3D Fracture Model Research Articles

Characterization of coal permeability considering fracture shape—Using the MP-Otsu threshold segmentation algorithm

Coal seepage simulation based on digital images is capable of visualizing the three-dimensional seepage process and providing permeability data. However, Otsu's conventional thresholding algorithm is prone to image mis-segmentation for extracting pores and fractures, which makes the reconstructed model unable to reestablish the coal structure truly. The present work first explains the failure mechanism of the conventional Otsu algorithm for image segmentation based on computed tomography (CT) images of coal. Three weighting factors, including the slope of the mineral content fitting curve against the Otsu threshold and the approximate proportion of the target in the image, are introduced to enhance the accuracy of the threshold relation. In continuing, the MP-Otsu thresholding algorithm is proposed. Finally, the 3D fracture model of the coal is reconstructed from the CT image via the MP-Otsu thresholding algorithm. Focusing on the shape of the model, the permeability is then calculated on the basis of the pipe flow model and the parallel plate model. The contribution of fractures with various radii in the pipe model and different apertures in the parallel plate model is appropriately incorporated into the permeability evaluation. The obtained results reveal that the presence of mineral components and the low porosity of coal are the chief reasons for the failure of the conventional Otsu algorithm in the digital image segmentation of coal. The porosities calculated by the improved MP-Otsu algorithm are predicted to be 7.13 %-72.03 % lower than those of the Otsu’s method, which effectively improves the over-segmentation of fractures by Otsu and could accurately extract fractures in images. The permeability model, considering the fracture shape, gives results similar to the simulation results, and parallel plate fractures remarkably affect the permeability of the coal body. In particular, fractures with radius R > 7 μm and apertures b > 50 μm account for more than 90 % of the permeability and thus play a key role in the seepage process.

Preliminary osteogenic and antibacterial investigations of wood derived antibiotic-loaded bone substitute for the treatment of infected bone defects.

Introduction: The development of reliable treatments for infected or potentially infected bone loss resulting from open fractures and non-unions is extremely urgent, especially to reduce the prolonged courses of antimicrobial therapy to which affected patients are subjected. Numerous bone graft substitutes have been used over the years, but there are currently no effective solutions to treat critical bone loss, especially in the presence of infection. The present study evaluated the use of the biomorphic calcium phosphate bone scaffold b. Bone™, based on a next-generation resorbable biomimetic biomaterial, in bone reconstruction surgery in cases of infection. Methods: Using an "in vitro 3D bone fracture model" to predict the behavior of this drug delivery system during critical bone loss at an infected (or potentially infected) site, the effects of scaffolds loaded with gentamicin or vancomycin on the viability and differentiation capacity of human mesenchymal stem cells (hMSCs) were evaluated. Results: This scaffold, when loaded with gentamicin or vancomycin, exhibits a typical drug release curve that determines the inhibitory effects on the growth of Staphylococcus aureus, Enterococcus faecalis, and Escherichia coli, as well as relative biofilm formation. Discussion: The study demonstrates that b.bone scaffolds can effectively address key challenges in orthopedic surgery and patient care by inhibiting bacterial growth and biofilm formation through rapid, potent antibiotic release, reducing the risk of treatment failure due to resistance, and providing a promising solution for bone infections and improved patient outcomes. Future studies could explore the combination of different antibiotics on these scaffolds for more tailored and effective treatments against post-traumatic osteomyelitis pathogens.

Mechanical mechanism of specimen size effect on impact toughness of Al 6061: Experiment and simulation

