating mechanism for the toughness improvement in these composites. These observations were consistent with the results obtained from photoelasticity experiments on a thin film AG/epoxy model composite.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Measurement of fracture toughness by nanoindentation methods: Recent advances and future challenges

In this study, we describe recent advances and developments for the measurement of fracture toughness at small scales by the use of nanoindentation-based methods including techniques based on micro-cantilever beam bending and micro-pillar splitting. A critical comparison of the techniques is made by testing a selected group of bulk and thin film materials. For pillar splitting, cohesive zone finite element simulations are used to validate a simple relationship between the critical load at failure, the pillar radius, and the fracture toughness for a range of material properties and coating/substrate combinations. The minimum pillar diameter required for nucleation and growth of a crack during indentation is also estimated. An analysis of pillar splitting for a film on a dissimilar substrate material shows that the critical load for splitting is relatively insensitive to the substrate compliance for a large range of material properties. Experimental results from a selected group of materials show good agreement between single cantilever and pillar splitting methods, while a discrepancy of ~25% is found between the pillar splitting technique and double-cantilever testing. It is concluded that both the micro-cantilever and pillar splitting techniques are valuable methods for micro-scale assessment of fracture toughness of brittle ceramics, provided the underlying assumptions can be validated. Although the pillar splitting method has some advantages because of the simplicity of sample preparation and testing, it is not applicable to most metals because their higher toughness prevents splitting, and in this case, micro-cantilever bend testing is preferred.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Measurement of mechanical and fracture properties of solid electrolyte interphase on lithium metal anodes in lithium ion batteries

Mechanical integrity of the solid electrolyte interphase (SEI) plays an essential role in determining the life and performance of lithium-ion batteries. Fracture and continued formation of the SEI contribute to consumption of lithium, drying of electrolyte, increase in impedance, and growth of dendrites resulting in capacity fade and premature failure. Electrolyte additives such as fluoroethylene carbonate (FEC) have been known to improve performance, but the underlying reasons have been elusive. Despite its importance, reliable methods for mechanical characterization of SEI have been lacking. In this paper, we present a new experimental technique that combines atomic force microscopy and membrane-bulge configuration to accurately measure the stress-strain behavior of SEI, including the onset of inelastic response and evolution of fracture. We characterize the SEI formed with two ethylene carbonate-based electrolytes, without and with fluoroethylene carbonate (FEC) additive. The measurements show a striking contrast; SEI with FEC additive has 80% higher elastic modulus and a vastly higher resistance to fracture. These findings offer a mechanical-behavior based rationale to understand how SEI controls battery performance. Moreover, the experimental technique offers a robust diagnostic tool to design electrolytes that can form SEI with the desired mechanical properties for optimal battery performance.

25 ENERGY STORAGE↗
DOE OSTI2025

Large scale polymer toughening of two-dimensional materials revealed by in situ TEM fracture tests and multiscale simulations

Two-dimensional (2D) materials offer significant potential for applications in energy-harvesting devices, batteries, sensors, and transistors. However, their intrinsic brittleness makes them prone to mechanical failure, limiting their practical use. In this work, we perform in situ transmission electron microscopy (TEM) fracture tests on monolayer MoSe2 and uncover an extrinsic toughening effect induced by an ultrathin adsorbed polystyrene adlayer. This adlayer substantially enhances the fracture resistance of the 2D flakes. Through a combination of molecular dynamics simulations and finite element analysis, we elucidate the molecular mechanism behind this toughening effect. Further, it arises from the active crack-bridging behavior of entangled polymer chains and the formation of a fracture process zone that stabilizes crack propagation and increases the energy required for crack extension. The proposed toughening mechanism offers a pathway to improving the mechanical reliability of 2D material-based devices by mitigating the risk of sudden failure.

2D materials↗
DOE OSTI2018

Areal sweep efficiency improvement by integrating preformed particle gel and low salinity water flooding in fractured reservoirs

The oil recovery from fractured reservoirs is usually low, which is usually caused by the existence of areal formation heterogeneity. Two existing enhanced oil recovery (EOR) technologies, low salinity water flooding (LSWF) and preformed particle gel treatment (PPG), have recently drawn great interest from the oil industry. We integrated both of these technologies into one process to improve both oil displacement and areal sweep efficiency. The objective of this study was to test how the integrated method could be used effectively to increase oil recovery and control water production. The semi-transparent five-spot models, which were made of sandstone cores and acrylic plates, were built. We investigated the effect of four parameters on the improvement of oil recovery and areal sweep efficiency of oil, including gel strength, water salinity, injection rate, and number of fractures. Two approaches were followed during core flooding, sequential mode and mixed mode. Here the result shows that PPG and LSW injected together as one mixture improved oil recovery factor more than the first approach. PPGs plugged the fractures and successfully improved areal sweep efficiency; however, they have little effect on displacement efficiency. LWSF increased displacement efficiency but had little or no effect on sweep efficiency. The integrated methods bypassed the limitations of each method when used individually and improved both displacement and sweep efficiency.

