Fracture Morphology Research Articles

Investigation on Microstructure, Mechanical Properties, and Fracture Morphology of Al7075/TiB2 Composites

Investigation on Microstructure, Mechanical Properties, and Fracture Morphology of Al7075/TiB2 Composites

Effect of corrosion pit on fatigue damage and failure in powder bed fusion AlSi10Mg

AbstractThis paper is concerned with environmental corrosion during service of load‐bearing aluminum alloys fabricated by additive manufacturing (AM) with a focus on damage evolution characterization and identification of dominated failure mechanisms of pre‐corroded selective laser melted aluminum alloy. An experimental strategy for analysis of the damage and failure process is presented, combining 3D surface measurement, 3D digital image correlation, and scanning electron microscopy, to provide a multi‐source experimental characterization of corrosion morphology, strain field evolution, and fracture morphology. Statistics and machine learning methods were employed to process the measured multi‐source experimental data, showing that local average roughness has a strong influence on macro‐crack initiation position. The analysis focuses on four primary types of fatigue micro‐crack initiation, namely, internal defect, diffuse corrosion, corrosion micro‐pit, and corrosion jut; internal defect and diffuse corrosion are unique features for powder bed fusion (PBF) AlSi10Mg. The micro‐crack initiation mechanisms for all four types are (i) local stress concentrations due to adjacent material micro‐structural defects, (ii) interaction of underlying alloy microstructure and corrosion‐induced stress/strain, and (iii) local stress/strain concentration at corrosion micro‐pit and jut, respectively.

Study on the fracture propagation of ground fissures with syn-depositional structure in Fenwei Basin, China

In Fenwei Basin, most of the tectonic ground fissures show characteristics of growth faults on the section. They continue to destroy the engineering properties of soil at different depths. This has introduced significant security risks to the construction processes of deep underground spaces. However, there are few studies have been conducted on syn-depositional ground fissures. Therefore, in this study, a physical simulation test was used to study the fracture propagation of syn-depositional ground fissures. The characteristics of sections and surface fractures were analyzed. The engineering properties of model soil were divided into bad and poor areas. The syn-depositional ground fissure fracture propagation process was divided into five phases. The results show that soil profile exhibited a composite Y-shaped fracture morphology. Syn-deposition affects the fracture angle and healing state of fractures. The soil strain and surface displacement were positively correlated with the number of deposition layers. The conclusions of this study provide a theoretical geological basis and practical engineering significance for design of deep underground space structures.

Study on the Interaction Propagation Mechanism of Inter-Cluster Fractures under Different Fracturing Sequences

Horizontal-well multi-cluster fracturing is one of the most important techniques for increasing the recovery rate in unconventional oil and gas reservoir development. However, under the influence of complex induced stress fields, the mechanism of interaction and propagation of fractures within each segment remains unclear. In this study, based on rock fracture criteria, combined with the boundary element displacement discontinuity method, a two-dimensional numerical simulation model of hydraulic fracturing crack propagation in a planar plane was established. Using this model, the interaction and propagation process of inter-cluster fractures under different fracturing sequences within horizontal well segments and the mechanism of induced stress field effects were analyzed. The influence mechanism of cluster spacing, fracture design length, and fracture internal pressure on the propagation morphology of inter-cluster fractures was also investigated. The research results indicate that, when using the alternating fracturing method, it is advisable to appropriately increase the cluster spacing to weaken the inhibitory effect of induced stress around the fractures created by prior fracturing on subsequent fracturing. Compared to the alternating fracturing method, the propagation morphology of fractures under the symmetrical fracturing method is more complex. At smaller cluster spacing, fractures created by prior fracturing are more susceptible to being captured by fractures from subsequent fracturing. The findings of this study provide reliable theoretical support for the optimization design of fracturing sequences and fracturing processes in horizontal well segments.