Impact toughness has a strong size effect, which restricts the accurate evaluation of material toughness and safety of structural design. However, our understanding of the internal mechanical mechanism that influences the size effect remains incomplete. To fill this gap, this paper adopts the method of combining experiment, theory, and simulation. From the point of view of the dependence of plastic and fracture behavior of material on stress state, the internal mechanical mechanism of the size effect of impact toughness (αk) was studied. Firstly, the Charpy impact tests of different sizes were carried out on Al 6061. αk was divided into cracking initiation toughness (αini) and cracking growth toughness (αgro). The variation of αini and αgro with specimen size was analyzed. Then, through a series of tests, the influence of stress state on the plastic and fracture behavior of Al 6061 was studied. To simulate the whole process of the Charpy impact test, an uncoupled 3D fracture model was proposed. Subsequently, a stress state dependent yield function, modified Voce hardening law, and the proposed fracture model were used to simulate the Charpy impact tests. The predicted results were in good agreement with the tests. Finally, the internal mechanical mechanisms of the size effects of αini and αgro were analyzed. The results show that: (1) The αini and αgro have significant size effects, and there are significant differences between them. (2) The internal mechanical mechanism of the size effect of αini was revealed; that is, the dependence of the plastic behavior of the material on the stress state is the internal root cause of the dependence of αini on the specimen size. (3) The internal mechanical mechanism of the size effect of αgro was revealed; that is, the dependence of the plastic behavior of the material on the stress state and the fracture behavior of the material under ultra-high stress triaxiality is the internal fundamental reason affecting the size effect of αgro. (4) This study reveals the internal complex and intimate relationships between plastic behavior, fracture behavior, toughness behavior, stress state, and the size effect, providing a valuable reference for accurate and comprehensive understanding, evaluation, and selection of metal materials.

Experimental Study on the Strength and Damage Characteristics of Cement–Fly Ash–Slag–Gangue Cemented Backfill

In order to achieve the goal of effectively utilizing solid waste resources and improving mining stability, it is necessary to incorporate various types of solid wastes in the production of cemented backfill. For investigating the compressive strength and damage characteristics of Cement–Fly Ash–Slag–Gangue (CFSG) cemented backfill under loading, real-time X-ray Computed Tomography (CT) scanning was employed to capture two-dimensional (2D) grayscale slices and three-dimensional (3D) fracture models during uniaxial compression testing. The study quantitatively assessed the evolution of cracks and microstructural damage in CFSG cemented backfill. The results indicate that the specimens underwent four stages of transformation, including compaction, linear elasticity, yielding, and residual deformation, during the uniaxial compression process. The specimens exhibited a measured compressive strength of 3.44 MPa and a failure strain of 0.95%. As the axial strain increased, there was an increase in 2D porosity observed in the CT images and a greater dispersion of crack distribution. A 3D model constructed from CT slices illustrated the feature of cracking expansion, with the fracture volume gradually increasing during the elastic deformation phase and experiencing rapid growth during the yielding and residual deformation phases. The damage variable, obtained from the volume of 3D cracks, exhibited a slow-growth pattern, characterized by a rapid increase followed by a more gradual rise with the increase in axial strain. This study serves as a significant reference for comprehending the micro-mechanisms involved in the damage process and cracking characteristics of cemented backfill mixed with solid wastes under external loading conditions.

Voronoi-based 3D phase field model and numerical simulations of granite crack propagation

The distribution of mineral grains within underground rocks and materials is crucial for understanding geological processes and the stability of engineering structures. However, numerical simulation methods that consider 3D mineral particles are still immature. This study presents a 3D phase-field fracture model of mineral grains based on Voronoi polygons, making some beneficial attempts in this regard. The phase-field method does not rely on mesh reconstruction or crack path tracking and can simulate complex crack propagation behavior. Meanwhile, the Voronoi polygon can better describe the microscopic structure of rock with grain boundaries. Rooted in Voronoi polygons, this model efficiently captures the complex geometric shapes of mineral grains and accurately characterizes their positions, shapes, and sizes. Therefore, this study combines Voronoi polygons to establish a 3D phase-field model. Through two numerical simulation cases, the model demonstrates its effectiveness in simulating the impact of three-dimensional mineral grains on crack propagation behavior, showing that cracks tend to propagate at the boundaries or inside softer mineral grains. The modeling approach proposed in this paper has good reference value for numerical simulation studies considering the microscopic structure of rocks.

Accuracy Analysis of 3D Bone Fracture Models: Effects of Computed Tomography (CT) Imaging and Image Segmentation

