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The Thesis committee for Raushan Kumar certifies that this is the approved version of the following thesis
Thesis
Presented to the Faculty of the Graduate School of The University of Texas at Austin in Partial Fulfillment of the Requirements for the Degree of
Dedication
To my parents: for their unconditional love. To my brother, Ravi and sister, Rashmi: for their presence and support.
Acknowledgements
I would like to extend my sincerest gratitude to Dr. J.E. Olson for his invaluable support, patience and guidance throughout my time at The University of Texas at Austin. He had been a wonderful supervisor and provided intellectual stimuli for this work. I would also like to offer sincere thanks to Dr. J. Holder for the assistance and inputs during experiments. He was very instrumental in solving issues related to hardware electronics and mechanical. I am also thankful to Glen Baum and Gary Miscoe for their input on safety practices. And thanks to Autumn Kaylor for helping me with point counts of my samples. I would like to thank the sponsors of my work - the member companies of FRAC (Fracture Research and Application Consortium) as well as a grant from ExxonMobil Research and Engineering Company in New Jersey. Thanks to Gareth Block of
ExxonMobil for taking interest in my fracture mechanics research. Special thanks to Libsen Castillo and Vinay Sahni for being wonderful friends during my stay at Austin. Lastly, I want to thank my father Prof. Suman Kumar, mother Smt. Bibha Sinha, brothers Ravi and Subodh and sister Rashmi for their support.
Abstract
Subcritical crack propagation experiments were performed using the double torsion test methodology on sandstone and granite samples. The control environments consisted of air, water, aqueous cationic surfactant solutions and aqueous caustic solutions of high pH. The expected reduction in fracture toughness and subcritical index going from air to water environments was observed, a result of water being a more reactive environment. The reduction in subcritical index correlated strongly with the clay content of the sandstones, but no other mineralogic parameters seemed to affect fracture results significantly. Caustic solutions reduced strength and subcritical index more than did water, but surfactant solutions performed approximately the same as water, even though they were expected to be more reactive. Activation volume values were estimated from velocity versus stress intensity factor curves using published values of crack-tip vi
radius of curvature, giving results on the order of 15.0 x 10-7 m3/mol for sandstone tested in air, about 5 times higher than previously reported values for quartz. The values dropped about 50% when measured in aqueous environments. A systematic study of variability in subcritical index values in air showed that subcritical index correlated inversely with the load drop observed during crack propagation. Subcritical indices decreased as load drop increased, with stable values usually resulting at load drops of 0.5 lbs or more for the 1.5 mm thick test samples. Tests performed in more reactive environments (i.e., aqueous solutions) typically resulted in higher load drops and less variable subcritical indices. High rate data acquisition techniques were implemented to try to capture crack propagation results beyond the stage I power-law velocity versus stress intensity factor behavior. The stage II constant velocity regime was observed, but only in one sample tested in air. Fracture roughness of experimentally created crack paths was also analyzed using fractal analysis. The degree of crack path tortuosity (actual rough path length divided by straight-line length, a measure of roughness) was clearly dependent on the scale at which it was measured. Using the modified divider technique, crack-path tortuosity exhibited a clear fractal nature, with results for sandstone, shale and limestone exhibiting fractal dimensions from D1.04 to D1.09. The fractal dimension indicated a negative
correlation with subcritical index, but the results showed a significant scatter.