Improvement of butt-fusion welding procedure and performance evaluation method for thick-walled bimodal polyethylene pipes

High-density polyethylene (HDPE) pipes have been continuously improved by the progress made by the resin industry and pipe manufacturers. Together with the advanced technology of welding equipment in terms of structure reliability and automations, HDPE pipes have been gradually applied to higher pressure level, bigger diameter, and thicker walls in operations which have become the preferred piping system for nuclear safety application in transporting cooling seawater. There are substantial differences in parameter settings when applying heat and force during different welding procedures, as well as the complicated evaluation methods for mechanical properties, which causes communication barriers between engineers and researchers. Thus, it is necessary to comprehensively study the welding procedures and evaluation methods to standardize the evaluation protocols in the industry. In this paper, based on the assumptions of temperature effect and molecular chain diffusion dynamics at the welding interface, the optimization of the welding procedure is proposed. Some well-established evaluation methods have been used for performance assessment and their feasibilities are discussed. The idea of creating crack along the weld interface is adopted as new method to evaluate the material ability of fracture resistance. Specimens with unilateral notch and weld interface crack are proposed and subjected for quasi-static axial tensile test. The fracture stress and fracture energy at the welding interface are used to differentiate the quality of the joint from different welding procedures. The fracture morphologies of the weld interface are analyzed. A complete picture is drawn for the mechanical fracture resistance of the weld interface. The method used in this paper can be corelated to the pipeline design conditions, therefore could be applied to the real-time engineering applications. Moreover, the evaluation method proposed in this paper is simple, reliable, and easy to implement.

Mesoscopic precursor anomaly characteristics of red sandstone under uniaxial compression after cyclic high-temperatures

The deformation and failure characteristics of rock caused by periodic changes of temperature are not only significantly different from that under normal temperature, but also significantly different from that produced by a single high-temperature event. Here, using a three-dimensional digital image correlation (3D-DIC) integrated test system, mechanical and micro-damage tests of red sandstone are performed under cycles of high-temperature and natural-cooling with a temperature range of 25°C to 300°C and the number of cycles varying between 0 and 25. Macroscopic, mesoscopic and microscopic characteristics such as rock strength, deformation, strain field and fracture morphology are examined and their evolution with the number of heating-cooling cycles is discussed. Using the time-history evolution of the differentiation rate of the precursor anomaly (En), the characteristic coefficient (K) and the damage variable (DF), three kinds of characteristic time points are put forward to quantify the incubation and development time of precursor abnormal characteristics and are used to divide the whole process of deformation and failure. These time points are the precursor abnormal differentiation time (PADT) tE, the precursor abnormal startup time (PAST) tK, and the precursor abnormal failure time (PAFT) tD. Test results show that: (1) The action of cyclic high-temperature natural-cooling not only shows the strengthening effect of temperature, but also shows the strengthening effect of a certain number of cycles. (2) The evolution sequence of the three precursor abnormal characteristic moments is PADT, PAST and PAFT in turn, and this sequence can intuitively describe the whole complex process of rock deformation and failure, and there are wave peaks in the evolution curve with the number of high-temperature cycle. (3) The effect of high temperature (i.e., 300°C) cyclic heating on rock properties is similar to the threshold effect of a single high-temperature heating event.

Influences of clean fracturing fluid viscosity and horizontal in-situ stress difference on hydraulic fracture propagation and morphology in coal seam

The viscosity of fracturing fluid and in-situ stress difference are the two important factors that affect the hydraulic fracturing pressure and propagation morphology. In this study, raw coal was used to prepare coal samples for experiments, and clean fracturing fluid samples were prepared using CTAB surfactant. A series of hydraulic fracturing tests were conducted with an in-house developed triaxial hydraulic fracturing simulator and the fracturing process was monitored with an acoustic emission instrument to analyze the influences of fracturing fluid viscosity and horizontal in-situ stress difference on coal fracture propagation. The results show that the number of branched fractures decreased, the fracture pattern became simpler, the fractures width increased obviously, and the distribution of AE event points was concentrated with the increase of the fracturing fluid viscosity or the horizontal in-situ stress difference. The acoustic emission energy decreases with the increase of fracturing fluid viscosity and increases with the increase of horizontal in situ stress difference. The low viscosity clean fracturing fluid has strong elasticity and is easy to be compressed into the tip of fractures, resulting in complex fractures. The high viscosity clean fracturing fluids are the opposite. Our experimental results provide a reference and scientific basis for the design and optimization of field hydraulic fracturing parameters.