The introduction of three-dimensional (3D) printed anatomical models has garnered interest in pre-operative planning, especially in orthopedic and trauma surgery. Identifying potential error sources and quantifying their effect on the model dimensional accuracy are crucial for the applicability and reliability of such models. In this study, twenty radii were extracted from anatomic forearm specimens and subjected to osteotomy to simulate a defined fracture of the distal radius (Colles’ fracture). Various factors, including two different computed tomography (CT) technologies (energy-integrating detector (EID) and photon-counting detector (PCD)), four different CT scanners, two scan protocols (i.e., routine and high dosage), two different scan orientations, as well as two segmentation algorithms were considered to determine their effect on 3D model accuracy. Ground truth was established using 3D reconstructions of surface scans of the physical specimens. Results indicated that all investigated variables significantly impacted the 3D model accuracy (p < 0.001). However, the mean absolute deviation fell within the range of 0.03 ± 0.20 to 0.32 ± 0.23 mm, well below the 0.5 mm threshold necessary for pre-operative planning. Intra- and inter-operator variability demonstrated fair to excellent agreement for 3D model accuracy, with an intra-class correlation (ICC) of 0.43 to 0.92. This systematic investigation displayed dimensional deviations in the magnitude of sub-voxel imaging resolution for all variables. Major pitfalls included missed or overestimated bone regions during the segmentation process, necessitating additional manual editing of 3D models. In conclusion, this study demonstrates that 3D bone fracture models can be obtained with clinical routine scanners and scan protocols, utilizing a simple global segmentation threshold, thereby providing an accurate and reliable tool for pre-operative planning.

Synergistically segmenting and reducing fracture bones via whole-to-whole deep dense matching

In bone fracture preoperative surgical planning, 3D fracture reduction is of great significance. However, segmenting 3D fracture bones into fragments and assembling the bone fragments to restore their original morphology are labor intensive and time consuming. Current works, however, omit their synergistic effects between reduction and segmentation, which, we envision, can significantly benefit the fracture reduction. To this end, a method is proposed to alternatively segment and assemble the fragments by incorporating the contralateral bone as template and leveraging the synergistic effect on segmentation and reduction. The 3D fracture model is initially segmented into separated outer surface of fragments. The reduction is then conducted by template matching, specifically, a whole-to-whole matching strategy through deep learning of dense features is employed. Thereafter, the segmentation is further refined with the assistance of the template. The process of reduction and segmentation is iterated until the algorithm converges. Experiments were conducted on simulated data and clinical data, the mean segmentation accuracy is 95.26%, the assembling translation error is 3.28 ± 3.01 mm, and the assembling rotation error is 1.62 ± 1.71°. Results demonstrated the superiority of our method over state-of-the-art methods, and it can be used as a feasible scheme for fracture reduction planning. Moreover, it is also proved that segmentation and reduction can promote each other.

A Coupled Poro-Elastic Fluid Flow Simulator for Naturally Fractured Reservoirs

Naturally fractured reservoirs are characterized by their complex nature due to the existence of natural fractures and fissures within the rock formations. These fractures can significantly impact the flow of fluids within the reservoir, making it difficult to predict and manage production. Therefore, efficient production from such reservoirs requires a deep understanding of the flow behavior via the integration of various geological, geophysical, and engineering data. Additionally, advanced simulation models can be used to predict reservoir behavior under different production scenarios and aid in decision making and effective management. Accordingly, this study presents a robust mathematical two-phase fluid flow model (FRACSIM) for the simulation of the flow behavior of naturally fractured reservoirs in a 3D space. The mathematical model is based on the finite element technique and implemented using the FORTRAN language within a poro-elastic framework. Fractures are represented by triangle elements, while tetrahedral elements represent the matrix. To optimize computational time, short to medium-length fractures adopt the permeability tensor approach, while large fractures are discretized explicitly. The governing equations for poro-elasticity are discretized in both space and time using a standard Galerkin-based finite element approach. The stability of the saturation equation solution is ensured via the application of the Galerkin discretization method. The 3D fracture model has been verified against Eclipse 100, a commercial software, via a well-test case study of a fractured basement reservoir to ensure its effectiveness. Additionally, the FRACSIM software successfully simulated a laboratory glass bead drainage test for two intersected fractures and accurately captured the flow pattern and cumulative production results. Furthermore, a sensitivity study of water injection using an inverted five-spot technique was tested on FRACSIM to assess the productivity of drilled wells in complex fractured reservoirs. The results indicate that FRACSIM can accurately predict flow behavior and subsequently be utilized to evaluate production performance in naturally fractured reservoirs.

Finite Element Analysis of the Mechanical Strength of Phalangeal Osteosynthesis Using Kirschner Wires.