58 GEOSCIENCES↗
DOE OSTI2025

Coupled phase field damage and crystal plasticity analysis of intragranular fracture: The role of crystallographic orientation and voids

Damage evolution in engineering metal alloys at the grain scale exhibits significant microstructural heterogeneity and anisotropy. These heterogeneities create local hotspots for stress and strain localization, leading to void nucleation. Crystal orientation influences the active slip systems around voids, affecting lattice rotation and potentially forming discontinuities. At low triaxiality, voids may change shape due to lower stress, rotation, elongation, and coalescence. At high triaxiality, the correlation between crystal orientation and void growth rate becomes stronger, resembling the behavior observed in isolated single crystals. Therefore, understanding the effects of crystal orientation, heterogeneous strain, and defect evolution is crucial for single crystal fracture characterization. Here, in this work, a coupled phase-field damage (PFD) and crystal plasticity (CP) model is implemented within a finite element framework to analyze crystal deformation and failure. The CP method employs a dislocation density-based constitutive model, while intragranular failure is modeled using an anisotropic PFD method. The PFD model considers both the stored energy due to elastic stretching and the energy release due to defect formation and crack formation. A single crystal Al2219 with an intracrystalline spherical void is chosen to analyze fracture. The study finds that fracture propagation is strongly correlated with crystal orientations. This coupled CP-PFD model provides accurate failure prediction in crystalline materials by incorporating the effects of crystal orientations and existing voids. This study demonstrates how the local microstructure and defects influence plastic deformation and failure mechanisms in metal alloys.

Aluminum alloy↗
DOE OSTI2020

Visualization of hydraulic fracture using physics-informed clustering to process ultrasonic shear waves

Ultrasonic transmission is sensitive to the spatial variation in mechanical properties of materials due to the presence of cracks/fractures. Wave propagation through fractured media introduces changes in the frequency content, travel time and transmission coefficient of the wave. A workflow based on physics-informed unsupervised learning is developed to process the transmitted ultrasonic-shear waveforms to non-invasively visualize the geomechanical alterations due to hydraulic fracturing. Novelty of the work involves the assignment of both statistically consistent and physically consistent clusters to the measurements of shear waveforms acquired across the one axial and two frontal planes. Physically consistent/relevant information is incorporated by considering the travel time of the peak of spectral energy and transmission coefficient of the transmitted waveform. The proposed workflow generates maps of geomechanical alterations across the frontal and axial planes of the sample. The outputs of the workflow are in good agreement with independent techniques viz. acoustic emission and X-ray computed tomography. Finally, the proposed workflow can be adapted for improved fracture characterization in the subsurface when processing sonic-logging, cross-wellbore seismic or surface seismic waveform data.

42 ENGINEERING↗
DOE OSTI2018

Metal plasticity and ductile fracture modeling for cast aluminum alloy parts

Here in this study, plasticity and ductile fracture properties were characterized by performing various tension, shear, and compression tests. A series of 10 experiments were performed using notched round bars, flat-grooved plates, in-plane shear plates, and cylindrical bars. Two cast aluminum alloys used in automotive suspension systems were selected. Plasticity modelling was performed and the results were compared with experimental and corresponding simulation results; further, the relationships among the stress triaxiality, Lode angle parameter, and equivalent plastic strain at the onset of failure were determined to calibrate a ductile fracture model. Finally, the proposed ductile fracture model shows good agreement with experimental results.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Sub-micron fracture mechanism in silica-based glass activated by permanent densification from high-strain loading

Several silica-based glasses were fractured at high strain energy via drop-weight testing on small specimens. A cylindrical specimen geometry was chosen to promote initially simple, axisymmetric, and uniform compressive loading. The imposed uniaxial compressive strain at impact was sufficiently high to qualitatively cause permanent densification. Produced fragments were collected for postmortem and a fraction of them, for all the silica-based glasses, consistently had distinct sub-micron-sized fractures (~ 300–1000 nm), designated here as “microkernels”, on their surfaces. They would most often appear as a sub-micron pore on the fragment - apparently if the microkernel had popped out as a consequence of the local crack plane running through it, tensile-strain release, and the associated formation of the fragment it was on. No fractographic evidence was found to show the microkernels were associated with local failure initiation. However, their positioning and habit sometimes suggested they were associated with localized crack branching and that they could have influenced secondary fracturing that occurred during overall crushing and comminution and associated fragment size and shape creation. Furthermore, the size range of these microkernels is much too small to affect structural flexure strength of these glasses for most applications but are of a size and concentration that may affect their ballistic, shock, crush, and comminution responses when permanent densification is concomitantly occurring.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Coupled physics simulation of fracture in nuclear fuel pellets induced by resistive heating