Multi-crack propagation analysis of double-side welded rib-to-deck joint in orthotropic steel decks

Rib-to-deck welded joints are among the most susceptible to fatigue in orthotropic bridge decks (OSDs). Prior research has primarily examined the stress intensity factor (SIF) and propagation morphology of a solitary fracture at these joints, allocating limited attention to the investigation of the propagation of multiple cracks. This paper presents a methodology for simulating and computing the weld toe magnification factor and the SIF of semi-elliptical surface cracks in innovative double-sided welded rib-to-deck (DWRTD) joints. The intention was to simplify the calculation of the SIF for this fatigue detail. The SIF obtained from the calculation model in combination with a multiple crack coalescence approach resulted in a series of fatigue life prediction models of multiple co-planar semi-elliptical cracks. Compared with the results of fatigue tests on the DWRTD joints, the calculated fatigue life and propagation morphology of multiple cracks from the model showed good agreement. Finally, the parameters were analysed to investigate the effects of crack number, bridge deck thickness, residual stress, and penetration rate. Compared to a single crack, multiple cracks reduced the service life of the bridge deck by approximately 30%. When the bridge deck thickness increases from 12 mm to 20 mm, the nominal stress amplitude near the weld ∆σ decreases by 2.2 times, resulting in a 7-fold increase in crack propagation time. Compared to penetration rate and residual stress, ∆σ is the most crucial factor affecting fatigue propagation life. Therefore, it is suggested to increase the thickness of the bridge deck during design.

The influence mechanism of periodic heterogeneous distribution of microstructure on fracture behavior in the 2319 aluminum alloy of wire-arc directed energy deposition

The microstructure of aluminum alloy components fabricated by wire-arc directed energy deposition (wire-arc DED) has typical periodic heterogeneous distribution characteristics, which will directly affect the fracture behavior of the components. Therefore, in this study, 2319 aluminum alloy components were additively manufactured by Cold Metal Transfer wire-arc DED (CMT wire-arc DED) system. Viewing the cross sections of fracture morphology from horizontal and vertical directions, the influence mechanism of periodic heterogeneous distribution of microstructure on fracture behavior of aluminum alloy components was analyzed. The results show that the mechanical properties of the additive components have obvious anisotropy. The tensile strength and elongation of the transverse tensile specimens are better than those of the longitudinal tensile specimens, and the former have better mechanical properties. With the metallographic structure and electron back scatter diffraction (EBSD) test results, it can be confirmed that the fracture location of the tensile specimens is located at the boundary region between the inter-layer area and the inner-layer area. Meanwhile, the fracture form is typical intergranular fracture. They are mainly due to the easy generation of porosity aggregation and precipitation of a large number of θ(Al2Cu) phases in the inter-layer and inner-layer junctions.

Mechanical Properties of Selective Laser Melting‐Processed Multihierarchical Lattice Structure Based on Body‐Centered‐Cubic Unit Cell