Background: Kirschner wire (K-wire) fixation is widely used to repair metacarpal and phalangeal fractures. In this study, we simulated K-wire osteosynthesis of a 3-dimensional (3D) phalangeal fracture model and investigated the fixation strength at various K-wire diameters and insertion angles to clarify the optimal K-wire fixation method for phalangeal fractures. Methods: The 3D phalangeal fracture models were created by using computed tomographic (CT) images of the proximal phalanx of the middle finger in five young healthy volunteers and five elderly osteoporotic patients. Two elongated cylinders representing K-wires were inserted according to various cross-pinning methods; the wire diameters were 1.0, 1.2, 1.5 and 1.8 mm, and the wire insertion angles (i.e. the angle between the fracture line and the K-wire) were 30°, 45° and 60°. The mechanical strength of the K-wire fixed fracture model was investigated by using finite element analysis (FEA). Results: The fixation strength increased with increasing wire diameter and insertion angle. Insertion of 1.8-mm wires at 60° achieved the strongest fixation force in this series. Fixation strength was generally stronger in the younger group than the elderly group. Dispersion of stress to cortical bone was a critical factor to increase fixation strength. Conclusions: We developed a 3D phalangeal fracture model into which we inserted K-wires; using FEA, we clarified the optimal crossed K-wire fixation method for phalangeal fractures. Level of Evidence: Level V (Therapeutic).

USE OF 3D-PRINTED FRACTURE MODELS VERSUS SAWBONES FOR SURGICAL RESIDENT TRAINING: A FEASIBILITY STUDY

Conventional fracture courses utilise prefabricated sawbones that are not realistic or patient specific. The aim of this study is to determine the feasibility of creating 3D fracture models and utilising them in fracture courses to teach surgical technique.We selected an AO type 2R3C2 fracture that underwent open reduction internal fixation. De-identified CT scan images were converted to a stereolithography (STL) format. This was then processed using Computer Aided Design (CAD) to create a virtual 3D model. The model was 3D printed using a combination of standard thermoplastic polymer (STP) and a porous filler to create a realistic cortical and cancellous bone. A case-based sawbone workshop was organised for residents, unaccredited registrars, and orthopaedic trainees comparing the fracture model with a prefabricated T-split distal radius fracture. Pre-operative images aided discussion of fixation, and post-operative x-rays allowed comparison between the participants fixation. Participants were provided with identical reduction tools. We created a questionnaire for participants to rate their satisfaction and experience using a Likert scale.The 3D printed fracture model aided understanding and appreciation of the fracture pattern and key fragments amongst residents and unaccredited trainees. Real case-based models provided a superior learning experience and environment to aid teaching. The generic sawbone provided easier drilling and inserting of screws. Preliminary results show that the cost of 3D printing can be comparable to generic sawbones.It is feasible to create a fracture model with a real bone feel. Further research and development is required to determine the optimum material to use for a more realistic feel.The use of 3D printed fracture models is feasible and provides an alternative to generic sawbone fracture models in providing surgical training to residents.

Phenomenological 2D and 3D Models of Ductile Fracture for Girth Weld of X80 Pipeline

Welding is the main method for oil/gas steel pipeline connection, and a large number of girth welds are a weak part of the pipeline. Under extremely complex loads, a steel pipeline undergoes significant plastic deformations and eventually leads to pipeline fracture. A damage mechanics model is a promising approach, capable of describing material fracture problems according to the stress states of the materials. In this study, an uncoupled fracture 2D model with a function of fracture strain and stress triaxiality, two uncoupled 3D fracture models, a consider the effect of Lode parameter stress-modified critical strain (LSMCS) model, and an extended Rice–Tracey (ERT) criterion were applied to X80 pipeline girth welds. Comprehensive experimental research was conducted on different notched specimens, covering a wide range of stress states, and the corresponding finite element models were established. A phenomenon-based hybrid numerical–experimental calibration method was also applied to determine the fracture parameter for these three models, and the stress triaxiality of the influence law of the tensile strength was analyzed. The results showed that the proposed fracture criterion could better characterize the ductile fracture behaviors of the girth welds of the X80 pipeline; however, the prediction accuracy of the 3D fracture model was higher than that of the 2D fracture model. The functional relationship between the tensile strength and stress triaxiality of the X80 pipeline girth welds satisfied the distribution form of the quadratic function and increased monotonically. The research results can be used to predict the fracture of X80 pipeline girth welds under various complex loads.

