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At least 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Fracture toughness and crack propagation in LX-17 and PBX 9502 insensitive high explosives

High explosive materials, and in particular insensitive high explosive (IHE) materials, are of significant interest. TATB-based LX-17 and PBX 9502 are two IHE’s and mechanical properties are an important metric of performance. In this work we present, for the first time, a study of fracture as a function of temperature and displacement rate and starter crack length on billet pressed IHE materials using a standard three point bend technique. We demonstrated that the technique can yield consistent results over time by measuring samples from the same lots 4 years later and observed that the fracture toughness of LX-17 and PBX 9502 are similar. We also determined the temperature dependence for different starter crack lengths and found that the fracture toughness generally decreases with larger starter crack sizes and temperatures. For the LX-17, where a wide temperature range of -60 C to 50 C was investigated, the impact of temperature on fracture toughness between -20 C and 23 C was less than expected. For the PBX 9502 we observed the difference in fracture toughness values between -20 C and 23 C did depend on the particular lot, and also there was a tendency of the fracture toughness to scale with the tensile strength. We also investigated the effect of a lower displacement rate and observed that while the impact on the fracture toughness was relatively small, the samples surprisingly did not break (fail) after exceeding the peak load. We took advantage of this to perform x-ray computed tomography (CT) of the samples to image crack propagation in the intact samples. We observed that cracks were generally straight and unaffected by the microstructure in the LX-17, in contrast to the PBX 9502 where the direction of the cracks would frequently change and were likely influenced by the underlying microstructure.

36 MATERIALS SCIENCE↗
NASA NTRS1993

Damage tolerance and arrest characteristics of pressurized graphite/epoxy tape cylinders

An investigation of the damage tolerance and damage arrest characteristics of internally-pressurized graphite/epoxy tape cylinders with axial notches was conducted. An existing failure prediction methodology, developed and verified for quasi-isotropic graphite/epoxy fabric cylinders, was investigated for applicability to general tape layups. In addition, the effect of external circumferential stiffening bands on the direction of fracture path propagation and possible damage arrest was examined. Quasi-isotropic (90/0/plus or minus 45)s and structurally anisotropic (plus or minus 45/0)s and (plus or minus 45/90)s coupons and cylinders were constructed from AS4/3501-6 graphite/epoxy tape. Notched and unnotched coupons were tested in tension and the data correlated using the equation of Mar and Lin. Cylinders with through-thickness axial slits were pressurized to failure achieving a far-field two-to-one biaxial stress state. Experimental failure pressures of the (90/0/plus or minus 45)s cylinders agreed with predicted values for all cases but the specimen with the smallest slit. However, the failure pressures of the structurally anisotropic cylinders, (plus or minus 45/0)s and (plus or minus 45/90)s, were above the values predicted utilizing the predictive methodology in all cases. Possible factors neglected by the predictive methodology include structural coupling in the laminates and axial loading of the cylindrical specimens. Furthermore, applicability of the predictive methodology depends on the similarity of initial fracture modes in the coupon specimens and the cylinder specimens of the same laminate type. The existence of splitting which may be exacerbated by the axial loading in the cylinders, shows that this condition is not always met. The circumferential stiffeners were generally able to redirect fracture propagation from longitudinal to circumferential. A quantitative assessment for stiffener effectiveness in containing the fracture, based on cylinder radius, slit size, and bending stiffnesses of the laminates, is proposed.

Ranniger, Claudia U.↗
NASA NTRS2008

Superposition of Cohesive Elements to Account for R-Curve Toughening in the Fracture of Composites

The relationships between a resistance curve (R-curve), the corresponding fracture process zone length, the shape of the traction/displacement softening law, and the propagation of fracture are examined in the context of the through-the-thickness fracture of composite laminates. A procedure that accounts for R-curve toughening mechanisms by superposing bilinear cohesive elements is proposed. Simple equations are developed for determining the separation of the critical energy release rates and the strengths that define the independent contributions of each bilinear softening law in the superposition. It is shown that the R-curve measured with a Compact Tension specimen test can be reproduced by superposing two bilinear softening laws. It is also shown that an accurate representation of the R-curve is essential for predicting the initiation and propagation of fracture in composite laminates.