Herein, three types of multihierarchical lattice structures (MHLSs) with different configurations are designed based on the body‐centered‐cubic (BCC) unit cell. The designed lattice structures are fabricated using Ti‐6Al‐4 V powder as feedstock material through selective laser melting (SLM) technology. The microstructure and surface morphology of the SLM‐formed samples are observed by optical microscopy and scanning electron microscopy, respectively. Theoretical calculation and quasistatic compression experiment are carried out to investigate their mechanical properties. The result shows that the size error of slave cell with small strut diameters is greater than that of master cell with larger strut diameters. All MHLSs exhibit superior mechanical properties compared to the BCC lattice structure. Moreover, the specific elastic modulus and specific yield strength of MHLSs with the best mechanical properties are 70.1% and 51.0% higher than that of BCC lattice structure, respectively. Meanwhile, theoretical calculation results of the elastic modulus and yield strength are consistent with the results of quasi‐static compression testing. The fracture morphology analysis indicates that the struts of the MHLSs samples exhibit a mixed brittle–plastic fracture mode, while the nodes exhibit a plastic fracture mode.

Fatigue Behaviors and Dislocation Evolution of Copper and Aluminum Alloy

Face centered cubic (FCC) metals are widely used in the field of structural materials due to their excellent mechanical properties, and their fatigue behaviors have always been a focus of attention. In this work, 1060 aluminum alloy with different processing states and copper were selected to study the high cycle fatigue performance at room temperature and high temperature. The fracture morphology and dislocation evolution were characterized through characterization methods such as scanning electron microscope (SEM) and transmission electron microscope (TEM). Based on the research, the main movement mode of dislocations (plane slip or wavy slip) is influenced by stacking fault energy (SFE), which further has a significant impact on fatigue performance. When the SFE of the FCC metal is higher, wavy slip dominates and the material is sensitive to temperature changes; on the contrary, during cyclic loadings, metal with lower SFE is dominated by plane slip, due to the reversibility of plane slip, the damage to the material with low SFE under fatigue loading is more uniform.This article is protected by copyright. All rights reserved.

The macroscopic and microscopic fatigue failure mechanisms of high-temperature thermally-damaged granite under cyclic impact loading

The rock surrounding wells for developing geothermal energy are in an extreme environment with high temperature and long-term dynamic disturbance. To study the influences of different temperatures and dynamic disturbances on the damage, mechanical properties, and fatigue failure mechanism of rocks, a series of microscopic thermal damage analysis and dynamic cyclic impact tests were conducted on granite specimens treated at 25 ∼ 900 °C. Results show that after being thermally treated to different extents, granite specimens are weakened in terms of the dynamic strength and deformation resistance under cyclic impact loading. As the temperature rises, the number of impacts bearable by specimens before failure decreases accordingly. Under the joint action of temperature and strain rate, 450 °C is found to be the threshold temperature for the significant reduction of dynamic strength of the rock. Under action of temperature and strain rate, the proportion of dissipated energy gradually reduces with rising temperature. Moreover, the dynamic failure mode of rock specimens at high temperatures gradually changes from splitting failure to crushing failure, the fractal dimension gradually increases, and the cumulative dissipated energy density decreases. Finally, the deterioration degree of elastic modulus was adopted to describe the progressive damage evolution of thermally-treated granite under cyclic impact loading. Furthermore, the fracture morphologies of rock specimens after failure were analyzed from the microscopic perspective to reveal the macroscopic and microscopic fatigue failure mechanisms of the rock under the coupling of temperature and strain rate.

Patients with more complex ankle fractures are associated with poorer patient-reported outcome: an observational study of 11,733 patients from the Swedish Fracture Register.