The effects of calcium carbonate precipitation on high-velocity flow behavior in 3D printed fracture models

A large amount of water is produced in oil and geothermal fields. Produced water is used in water injection for oil displacement and pressure maintenance in oil fields. However, there is a possibility of forming different precipitations when the injected water and formation water combine, which can cause serious problems in the reservoirs. In the world, more than 60% of oil and more than 40% of gas reservoirs are fractured carbonate rocks, and the mineral precipitation observed in these formations is mostly CaCO3 due to temperature and incompatibility between the injected and formation water. There are few techniques available for CaCO3 scaling removal due to their relative hardness and low solubility. In most cases, the scaled-up wells are caused by the formation of carbonate. In the well tests, it is seen that the flow from the matrix to the fracture is quite low, and the flow in the fracture dominates the whole flow. Therefore, it is essential to properly understand the kinetics of CaCO3 scale formation and its detrimental effect on fracture.It is known from studies that kinetic models can give better results in determining precipitation behavior. However, there are not enough experimental studies on the effects of flow on mineral precipitation in fractured media. Therefore, the kinetic and thermodynamic models are used in this study to reliably predict the amount of mineral precipitation. This work investigates the behavior of precipitation in different temperature conditions, laminar or turbulent flow conditions, and fracture properties like high roughness, length, and aperture. The amounts of precipitation in fracture under different conditions that have not been determined in the literature are given. After flow experiments, the amount of CaCO3 precipitation and pressure differences were measured. When the temperature is 80 °C, the flow rate is 4.16 × 10−5 m³/s, and the roughness is high, precipitation is 47.5% higher than when the temperature is 50 °C. Repeating the same fracture characteristics for different flow conditions in fracture flow tests is essential. By using 3D fracture models, the same fracture properties were obtained under different flow conditions.In addition to precipitation amounts, this article presents decreasing crack permeability due to precipitation. Precipitation of minerals can drastically influence the reservoir's permeability and ability to transmit mass and energy. With the pressure differences measured in the experiments, permeability decreases due to precipitation were calculated using Poiseuille's law (cubic law) for laminar flow and Forchheimer's equation for turbulent flow. After 3.5 days of flow, the study's permeability at high roughness and high flow decreased by 23% at 50 °C and 44% at 80 °C. This study's findings can help better understand that the permeability reduction of fracture is greater in turbulent flow conditions compared to laminar flow. In addition, temperature and high roughness are very effective parameters in precipitation and permeability change. At high temperatures and high roughness, more minerals precipitate, and permeability values decrease considerably. In the later injection periods, the decrease in permeability caused by the precipitation can make the fracture impermeable and increase the pressure losses during the injection.

3D natural fracture model of shale reservoir based on petrophysical characterization

The existence and distribution of natural fractures in shale reservoirs is of great significance to shale gas exploitation. A 3D fracture spatial distribution model with varying reservoir burial depth and regional tectonicsin southeastern Chongqing is constructed based on an enhanced DFN modeling method. Fracture volume density (P32) is calculated by petrophysical test and verified from test wells. The geometric parameters of fractures (length, occurrence, opening) are clustered by regional tectonics. Uncertainties are considered by a stochastic description of the fracture network geometry, utilizing Monte Carlo simulation techniques. The application of the model in seven wells and the quantitative analysis of the relationship between fracture density and burial depth allow the modeling to be extended to deep and ultra-deep reservoirs. Fracture models with reservoirs buried depth over 3000 m are predicted and analyzed. For the various input parameters, the influence of model size and fracture shape on model reliability is analyzed. The establishment of fracture model can effectively quantitatively characterize the reservoir fracture distribution at different burial depths, and its efficient implementation in finite element software can provide support for shale gas mining engineering.

Effect of Calcar Screw in Locking Compression Plate System for Osteoporotic Proximal Humerus Fracture: A Finite Element Analysis Study.

This study proposes a finite element analysis (FEA) model for complex fractures at the osteoporotic proximal humerus and investigates the relevance of using a calcar screw in surgical treatments using this model. Two types of three-dimensional (3D) fracture models of patients with osteoporotic humerus were constructed reflecting the mechanical properties of the osteoporotic humerus, such as the Young's modulus and Poisson's ratio, and two load conditions mimicking the clinical environment were applied for simulation. Using the 3D models and the conditions, the FEA software calculated the concentration and distribution of stresses developing in the humerus, locking compression plate (LCP), and screws. Then, we evaluated and predicted the fixed state of a LCP system depending on whether the maximum stress value exceeded tensile strength. When axial force was applied, insertion of the calcar screw led to significant reduction of stress applied on screws in the fracture model having a medial gap by approximately 61%, from 913.20 MPa to 351.84 MPa. Based on the results, it was clearly confirmed that using of calcar screws improved the stability of a three-part fractures and simultaneously reinforced medial support.