While it is well known that the UO 2 fuel used in light-water reactors cracks early in its life in the reactor, it is very difficult to collect in-reactor data regarding fuel cracking initiation and propagation to validate fracture models in fuel performance codes. Most fracture data comes from the post-irradiation examination of fuel that has been subjected to long and complex power histories. Replicating the thermal gradients experienced in this fuel to study crack initiation and propagation in a laboratory environment is challenging. This is primarily because the fuel is heated volumetrically by fission, which is difficult to replicate. One way to approximate this volumetric heating out of the reactor is to use electrical resistance (or Joule heating). An electrical conductivity model has been developed and coupled with the existing thermomechanical modeling capability in the BISON nuclear fuel performance code. This will permit simulation of experiments that use resistive heating for the purpose of validating fracture models in BISON. The modeling approach developed here is applied to simulate both historical and current resistive heating experiments on ceramic nuclear fuel.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Fracture toughness measurement of ceramics with fuel pellet geometry

The crack initiation of nuclear fuel pellets, driven by extreme temperature gradients, is a critical factor impacting reactor performance. Although this fact is widely acknowledged, there is limited fracture toughness data for specimens with representative geometry and fabricated using relevant processing methods. Here, to address this, a new chevron-notched short-rod specimen configuration with diameter and length both equal to 10 mm, representative of a conventional fuel pellet and tested in tension, was developed in an attempt to validly measure Mode I fracture toughness, K Ic . Test calibration was carried out by testing polycrystalline ZrO 2 , SiC, and Si 3 N 4 ceramics fabricated with conventional fuel pellet geometry and known fracture toughnesses. The results suggest that the method described in this paper produces valid K Ic measurements using conventional ceramic fuel pellets.

Ceramics↗
DOE OSTI2025

Through-thickness fracture behavior of neutron-irradiated nuclear graphite NBG-17 Using X-ray micro-CT

Achieving precise control over crack propagation in nuclear graphite and conducting quantitative analysis remain challenging. In this study, the through-thickness fracture behavior of pristine and neutron-irradiated (700 °C, ∼7 dpa) NBG-17 nuclear graphite was investigated using split-disc testing coupled with micro-computed tomography (micro-CT). A notably lower number of micropores was observed in the neutron-irradiated specimen. The fracture toughness of neutron-irradiated NBG-17 was measured to be 1.45 MPa√m, compared to 1.17 ± 0.05 MPa√m for the pristine specimen. In both materials, cracks were found to initiate at the filler–binder interface, and often correlated with microstructural features such as pores and thermal cracks. Crack bridging and deflections emerged as the primary toughening mechanisms in both unirradiated and irradiated NBG-17. However, compared with the pristine specimen, the cracks in the neutron-irradiated specimen were more likely to grow trans granularly, resulting in less deflected crack paths. The reduced micro-porosity and strengthened filler–binder boundaries were considered to be the cause of the observed differences in crack morphologies. In conclusion, this study provides a qualitative analysis of the fracture behavior of neutron-irradiated nuclear graphite in the absence of radiolytic oxidation.

36 - MATERIALS SCIENCE↗
DOE OSTI2019

Electrochemically induced fractures in crystalline silicon anodes

This communication presents our recent discovery on electrochemically induced fracture behavior of a single-crystal silicon (Si) anode, with particular focus on the initialization and propagation of cracks. Intensive efforts have investigated mechanical properties and cracking behavior of Si electrodes overextended electrochemical cycles. However, it is still elusive how cracks nucleate and propagate in the crystalline Si anodes at the very early stage. Here, we examined the morphology evolution of the Si (100) wafer electrodes during the first electrochemical cycle, and we found that the formation of <110>-oriented buckles - induced by the anisotropic lithiation in crystalline Si during 1st lithiation - results in cracks propagated along the <110> direction in the buckled region during 1st delithiation. Surprisingly, as the delithiation proceeds, new cracks oriented along the <100> direction appear in the intact area where no macroscopic deformation occurred during the previous lithiation. The <100>-oriented cracks have not been studied previously. Herein, we introduce a linear elastic fracture mechanics model to help understand underlying mechanisms for such crack propagation. The findings in this work provide significant insights into the fracture behavior and formation mechanism, as well as possible strategies to inhibit crack propagations of Si electrodes at the beginning stage of cycling.

25 ENERGY STORAGE↗