Patient-reported outcome measures (PROMs) following ankle fractures, including all fracture types, have not been reported. It is therefore unclear whether fracture morphology correlates with outcome. We aimed to analyze PROMs in patients with an ankle fracture in relation to the Arbeitsgemeinschaft für Osteosynthesefragen/Orthopaedic Trauma Association (AO/OTA) fracture classification using population-based register data from the Swedish Fracture Register (SFR). All patients aged ≥ 18 years with an ankle fracture (AO/OTA 44A1-C3) registered in the SFR between 2012 and 2019 were retrieved from the register. Patients with completed PROM questionnaires (Short Musculoskeletal Function Assessment and EuroQol-Visual Analogue Scale) on both day 0 (pre-trauma) and 1-year post-trauma were included. The difference in PROMs between day 0 and 1 year was calculated for each patient (delta value) and mean delta values were calculated at group level, based on the AO/OTA fracture classification. 11,733 patients with 11,751 fractures with complete PROMs were included. According to the AO/OTA classification, 21% were A fractures, 67% were B fractures and 12% were C fractures. All groups of patients, regardless of fracture class (A1-C3), displayed an impairment in PROMs after 1 year compared with day 0. Type C fractures displayed a larger impairment in PROMs at group level than type B, which in turn had a greater impairment than type A. The same pattern was seen in groups 3, 2, and 1 for A and B fractures. We found that the AO/OTA classification is prognostic, where more complex fractures were associated with poorer PROMs.

In‐situ strain evolution mechanisms within a prestressed carbon composite

AbstractThermal residual stress generated during curing is known to be detrimental to mechanical performance of a carbon composite. Fiber prestressing technique has been developed for decades to counterbalance these negative effects. Although there have been some achievements in development of the prestress mechanisms, these are mainly based on the extrapolations from macroscopic mechanical characterizations, lack of direct evaluation of the in‐situ in‐plane strain or stress evolution mechanisms, in order to reveal the impact induced by different prestressing methods. Here, we investigated the in‐situ strain evolution mechanisms in producing a prestressed carbon composite. Since clamping of the uncured prepreg is the most challenging, both the strain evolutions with and without precured prepreg edges were evaluated to reveal the underlying mechanisms induced by stress relaxation during fiber prestressing. Mechanical tests in terms of Charpy impact and three‐point bending, as well as fractured morphology were carried out to evaluate the prestress effects. The underlying mechanisms were then proposed to reveal the fundamentals in producing a prestressed composite. These are expected to revolutionize industrial production and applications of prestressed polymeric composites, indicating detrimental mechanisms on precuring strip ends following conventional prestress procedures.Highlights There is an optimal prestrain level to maximize properties of a composite. Internal strain development is dependent on the fiber clamping methods. Stress relaxation is beneficial to induce compressive stress within a composite. In‐situ strain evolution mechanics is revealed for prestressed carbon composite.

Effects of modified coal gasification fine slag on the processing and mechanical properties of natural rubber composites

AbstractCoal gasification fine slag (CGFS) is rich in unburned residual carbon, silica and alumina, and has a large specific surface area, making it a potential polymer‐reinforcing filler. Tea polyphenol (TP)‐modified coal gasification fine slag (TP‐CGFS‐T) was prepared using flotation and modification methods in this study. The effects of unmodified and modified CGFS‐T on the sulfurization performance, processing properties, thermal stability, fracture morphology, and mechanical properties of natural rubber composite materials were investigated. Results indicated that after TP modification, CGFS‐T exhibited highly uniform dispersion on the surface without the agglomeration of fillers. When the dosage of TP‐CGFS‐T was 20 phr, the comprehensive performance of the natural rubber (NR) composite material was optimal, with a tensile strength of 12.12 MPa, the elongation at break of 1208.83%, the tear strength of 30.94 kN/m, and the shore hardness of 38.7 A. As the amount of TP‐CGFS‐T increased, the scorch time of NR increased, which enhanced the processing safety of rubber. This study provides a strategy for treating CGFS, which can both reduce the pollution caused by CGFS and save costs for NR composite materials.Highlight The CGFS is separated into concentrate and tailings by flotation. The compatibility between fillers and the matrix is enhanced by TP modification of CGFS‐T. The composite materials show excellent mechanical and processing properties.