vii
Table of Contents
List of Tables ...........................................................................................................x List of Figures ........................................................................................................ xi Chapter 1: Introduction ............................................................................................1 1.1 Objective ................................................................................................1
Chapter 2: Mechanical and Thermodynamical Basis ..............................................3 2.1 Rock Fracture Mechanics ......................................................................3 2.1.1 Critical Crack Growth...................................................................3 2.1.2 Modes of Crack Surface Displacement.........................................4 2.1.3 Subcritical Crack growth ..............................................................5 2.2 2.3 Thermodynamical Basis.........................................................................7 Effect of Chemically-active Environment ...........................................13 2.3.1 Rebinder Effect ...........................................................................14 2.3.2 Westwood Approach...................................................................15 2.3.3 Stress Corrosion ..........................................................................18 2.3.3.1 2.3.3.2 2.3.3.3 2.3.4.1 2.3.4.2 2.3.4.4 Chemical Reaction Rate Theory ..................................19 The Lawn-Cook Model................................................22 Power Law vs. Exponential Law .................................25 Diffusion ......................................................................29 Dissolution ...................................................................29 Microplasticity .............................................................30
Chapter 3: Measurement of Subcritical Crack Index.............................................31 3.1 Test Description ...................................................................................31 3.1.1 Mathematical Description of Stress Intensity Factor for Double Torsion Test ................................................................................33 3.1.1.1 Expression for Crack Velocity for Constant Displacement Method ...............................................................................36 viii
3.1.1.2 Data Analysis and Reduction Method .........................37 3.2 Sample Preparation ..............................................................................41
Chapter 4: Experimental Results and Analysis......................................................44 4.1 4.2 Petrographic Information .....................................................................44 Results Subcritical indices and Fracture Toughness.........................49 4.2.1 Dependence of Subcritical Indices on Loading Magnitude........52 4.2.2 Effect of Rock-types and Environmental Control ......................61 Chapter 5: Velocity vs. Stress-intensity Curves ....................................................68 5.1 Data Noise Reduction ..........................................................................68 5.1.1 Spline Average of Recorded Data-points ...................................68 5.1.2 Numerical Differentiation Technique .........................................69 5.2 5.3 Region-II Crack-growth.......................................................................70 Activation Volume Calculation ...........................................................73
Chapter 6: Fracture Roughness Analysis...............................................................76 6.1 6.2 6.3 6.4 Background ..........................................................................................76 Fractal and Fractal-dimension..............................................................76 Fractal Applied to Fractures.................................................................78 Measuring Fracture Surface Roughness ..............................................79 6.4.1 Crack Imaging.............................................................................80 6.4.2 Crack-path Digitization...............................................................81 6.4.3 Data Analysis ..............................................................................83 6.5 Fractal Analysis ...................................................................................85 6.5.1 Application of Modified Divider Technique ..............................85 6.5.2 Fractal Analysis Random Path.................................................88 6.5.3 Fractal Analysis Subcritical Test Samples...............................90 Chapter 7: Conclusions ..........................................................................................96 Bibliography ..........................................................................................................99 Vita .....................................................................................................................108
ix
List of Tables
Table 2.1: Expressions for the crack velocity from literature................................27 Table 2.2: Expressions for time to failure from literature. ....................................28 Table 4.1(a): Point-count data. Numbers in each column denote raw count out of the total number of counts in the right-most column..............................46 Table 4.1(b): Summary of point-count data reported percentages. .......................47 Table 4.2: A summary of the dual torsion tests performed for all samples. n is the subcritical index, KIMAX is the stress-intensity factor corresponding to peak load, and P is the load drop observed after 300 seconds. ......50 Table 4.2: Contd.....................................................................................................51 Table 4.3(a): Mean and standard deviation of subcritical indices data for different samples..............................................................................................64 Table 4.3(b): Youngs modulus and fracture toughness of different specimens in different control environments..........................................................65 Table 5.1: Activation volume and subcritical index for three different sandstone samples..............................................................................................75 Table 6.1: Comparisons of mean, standard deviation and skewness parameters of an actual crack-path and a randomly generated crack-path with segment lengths in a Gaussian distribution. ....................................................88 Table 6.2: A summary of fractal analysis results and sub-critical indices for given samples..............................................................................................94