Three-dimensional phase-field modeling of brittle fracture using an adaptive octree-based scaled boundary finite element approach

In this paper, an adaptive phase-field approach is proposed for three-dimensional fracture modeling in brittle materials. The scaled boundary finite element method (SBFEM) is used to solve the phase-field and elasticity equations in a staggered scheme. This is motivated by the ability of the SBFEM to handle polyhedral elements with hanging nodes straightforwardly. Such elements occur in octree meshes, which facilitate rapid transitions in element size and lend themselves to adaptive refinement. The SBFEM also provides an energy-based error indicator, which follows directly from the semi-analytical solution approach and does not require stress recovery. The error indicator is used to ensure the solution accuracy for both fields and combined with a criterion based on phase-field evolution. The computational cost associated with 3D fracture modeling is further reduced by exploiting the geometric similarity of cells occurring in balanced octree meshes. To validate the proposed method, several classical benchmark problems are solved, resulting in efficient and robust solutions compared to the literature.

Ability of modern proximal tibial lateral plates to capture posterolateral tibial plateau fracture fragments.

BackgroundThe surgical treatment of posterolateral tibial plateau fractures involves a challenging and diverse set of considerations, one of which is the lack of proper and satisfactory internal fixations to purchase posterolateral fragments. Evaluating the configuration of internal fixations is often overlooked, despite it being important to outcomes of fracture fixation. This study aimed to (I) propose a new digital methodology of internal fixation evaluation that based on actual fracture cases and (II) evaluate the fixation effectiveness of four commercially available proximal tibial lateral plate-screw constructs for posterolateral fragments.MethodsTibial plateau fractures involving the posterolateral column were retrospectively reviewed. The reconstructed three-dimensional (3D) fracture models were virtually reduced, and targeted internal fixations were modeled digitally in specialized software. Four implants from three manufacturers (DePuy Synthes, Westchester, NY, USA; Zimmer, Warsaw, IN, USA; and Biomet, Warsaw, IN, USA) were placed on each fracture in an optimal position to simulate surgical fixation and quantitatively evaluate fixation effectiveness. The fragment was considered to be “captured” if it was purchased by at least two screws. The 3D fracture maps and heat maps were created by graphically superimposing all uncaptured fracture fragments onto a tibia template.ResultsThis study included 144 posterolateral tibial plateau fractures. When not using screws in a variable angle (VA) manner, the fixation effectiveness for posterolateral fragments was 58.3% for the DePuy Synthes locking compression plates (LCP), 47.9% for the DePuy Synthes VA-LCP, 50.7% for the Zimmer plate, and 43.8% for the Biomet plate. In contrast, the capturing rates boosted to 76.4% and 71.5% when utilizing VA screws in the DePuy Synthes VA-LCP and the Biomet plate. The high-frequency uncaptured areas tended to concentrate on the rim of the posterolateral wall and were mainly distributed in the posterior 1/2 to 3/4 of the parallel position of the fibula head.ConclusionsThe proposed new digital methodology was demonstrated feasible and may improve the quantitative evaluation of the implants and optimize the design of implants. The commercially available proximal tibial lateral plate-screw constructs were insufficient in capturing posterolateral fragments, and design-improved or additional implants may be necessitated.

3D fracture modeling based on the coupling between damage criteria, phase field and crack propagation

In addition to predicting the onset of fracture, some specific material forming processes require the modeling of crack propagation and the accurate prediction of the fracture surface. In such configurations, the use of the deletion element technique is not adapted since it suffers from major mesh dependency and spurious artificial volume loss. This work introduces a new alternative in which the phase field method is coupled to a 3D automatic crack initiation and propagation technique within the Forge® finite element software.