Quantitative characterization and fracture morphology in reservoirs with various lithologies: An experimental investigation

Accurately quantifying the development of hydraulic fractures is pivotal for further elucidating the relationship between reservoir physical properties and hydraulic fracture propagation. In this research, we centered on reservoirs featuring diverse lithologies, procured downhole full-diameter cores, conducted triaxial hydraulic fracturing experiments, and employed CT scanning and electron microscopy to characterize fracture morphology. The primary findings are summarized as follows: sandstones specimens typically exhibit bi-wing fractures inclined at a certain angle to σH, with internal microfractures predominantly comprised of corrugated shear fractures traversing mineral grains. Conversely, conglomerate specimens display a higher prevalence of branching fractures, with fracture zones forming in areas of gravel densities and weak heterogeneous matrices, along with the development of multiple microfractures. Volcanic rock specimens fractures primarily propagate via deflection following NF activation, showcasing two modes of microfracture propagation: through and alongside the NF. Quantitative parameters of fracture morphology indicate that the fractal dimension ranges from 2.02 to 2.08 for sandstone fractures, 2.19 to 2.22 for conglomerate fractures, and 2.11 to 2.13 for volcanic rock fractures. Notably, the NF filler in volcanic rock undergoes erosion by fracturing fluid, accumulating non-uniformly on the surface of rock crystals, thereby augmenting fracture tortuosity. Additionally, the fracture surface area of conglomerates surpasses that of sandstones and volcanic rocks by 1.3 times, with the stripping rate of conglomerate fracture surfaces exceeding 10%. Furthermore, the average normal width of conglomerate fractures surpasses 2 mm, whereas volcanic rock and sandstone measure 1.6 mm and 1.1 mm, respectively. Notably, sandstone fractures exhibit uniform normal width distribution, while conglomerate fractures, especially those around gravels and eroded by fracturing fluid, manifest larger widths. Moreover, NF influenced volcanic rock fractures also exhibit wider widths. Elucidating the quantitative attributes of fracture morphology in lithologically diverse reservoirs holds significant implications for formulating hydraulic fracturing and targeted optimization strategies aimed at enhancing fracturing efficacy.

Influence of weak interlayer thickness on mechanical response and failure behavior of rock under true triaxial stress condition

In this study, we meticulously investigate the influence of the thickness of weak interlayer on mechanical response and failure behavior of rock mass near the free surface of tunnel, with the aid of a true triaxial test system. We simulated the true triaxial stress condition of rock mass containing weak interlayer proximate to the excavation boundary, where one face remains free, while others are subjected to loading stress and increasing tangential stress. The experimental results reveal a distinct change in the fracture morphology near the free surface of rock mass as the thickness of weak interlayer increases, concomitant with a gradual decrease in the fractal dimension. With the increase of the thickness of weak interlayer, the failure characteristics of rock mass change from a “binary” to a “unitary” feature, i.e. mixed tension-shear failure near the free surface and shear failure far away from the free surface changes to mixed tension-shear failure that only occurs near the free surface. Moreover, an inverse relationship is observed between the bearing capacity of the rock mass and the thickness of weak interlayer. Conversely, the peak strain in the tangential stress direction increases with the increase of the thickness of weak interlayer, illustrating that the slip shear strain of rock block positioned above the weak interlayer is gradually formed, and governs the strain behavior of rock mass in the tangential stress direction with the increases of the thickness of weak interlayer. By employing the finite-discrete element method (FDEM), we replicated the failure process of surrounding rocks containing weak interlayers near the free surface of tunnel, demonstrating considerable congruity with our physical test results. In light of the failure characteristics of surrounding rocks containing weak interlayers, we advocated a localized area priority reinforcement support strategy, prioritizing regions with weak interlayers. Numerical simulations verified the effectiveness of this approach in controlling fracture proliferation in surrounding rocks and inhibiting the splitting failure of surrounding rocks containing weak interlayers near the free surface of tunnel.