List of Figures
Figure 2.1: Three basic modes of loading for a crack: a) Mode I, b) Mode II, and c) Mode III (adapted from Whittaker et al., 1992)..................................5 Figure 2.2: Schematic crack-velocity/stress-intensity diagram. K0 is the stress corrosion limit and KIC is the fracture toughness; experiments yet to confirm K0 in rocks and minerals (Atkinson, 1984). ..........................6 Figure 2.3: a) Griffith crack system b) energetic of Griffith crack in uniform tension, plane stress (adapted from Lawn, 1993). ............................................8 Figure 2.4: Irwin-Orowan extension of the Griffith concept: small-scale zone model ...........................................................................................................10 Figure 2.5: Thermodynamically admissible kinetic relations: a) thermally activated crack growth in vacuum; lattice trapping, b) environmentally assisted crack growth, c) three typical stages, d) environment is surface active but unable to reach separating crack tip bonds, e) strongly surface active environment makes negative but unable to reach tip (Rice, 1978)...12 Figure 2.6: Interaction between water molecules and strained crack-tip bond in glass: (A) adsorption, (B) reaction and (C) separation (Michalske and Freiman, 1984). ................................................................................................19 Figure 2.7: Schematic of potential rate-limiting phenomena (Lawn, 1993)..........23 Figure 3.1: Loading configuration of the Double Torsion test (Nara and Kaneko, 2005). ................................................................................................32 Figure 3.2: Schematic diagram of a point loaded rectangular torsion bar (from Williams and Evans, 1973). ..............................................................34
xi
Figure 3.3: Load vs. relative time from Double Torsion test; blue triangles represent actual data acquired and red diamond represents the power-law fit to calculate the subcritical index...........................................................40 Figure 3.4: Load vs. relative time from Double Torsion test. Sharp drop in load (dashed blue box) denotes critical failure. Maximum load is used to calculate fracture toughness of the specimen....................................41 Figure 3.5: Schematic representation of the compliance relationship for DT test method (adapted from Fuller, 1979). ................................................42 Figure 3.6: Evolution of the crack front with crack extension (Chevalier et al., 1996). ...........................................................................................................43 Figure 4.1: Q-F-L diagram for the point-count data for different specimens........48 Figure 4.2: Load-decay data of sample 5950_1A (Test a) tested in air shows bumps during initial time..............................................................................56 Figure 4.3: Subcritical index vs. load-drop for Sandstone A1, A2 and A3 combined (A) air, (B) water, and (C) caustic. ...................................................57 Figure 4.4: Subcritical index vs. load-drop for Canyon I, II and III combined (A) air, (B) water, and (C) caustic. ................................................................57 Figure 4.5: Subcritical index vs. load-drop for MesaVerde (A) air, (B) water, and (C) caustic. ..............................................................................................58 Figure 4.6: Subcritical index vs. load-drop for Granite (A) air, (B) water. ...........58 Figure 4.7: Load-drop vs. maximum-KI for Sandstone A1, A2 and A3 combined (A) air, (B) water, and (C) caustic...........................................................59 Figure 4.8: Load-drop vs. maximum-KI for Canyon I, II and III combined (A) air, (B) water, and (C) caustic. ......................................................................59
xii
Figure 4.9: Load-drop vs. maximum-KI for MesaVerde (A) air, (B) water, and (C) caustic. ..............................................................................................60 Figure 4.10: Load-drop vs. maximum-KI for Granite (A) air, and (B) water........60 Figure 4.11: Crack-velocity vs. load for sandstone sample. Leftward shift of the curve indicates lower energy requirement for crack-growth in water and surfactant...........................................................................................66 Figure 4.12: Percentage change in subcritical index from air to water, surfactant and caustic vs. clay-content. ....................................................................67 Figure 5.1: Comparison between actual experimental data-points and spline data-fit. Blue diamonds represents the spline-smoothed curve and the red squares are the actual data..............................................................................69 Figure 5.2: (a) (a) Load-decay curve, and (b) velocity stress-intensity factor curve for specimen MV3 (Test b). The rollover of velocity at higher KI (earlier in the load decay) represents Stage II behavior. Start of RegionIII can also be observed (for first few load-decay data). ..................72 Figure 5.3: v-K curve for the specimen Sandstone-A1_3A (Test a) - test conducted in caustic (a) power-law fit, and (b) exponential fit. ............................74 Figure 5.4: Activation volume vs. subcritical index for three sandstone types. ....75 Figure 6.1: Illustration of self-similar and self-affine fractals (Kulatilake, 1995).77 Figure 6.2: Patterns of a Microcrack coalescence process. (a) just before fracture, and (b) a newly nucleated microcrack triggers the catastrophic failure (adapted from Lu et al., 1994.) .........................................................78 Figure 6.3: Environmental Scanning Electron Microscope (ESEM) facility at JSG, UT Austin..........................................................................................80