Davila, Carlos G.↗
DOE OSTI2022

Fracture toughness of schist, amphibolite, and rhyolite from the Sanford Underground Research Facility (SURF), Lead, South Dakota

The Cracked Chevron Notched Brazilian Disc (CCNBD) method was selected for Mode I fracture toughness tests on Poorman schist, Yates amphibolite, and rhyolite dikes from the EGS Collab site at the SURF in Lead, South Dakota. The effects of lithology, anisotropy, and loading rate were investigated. Fracture toughness was greatest in amphibolite, with schist and rhyolite having similar toughness values ($K$ amphibolite > $K$ rhyolite ≈ $K$ schist ). The effects of anisotropy on fracture toughness were investigated in the foliated schist samples. Schist samples were prepared in three geometries (divider, arrester, and short transverse) which controlled how the fracture would propagate relative to foliations. The divider geometry was strongest and short transverse geometry was the weakest ($K$ divider > $K$ arrester > $K$ shorttransverse ). Fracture toughness was observed to decrease with decreasing loading rate. Optical and SEM microscopy revealed that for the short transverse geometry, fractures tended to propagate along grain boundaries, whereas in arrester and divider geometries fractures tended to propagate through grains. In foliated samples, the tortuosity of the fracture observed in thin section was greater in arrester and divider geometries than in short transverse geometries.

58 GEOSCIENCES↗
DOE OSTI2021

Close Observation of Hydraulic Fracturing at EGS Collab Experiment 1: Fracture Trajectory, Microseismic Interpretations, and the Role of Natural Fractures

Abstract Despite the wide application of hydraulic fracturing in enhanced geothermal system (EGS) development and unconventional hydrocarbon production, our understanding of the many factors affecting the propagation of hydraulic fractures has relied on circumstantial evidence. This is partly due to the scarcity of direct observations in the subsurface. The EGS Collab project attempts to address these issues in the context of EGS research by performing intermediate‐scale (∼10 m) hydraulic stimulation experiments in a thoroughly characterized and heavily instrumented underground testbed. This paper analyzes the data collected from the first suite of hydraulic fracturing tests in this testbed, consisting of seven stimulation episodes. High‐quality microseismic data delineate five planar features very clearly. Combining fracture‐wellbore intersection observations from distributed temperature sensing (DTS) and visual observations from an open‐hole well, as well as prior in‐situ stress measurements, we conclude with high certainty that the four larger planes were hydraulic fractures. The growth of the hydraulic fractures was temporarily halted by a prominent, open natural fracture in the testbed but they eventually crossed and slightly reoriented under continued stimulation. Mineral‐filled (i.e., healed) natural fractures, though prevalent in the testbed, did not have perceivable effects on hydraulic fracture propagation. The high‐quality, mutually corroborating data sets allowed conclusions to be drawn with high confidence and attests to the advantage of intermediate‐scale experiments in subsurface research.

58 GEOSCIENCES↗
NASA NTRS1973

Tensile fracture of unidirectional B-Al composite.

Fracture studies on unidirectional boron filament/aluminum matrix composite under axial tension were conducted using scanning electron microscopy, microradiography, and an acoustic emission technique. The combination of these analysis techniques has allowed the description and microstructural characterization of a new noncumulative fracture mode which involves filament break propagation. This fracture mode was found to severely limit the tensile strength of the composite, since the initiation of break propagation leads immediately to catastrophic failure at filament stress levels above a critical value. This critical filament stress was found to be 170,000 psi, and it appeared to be independent of filament diameter, number of filament layers, and the type of matrix alloy.

