Publications

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A non-local formulation of classical continuum mechanics theory known as peridynamics is used to study fracture initiation and growth from a wellbore penetrating the subsurface within the context of propellant-based stimulation. The principal objectives of this work are to analyze the influence of loading conditions on the resulting fracture pattern, to investigate the effect of in-situ stress anisotropy on fracture propagation, and to assess the suitability of peridynamics for modeling complex fracture formation. It is shown that the loading rate significantly influences the number and extent of fractures initiated from a borehole. Results show that low loading rates produce fewer but longer fractures, whereas high loading rates produce numerous shorter fractures around the borehole. The numerical method is able to predict fracture growth patterns over a wide range of loading and stress conditions. Our results also show that fracture growth is attenuated with increasing in-situ confining stress, and, in the case of confining stress anisotropy, fracture extensions are largest in the direction perpendicular to the minimum compressive stress. Since the results are in broad qualitative agreement with experimental and numerical studies found in the literature, suggesting that peridynamics can be a powerful tool in the study of complex fracture network formation.

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An adage within the Additive Manufacturing (AM) community is that “complexity is free”. Complicated geometric features that normally drive manufacturing cost and limit design options are not typically problematic in AM. While geometric complexity is usually viewed from the perspective of part design, this advantage of AM also opens up new options in rapid, efficient material property evaluation and qualification. In the current work, an array of 100 miniature tensile bars are produced and tested for a comparable cost and in comparable time to a few conventional tensile bars. With this technique, it is possible to evaluate the stochastic nature of mechanical behavior. The current study focuses on stochastic yield strength, ultimate strength, and ductility as measured by strain at failure (elongation). However, this method can be used to capture the statistical nature of many mechanical properties including the full stress-strain constitutive response, elastic modulus, work hardening, and fracture toughness. Moreover, the technique could extend to strain-rate and temperature dependent behavior. As a proof of concept, the technique is demonstrated on a precipitation hardened stainless steel alloy, commonly known as 17-4PH, produced by two commercial AM vendors using a laser powder bed fusion process, also commonly known as selective laser melting. Using two different commercial powder bed platforms, the vendors produced material that exhibited slightly lower strength and markedly lower ductility compared to wrought sheet. Moreover, the properties were much less repeatable in the AM materials as analyzed in the context of a Weibull distribution, and the properties did not consistently meet minimum allowable requirements for the alloy as established by AMS. The diminished, stochastic properties were examined in the context of major contributing factors such as surface roughness and internal lack-of-fusion porosity. This high-throughput capability is expected to be useful for follow-on extensive parametric studies of factors that affect the statistical reliability of AM components.

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