This SAND report fulfills the final report requirement for the Born Qualified Grand Challenge LDRD. Born Qualified was funded from FY16-FY18 with a total budget of ~$13M over the 3 years of funding. Overall 70+ staff, Post Docs, and students supported this project over its lifetime. The driver for Born Qualified was using Additive Manufacturing (AM) to change the qualification paradigm for low volume, high value, high consequence, complex parts that are common in high-risk industries such as ND, defense, energy, aerospace, and medical. AM offers the opportunity to transform design, manufacturing, and qualification with its unique capabilities. AM is a disruptive technology, allowing the capability to simultaneously create part and material while tightly controlling and monitoring the manufacturing process at the voxel level, with the inherent flexibility and agility in printing layer-by-layer. AM enables the possibility of measuring critical material and part parameters during manufacturing, thus changing the way we collect data, assess performance, and accept or qualify parts. It provides an opportunity to shift from the current iterative design-build-test qualification paradigm using traditional manufacturing processes to design-by-predictivity where requirements are addressed concurrently and rapidly. The new qualification paradigm driven by AM provides the opportunity to predict performance probabilistically, to optimally control the manufacturing process, and to implement accelerated cycles of learning. Exploiting these capabilities to realize a new uncertainty quantification-driven qualification that is rapid, flexible, and practical is the focus of this effort.
Injection of large amounts of fluid into the subsurface alters the states of pore pressure and stress in the formation, potentially inducing earthquakes. Increase in the seismicity rate after shut-in is often observed at fluid-injection operation sites, but mechanistic study of the rate surge has not been investigated thoroughly. Considering full poroelastic coupling of pore pressure and stress, the earthquake occurrence after shut-in can be driven by two mechanisms: (1) post shut-in diffusion of pore pressure into distant faults and (2) poroelastic stressing caused by fluid injection. Interactions of these mechanisms can depend on fault geometry, hydraulic and mechanical properties of the formation, and injection operation. In this work, a 2D aerial view of the target reservoir intersected by strike-slip basement faults is used to evaluate the impact of injection-induced pressure buildup on seismicity rate surge. A series of sensitivity tests are performed by considering the variation in (1) permeability of the fault zone, (2) locations and the number of faults with respect to the injector, and (3) well operations with time-dependent injection rates. Lower permeability faults have higher seismicity rates than more permeable faults after shut-in due to delayed diffusion and poroelastic stressing. Hydraulic barriers, depending on their relative location to injection, can either stabilize or weaken a conductive fault via poroelastic stresses. Gradual reduction of the injection rate minimizes the coulomb stress change and the least seismicity rates are predicted due to slower relaxation of coupling-induced compression as well as pore-pressure dissipation.
The fluid injection into deep geological formations altar the states of pore pressure and stress on the faults, potentially causing earthquakes. In the multiphase flow system, the interaction between fluid flow and mechanical deformation in porous media is critical to determine the spatio-temporal distribution of pore pressure and stress. The contrast of fluid and rock properties between different structures produces the changes in pressure gradients and subsequently stress fields. Assuming two-phase fluid flow (gas-water system), we simulate the two-dimensional reservoir including a basement fault, in which injection-induced pressure encounters the fault directly given injection scenarios. The single-phase flow model with the same setting is also conducted to evaluate the multiphase flow effects on mechanical response of the fault to gas injection. A series of sensitivity tests are performed by varying the fault permeability. The presence of gaseous phase reduces the pressure buildup within the gas-saturated region, causing less Coulomb stress change. The low-permeability fault prevent diffusion initially as observed in the single-phase flow system. Once gaseous phase approaches, the fault acts as a capillary barrier that causes increases in pressure within the fault zone, potentially inducing earthquakes even without direct diffusion.
The migration and trapping of supercritical CO2 (scCO2) in geologic carbon storage is strongly dependent on the geometry and wettability of the pore network in the reservoir rock. During displacement, resident fluids may become trapped in the pits of a rough pore surface forming an immiscible two-phase fluid interface with the invading fluid, allowing apparent slip flow at this interface. We present a two-phase fluid dynamics model, including interfacial tension, to characterize the impact of mineral surface roughness on this slip flow. We show that the slip flow can be cast in more familiar terms as a contact-angle (wettability)-dependent effective permeability to the invading fluid, a nondimensional measurement which relates the interfacial slip to the pore geometry. The analysis shows the surface roughness-induced slip flow can effectively increase or decrease this effective permeability, depending on the wettability and roughness of the mineral surfaces. Configurations of the pore geometry where interfacial slip has a tangible influence on permeability have been identified. The results suggest that for large roughness features, permeability to CO2 may be enhanced by approximately 30% during drainage, while the permeability to brine during reimbibition may be enhanced or diminished by 60%, depending on the contact angle with the mineral surfaces and degrees of roughness. For smaller roughness features, the changes in permeability through interfacial slip are small. A much larger range of effective permeabilities are suggested for general fluid pairs and contact angles, including occlusion of the pore by the trapped phase.