Steele, J. H.↗
DOE OSTI2021

Predicting Fracture Network Development in Crystalline Rocks

The geometric properties of fractures influence whether they propagate, arrest, or coalesce with other fractures. Thus, quantifying the relationship between fracture network characteristics may help predict fracture network development, and perhaps precursors to catastrophic failure. To constrain the relationship and predictability of fracture characteristics, we deform eight one centimeter tall rock cores under triaxial compression while acquiring in situ X-ray tomograms. The tomograms reveal precise measurements of the fracture network characteristics above the spatial resolution of 6.5 µm. We develop machine learning models to predict the value of each characteristic using the other characteristics, and excluding the macroscopic stress or strain imposed on the rock. The models predict fracture development more accurately in the experiments performed on granite and monzonite, than the experiments on marble. Fracture network development may be more predictable in these igneous rocks because their microstructure is more mechanically homogeneous than the marble, producing more systematic fracture development that is not strongly impeded by grain contacts and cleavage planes. The varying performance of the models suggest that fracture volume, length, and aperture are the most predictable of the characteristics, while fracture orientation is the least predictable. Orientation does not correlate with length, as suggested by the idea that the orientation evolves with increasing differential stress and thus fracture length. This difference between the observed and expected relationship between orientation and length highlights the influence of mechanical heterogeneities and local stress perturbations on fracture growth as fractures propagate, link, and coalesce.

58 GEOSCIENCES↗
DOE OSTI2021

In situ observation of the deformation and fracture of an alumina-alumina ceramic-matrix composite at elevated temperature using x-ray computed tomography

The deformation and fracture of a 0/90° Nextel 720 mullite fibre / alumina matrix ceramic-matrix composite material has been observed by in situ synchrotron x-ray computed micro-tomography at ambient temperature and at 1100 °C. A three-point loading configuration was used and samples were loaded monotonically until final fracture. Here, the flexural strength was found to be unaffected by temperature. 3D visualisation of the microstructure showed fracture occurred by propagation of internal cracks at stresses close to the flexural strength. Shear fractures propagated across fibre bundles that were oriented perpendicular to the flexural stress at both room temperature and 1100 °C. At the higher temperature, an additional failure mode of delamination was observed, that may arise from relaxation of thermal residual stresses and creep.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Geomechanical Characterization of the Mount Simon Sandstone and Eau Claire Formation of Northern Illinois Basin

The purpose of this paper is to analyze publicly available geomechanical data from two carbon storage sites in the Illinois Basin: the Illinois Basin-Decatur Project (IBDP) in Macon County, IL and the FutureGen2.0 project in Morgan County, IL, cancelled before injection began. This study estimates the magnitudes and directions of the least compressive principal stress gradient using hydraulic fracture-based stress measurement tests, borehole breakouts, and sonic logs in the Eau Claire Formation (primary confining zone) and the Mount Simon Sandstone (targeted reservoir). The range of stresses expected in the underlying Precambrian basement is also investigated. The evaluation of the state of stress is carried out in a probabilistic manner using the State of Stress Analysis Tool (SOSAT) developed under the National Risk Assessment Partnership (NRAP) program. Finally, the paper also provides a discussion on distinctions between fracture initiation pressure, propagation pressure, and fracture closure pressure, given that hydraulic fracture testing results show a significant difference between these three values. The discussion also addresses why the fracture closure pressure should be preferred in injection pressure determinations, a critical point in geological carbon storage projects.

de Toledo Camargo, Julia↗
NASA NTRS1972

An Experimental Investigation of the Effects of Vacuum Environment on the Fatigue Life, Fatigue-Crack-Growth Behavior, and Fracture Toughness of 7075-T6 Aluminum Alloy