Dual-scale porosity effects on crack growth in additively manufactured metals: 3D ductile fracture models

The presence of microstructural defects resulting in unpredictable failure behavior has limited the use of additively manufactured (AM) metals in structural applications. In addition to the distributed porosity responsible for ductile fracture in conventional metals, larger defects (20–50 μm) can be introduced during additive manufacturing resulting in a dual-scale porosity failure process in AM metals. Here, we subject a three-dimensional, small-scale yielding boundary layer model containing a centerline crack to remote mode I K-field loading to study the effects of such dual-scale porosity on crack-defect interactions in an AM Ti-6Al-4V alloy. We model the background porosity implicitly within the fracture process zone viz. several rows of void-containing computational cell elements governed by the Gurson porous material relation, while the larger AM void defects are discretely represented based on size and porosity distributions of actual AM Ti-6Al-4V specimens characterized using optical and electron microscopy. Results show that AM defects can contribute to an increased apparent toughness of the AM metal over its conventional counterpart by activating isolated and/or clustered damage zones surrounding the crack, which shields and blunts the crack-tip and promotes crack tortuosity. However, the presence of planar clusters of AM defects can also accelerate crack growth and cause premature failure by forming preferential crack paths.

New Technology Yields High-Resolution 3D Modeling for Fracture Analyses

This article, written by JPT Technology Editor Chris Carpenter, contains highlights of paper SPE 203108, “High-Resolution Fracture Analyses and 3D DMX DFN Modeling of Triassic Dolomites, Wadi Bih, Ras Al Khaimah, UAE,” by Janpieter van Dijk and Raffik Lazzar, GeoModl, prepared for the 2020 Abu Dhabi International Petroleum Exhibition and Conference, Abu Dhabi, held virtually 9–12 November. The paper has not been peer reviewed. The complete paper outlines a high-resolution 3D fracture modeling exercise using the DMX protocol applied to Triassic dolomites of the United Arab Emirates. The outcropping rocks show a low primary porosity, are well bedded, and are highly fractured (jointed) up to centimeter scale. The exercise shows the relevance of applying new technologies to outcrop observations and shows several elements and related technologies that, to the authors’ knowledge, have not been presented previously. Introduction The focus area of the complete paper is a small outcrop situated in Wadi Bih in the territory of Ras Al Khaimah (Fig. 1) along a small road near a recently constructed artificial lake. This outcrop, which is approximately 150 m2 in size, shows well-bedded, highly fractured Triassic dolomites. Both section views and bedding-plane views can be observed. The outcrop was selected because it represents an analog of the Triassic Khuff formation, an important hydrocarbon-producing reservoir in the region. The outcrop is easily accessible and displays a clearly defined fracture (joint) network with recognizable sets, also showing truncation relationships between fractures, joints, and bedding that can be examined. Geological Context The area shows a complete series of Permian to Cretaceous, mostly carbonate sediments, outcropping in a series of north/south to north-northeast/south-southwest anticlines and synclines bounded by mostly west-vergent thrust faults. The Wadi Bih outcrop is situated on the moderately east-dipping flank of the north/south-trending Hagab Anticline, also called the Hagil Window after the area of the nearby Wadi Hagil, where the deepest Permian series are outcropping in the core of the anticline. This anticline is situated on the foot-wall of a major north/south-trending thrust fault. The geological history of the area is connected to the initial Mesozoic deposition of the series on the shelf area along the northeast flank of the Arabian shield. In the outcrop study, the focus is on the joint network. The authors write that this network is tilted together with the bedding as part of the flank of the anticline. No relation can be detected between the joint network sets and the fault and anticline axis pattern dominating the area. The joint network, therefore, most probably was formed in the early stages after lithification and dolomitization of the rock.

An efficient matrix-free preconditioned conjugate gradient based multigrid method for phase field modeling of fracture in heterogeneous materials from 3D images

In this paper, we present a new and efficient strategy to perform 3D computational fracture modeling from computed tomography (CT) images. The image-based fracture modeling creates a new way to more accurately predict fracture in realistic structures. However, it is currently complex and expensive to perform such simulations. In this work, we propose to use a matrix-free type preconditioned conjugate gradient solver based multigrid method to achieve the fastest numerical performance for phase field modeling of fracture. Several specific methods are investigated to enhance the robustness and to improve the efficiency of the proposed strategy. An automatic load control strategy to control crack propagation is investigated. High performance computing is applied using a hybrid MPI/OpenMP strategy. With all of the proposed procedures, the phase field modeling of fracture can be performed in the real 3D microstructure of heterogeneous materials using tomographic images.