xiii
Figure 6.4: A screenshot of the profile generated from the crack-path in a sample from Canyon Sand tested in air, (a) BSE image, and (b) discrete digitized image..................................................................................82 Figure 6.5: Effect of scale-length on estimation of length with the original divider method...............................................................................................84 Figure 6.6: A screenshot of Excel VBA Tool developed for fractal analysis........84 Figure 6.7: Variation of log (Normalized length) with log (scale) for crack-roughness data of Canyon samples from 6071 ft. depth for with the magnification factor of (a) 100, and (b) 1000; Sub-critical test carried out in an aqueous environment of pH 13. ........................................................86 Figure 6.8: Variation of fractal dimension with magnification factor for crack-path roughness data (Canyon samples from 6071 ft. depth).....................87 Figure 6.9: Variation of fractal dimension with magnification factor for fracture surface roughness data (adapted from Kulatilake, 2006)..................87 Figure 6.10: A comparison of fractal analysis from the actual crack-path and randomly generated crack-path; red triangles are from actual crack-path follow power law systematically; blue diamonds are from randomly generated crack-path continuously curving. ..................................89 Figure 6.11: BSE images of crack-path in Canyon Sandstone and Barnett Shale, both tested in air, at magnification 1000x.................................................91 Figure 6.12: Variation of log (Normalized length) with log (scale) for crackroughness data of Canyon samples from 6071 ft. depth with the magnification factor of 100x in (a) air, and (b) caustic with pH 13. 92 Figure 6.13: A comparison of fractal analysis for Canyon sand (D = 1.092) and Barnett shale (D = 1.045)..................................................................93 xiv
Figure 6.14: Fractal analysis of a Yates sample; fractal dimension is 1.0849, which is in the same range as Canyon sandstone; visual impression also gives the same order of roughness for the samples..........................................93 Figure 6.15: (a) fractal dimension vs. subcritical index, (b) y-intercept vs. subcritical index..................................................................................................95
xv
Chapter 1: Introduction
1.1 OBJECTIVE Understanding the mechanics of rock fracture has been the continued interest of engineers and scientists. In the oil and gas industry, fracture mechanics has conventionally been applied to: 1) characterize naturally fractured reservoirs for better modeling and prediction of flow-behavior, 2) stimulate oil and gas wells by hydraulic fracturing, and 3) resolve issues related to wellbore integrity and stability. Applications are being extended to fragmentation of oil shale beds for in-situ retorting, and stability of thermal-stress induced fracturing of geothermal wells. Understanding the mechanics of rock-fracture has helped in formulating laws to explain how stresses remotely applied at the outer boundaries of a specimen transmit to the crack tip (Tada, Paris and Irwin, 2000), and in defining criteria for extension of cracks in terms of some parameter which characterizes the intensity of locally concentrated stress fields at the crack-tip (Irwin and Wells, 1965). Understanding the mechanism needs investigation on a micro-scale to understand the processes involved in fracture at the crack-tip and the process-zone. Lawn (1983) stated: For those who concern themselves primarily with the question of when fracture occurs, as engineers do, the methodology of fracture mechanics appears to be totally adequate as a predictive tool. However, if we ask ourselves why fracture occurs, things start to go wrong. Therefore, understanding the mechanism is vital to resolve the issues related to engineering application of fracturing in a more effective way. In oil and gas engineering, it can further be applied to explain the observations and to resolve the issues related to increased rate of drilling in the presence of surface-active media, increased injectivity during matrix-acidization with acid-surfactant mixture, and possible loss of 1
ground stability after secondary oil recovery both during injection of water and surfactant-water system. During critical (irreversible catastrophic) failure, crack propagate unstably with a velocity of the order of the shear wave velocity (103 ms-1). The most important parameter based on the premise of linear elastic fracture mechanics to characterize this type of rapid fracture growth is fracture toughness or critical stress intensity factor. Subcritical, slow or stable crack growth at velocities less than 10-1 ms-1 can occur at stress intensities far below the critical stress intensity factor. The presence of aggressive chemical environment and elevated temperature, under sustained or residual loading condition, further aggravates the kinetics of subcritical crack growth. The purpose of this study is to document the mechanism of crack-growth (critical and subcritical) in the presence of various chemical environments and to subsequently characterize the observations in terms of fracture mechanics parameters. An attempt has been made to couple the experimental observations with pertinent theoretical and empirical models available in the area of material science of metals, glass, ceramics and rocks to understand the processes involved at the crack-tip. An attempt has also been made to relate sub-critical crack growth index to fractal dimension of the crack-path roughness.