Axial load fatigue life, fatigue-crack propagation, and fracture toughness tests were conducted on 0.090-inch thick specimens made of 7075-T6 aluminum alloy. The fatigue life and fatigue-crack propagation experiments were conducted at a stress ratio of 0.02. Maximum stresses ranged from 33 to 60 ksi in the fatigue life experiments, and from 10 to 40 ksi in the fatigue-crack propagation experiments, and fatigue life experiments were conducted at gas pressures of 760, 0.5, 0.05, and 0.00000005 torr. Fatigue-crack-growth and fracture toughness experiments were conducted at gas pressures of 760 and 5 x 10 to the minus 8th power torr. Residual stress measurements were made on selected fatigue life specimens to determine the effect of such stresses on fatigue life. Analysis of the results from the fatigue life experiments indicated that fatigue life progressively increased as the gas pressure decreased. Analysis of the results from the fatigue-crack-growth experiments indicates that at low values of stress-intensity range, the fatigue crack growth rates were approximately twice as high in air as in vacuum. Fracture toughness data showed there was essentially no difference in the fracture toughness of 7075-T6 in vacuum and in air.

Hudson, C. M.↗
NASA NTRS2007

Progressive Fracture of [0/90/ + or - Theta]s Composite Structure Under Uniform Pressure Load

S-Glass/epoxy [0/90/plus or minus theta]s for theta =45 deg., 60 deg., and 75 deg. laminated fiber-reinforced composite stiffened plate was simulated to investigated for damage and fracture progression under uniform pressure. An integrated computer code was augmented for the simulation of the damage initiation, growth, accumulation, and propagation to fracture and to structural collapse. Results show in detail the damage progression sequence and structural fracture resistance during different degradation stages. Damage through the thickness of the laminate initiated first at [0/90/plus or minus 45]s at 15.168 MPa (2200 psi), followed by [0/90/plus or minus 60]s at 16.96 MPa (2460 psi) and finally by [0/90/plus or minus 75]s at 19.3 MPa (2800 psi). After damage initiation happened the cracks propagate rapidly to structural fracture.

Gotsis, Pascalis K.↗
DOE OSTI2022

Mechanisms for the Generation of Complex Fracture Networks: Observations From Slant Core, Analog Models, and Outcrop

We use observations of hydraulic fractures in core, outcrop attributes of natural hydraulic fractures, and analogue models, to address how hydraulic fracture networks evolve. A slant core from the Wolfcamp Formation—an unconventional shale hydrocarbon reservoir in the Permian Basin of West Texas—collected within 18 m and 30 m of two hydraulically stimulated horizontal wells, provided an opportunity to examine hydraulic fractures directly. In approximately 183 m of core, 309 calcite-sealed natural opening-mode fractures and 375 hydraulic fractures were identified. Many hydraulic fractures in the core show complex morphology, including twist-hackle segmentation, diversion, and bifurcation; these structures most commonly develop at lithological bed boundaries and mechanical heterogeneities such as natural fractures and concretions. An outcrop of bed-parallel pavements in the Cretaceous Boquillas Formation in West Texas contains opening-mode fractures that likely formed by natural hydraulic fracturing. Fracture traces provide evidence of twist-hackle segmentation, and are typically associated with bed boundaries and preexisting bed-parallel stylolites. A laboratory study of hydraulic fracturing of 33 synthetic blocks of gypsum and hydrostone revealed fracture steps, diversions, twist hackles, and multiple overlapping fractures together with information on fracture growth directions. These complexities in the fracture network were dominantly nucleated at inclusions used to simulate pre-existing fractures, and as a result of mechanical heterogeneity introduced by the wellbore and perforations. Collectively, our results show that complex fracture networks are produced in hydraulic fracturing of self-sourced reservoir strata. Mechanical stratigraphic boundaries and other heterogeneities are likely to enhance fracture network complexity through the processes of segmentation, diversion, and bifurcation. These processes create multiple fracture strands, resulting in an increased number of hydraulic fractures over those initiated, thereby increasing total fracture surface area. Our study provides insight into hydraulic fracture network propagation, and has applications for evaluation, completion, production, and fracture modeling of unconventional reservoirs.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS1993

Environment enhanced fatigue crack propagation in metals: Inputs to fracture mechanics life prediction models