Effect of La2O3 on the properties of molybdenum rhenium alloy

Adding rhenium to molybdenum can improve room temperature processing performance and reduce the ductile brittle transition temperature. Adding lanthanum oxide to molybdenum can refine grain size and improve strength. This work analyzes the effect of adding different amounts of lanthanum oxide to molybdenum rhenium alloys on their properties. The results indicated that with the increase of lanthanum oxide, the tensile strength increased, but the room temperature elongation only increased at 0.6%; as the temperature increases, the trend of tensile strength and elongation at 900 °C and 1100 °C is similar; at 1300 °C, the strength decreases significantly but the elongation increases sharply; the corresponding changes can be explained by the fracture morphology.

Experimental Study on the Effect of Rock Mechanical Properties and Fracture Morphology Features on Lost Circulation

Summary At present, lost circulation remains a complicated drilling problem in fractured formations that needs to be addressed urgently. However, the influence of actual rock mechanical properties (RMP) and fracture morphological features (FMF) on lost circulation is easily ignored in the current research on leakage mechanism and evaluation, which may lead to deviation from the analysis results, thus affecting the success rate of plugging treatments. Therefore, the complicated effects have been investigated using the improved plugging experimental instruments in this paper. The results indicate that both RMP and FMF have a prominent influence on the plugging and sealing effects of plugging slurries. This research suggests that the bridging and plugging capabilities of the slurry can be improved by increasing the type and amount of lost circulation materials (LCM). Moreover, depending on the fracture morphology difference, the same plugging slurry will have different plugging effects on the same width-size opening fracture channel. In addition, a novel evaluation method is developed to assess the effective sealing ability of plugging slurry against formation fractures, which has been successfully applied in the field. To the best of our knowledge, this is the first evaluation method that investigates simultaneously the mechanical properties of rocks and fracture characteristics of formations. The novel evaluation method incorporates the critical parameters of the lost circulation effect into the design of the plugging evaluation model. Thus, the proposed method can be used to quantitatively evaluate the plugging capability of the LCM and slurries and the loss capacity of the loss channels. However, the higher plugging coefficient (λ) of the slurry does not necessarily mean that the plugging slurry has a stronger plugging capacity (SP). Adopting the suitable fracture channel model can avoid overestimating or underestimating the plugging capability of the LCM slurries. Therefore, it is necessary to improve the formula design of the LCM slurry in combination with the geological engineering background. This perception has significant implications for the analysis of the lost circulation mechanisms and the optimization formula design of the plugging slurries.

Multiple hydraulic fracture propagation simulation in deep shale gas reservoir considering thermal effects

Deep and ultra-deep shale gas will gradually become the focus of unconventional oil and gas resources in the petroleum industry. In the development of shallow shale reservoirs, the multi-cluster hydraulic fracturing of horizontal wells is the commonly applied technique to create a network of fractures and achieve reservoir stimulation. However, for deep shale reservoirs, the behavior of multiple hydraulic fracture propagation is affected by stress interference between fractures. On the other hand, it is also influenced by the temperature disturbances caused by the injection of low-temperature fracturing fluids into high-temperature formations and the resulting thermal effects. Currently, most research on multiple hydraulic fracture propagation in shale only considers the interaction between fluids and solids while neglecting thermal effects. Therefore, based on the displacement discontinuity method, finite volume method, and finite difference method, this study established a numerical model for the non-planar propagation of multi-cluster hydraulic fractures in deep shale, considering the thermal effects. And the model was validated through numerical solutions of the temperature field and double-fracture propagation. Moreover, the number of fracture clusters, pumping rate, and formation temperature were selected as influencing factors, and the differences in multiple hydraulic fracture propagation with and without considering thermal effects were analyzed. The results show that as the formation temperature increases, the thermal effects become more significant, leading to greater differences in the morphology of multi-cluster fractures. Moreover, the thermal effects are more significant when the formation temperature exceeds 90 °C. Additionally, appropriately reducing the number of fracture clusters or increasing the pumping rate can to some extent mitigate stress interference between fractures and promote uniform fracture propagation. The findings of this study contribute to understanding the influence of thermal effects on multiple hydraulic fracture propagation and provide theoretical basis for the efficient development of deep shale gas.