This report is a critical review of both environment-enhanced fatigue crack propagation data and the predictive capabilities of crack growth rate models. This information provides the necessary foundation for incorporating environmental effects in NASA FLAGRO and will better enable predictions of aerospace component fatigue lives. The review presents extensive literature data on 'stress corrosion cracking and corrosion fatigue.' The linear elastic fracture mechanics approach, based on stress intensity range (Delta(K)) similitude with microscopic crack propagation threshold and growth rates, provides a basis for these data. Results are presented showing enhanced growth rates for gases (viz., H2 and H2O) and electrolytes (e.g. NaCl and H2O) in aerospace alloys including: C-Mn and heat treated alloy steels, aluminum alloys, nickel-based superalloys, and titanium alloys. Environment causes purely time-dependent accelerated fatigue crack growth above the monotonic load cracking threshold (KIEAC) and promotes cycle-time dependent cracking below (KIEAC). These phenomenon are discussed in terms of hydrogen embrittlement, dissolution, and film rupture crack tip damage mechanisms.

Gangloff, Richard P.↗
NASA NTRS1973

A study of fatigue and fracture in 7075-T6 aluminum alloy in vacuum and air environments

Axial load fatigue life, fatigue-crack propagation, and fracture toughness experiments were conducted on sheet specimens made of 7075-T6 aluminum alloy. These experiments were conducted at pressures ranging from atmospheric to 5 x 10 to the minus 8th torr. Analysis of the results from the fatigue life experiments indicated that for a given stress level, lower air pressures produced longer fatigue lives. At a pressure of 5 x 10 to the minus 8th torr fatigue lives were 15 or more times as long as at atmospheric pressure. Analysis of the results from the fatigue crack propagation experiments indicated that for small stress intensity factor ranges the fatigue crack propagation rates were up to twice as high at atmospheric pressure as in vacuum. The fracture toughness of 7075-T6 was unaffected by the vacuum environment. Fractographic examination showed that specimens tested in both vacuum and air developed fatigue striations. Considerably more striations developed on specimens tested at atmospheric pressure, however.

Hudson, C. M.↗
DOE OSTI2026

Capturing the fractocohesive length scale in elastomers through a statistical mechanics-based gradient enhanced damage model

Here, this study aims to examine modeling flaw sensitivity in elastomers. The direct incorporation of polymer chain statistical mechanics considerations into a continuum stretch-based gradient-enhanced damage formulation, in turn, allows a representation of diffuse chain damage and fracture events that align with known micromechanical mechanisms. Through a series of numerical experiments, we simulate crack propagation and extract the fracture energy as an output of the model, while keeping track of the micromechanical signatures of diffuse chain damage that accommodate fracture propagation and eventually influence flaw sensitivity. Finally, by combining the fracture toughness and the work to rupture, we identify a fractocohesive length of the material, corresponding to the full width of the damage process zone. As the damage-to-fracture cascade in the proposed GED model is influenced by the introduction of a length scale associated with network imperfection and long-range load transfer, the emerging relationship of the two length scales is discussed, providing a potential link between microscopic damage mechanisms and the observed macroscopic fracture response.

36 MATERIALS SCIENCE↗
NASA NTRS1989

Influence of dissolved hydrogen on aluminum-lithium alloy fracture behavior

The objective of this work is to study the effects of dissolved hydrogen on the mechanical properties of 2090 and 2219 alloys. Prior to mechanical testing, potentiostatic and potentiodynamic tests were performed using NaCl/HCl solutions varying in pH from 1.5 to 7.5 (3.5 pct NaCl in deionized water). After analysis of the potentiodynamic curve for each solution, several potentiostatic experiments were conducted for various times (from 10 minutes to several hours) with a cathodic overpotential of 300 mV. These experiments were performed to select charging conditions. It is shown that the fracture of L-S and T-S orientations proceeds via slipping of layers in the S-T direction. The T-S and L-S orientations fractured with substantially higher propagation energy that the L-T and T-L orientations, due in large part to the extensive delamination propagation of the fracture.

Rivet, F. C.↗