The stress intensity factor KI for a sharp crack at in an infinite body is given by:
KI = I c
(2.2)
where c is the fracture half-length and I is the applied remote stress. Near crack-tip stresses, that cause crack growth, are directly proportional to stress-intensity factor and are given by a generalized equation:
i =
KI f i ( ) 2 r
(2.3)
where KI depend on the outer boundary conditions (i.e., on the applied loading and specimen geometry). The remaining factors depend on the spatial coordinates about the
tip, and determine the distribution of the field: the coordinates factors consist of a radial component (r-1/2) and an angular component (f()). Thus, KI characterizes the crack-tip conditions, and therefore the fracture of the material must occur at a critical stress intensity factor, KIC, also called the fracture toughness of the material. Irwin (1957) showed that the energy approach is equivalent to the strength approach and the stress-intensity factor KIC is related to Gc by: Gc = where E '
2 K IC , E'
=E = E / (1-2)
2.1.2
Modes of Crack Surface Displacement Different loading configurations lead to different modes of crack surface
displacement. Generally, three different modes are defined (Figure 2.1): 1) Mode I, the tensile opening mode corresponds to normal separation of the crack walls where displacements of crack surfaces are perpendicular to the crack-plane 2) Mode II, the sliding (in-plane shear) mode corresponds to longitudinal shearing of the crack walls where displacements of the crack surfaces are in the crack plane and perpendicular to the crack front and 3) Mode III, the tearing (out-of-plane) mode corresponds to lateral shearing of the crack walls where displacements of the crack surfaces are in the crack planes and perpendicular to the crack-front. Throughout this thesis, only Mode I fracture has been taken into consideration while studying different fracture parameters. 4
(a)
(b)
(c)
Figure 2.1: Three basic modes of loading for a crack: a) Mode I, b) Mode II, and c) Mode III (adapted from Whittaker et al., 1992). 2.1.3 Subcritical Crack growth Subcritical crack growth was first observed in glass by Grenet (1899). Gurney (1947) and Gurney and Pearson (1949) studied the effect of environment on delayed failure of glass and used thermodynamic concepts to explain moisture enhanced crack growth. It has been subsequently investigated using glass (Charles, 1958a, b; Wiederhorn, 1967; Kies and Clark, 1969; Wiederhorn and Bolz, 1970; Bhatnagar et al., 2000), ceramics (Evans, 1974; Wu et al., 1978; Wiederhorn et al. 1980), metals (Williams and Evans, 1973; Pabst and Weick, 1981), cement (Beaudoin, 1985a, 1985b, 1987), and rocks and minerals (Henry et al., 1977; Atkinson, 1979, 1980, 1981, 1984; Atkinson and Meredith, 1981; Meredith and Atkinson, 1983; Holder et al., 2001; Rijken, 2005, Adefashe, 2006). Stress-corrosion has been considered the main mechanism for subcritical crackgrowth in brittle rocks. Crack-velocity (v) stress intensity factor (KI) diagram (Wiederhorn, 1967) has been used to study the subcritical crack growth and the effect of 5
different control environments on it. Wiederhorn (1967) identified trimodal behavior of log v - KI plot (Figure 2.2) and classified it into three distinct regions of crack-growth behavior: 1) Region I, characterized by a strong dependence of crack-velocity on stress intensity factor and considered to be controlled by the rate of stress-dependent chemical reaction, 2) Region II, where the crack-velocity is almost independent of the stress intensity factor and is limited by transport of reactive species to the crack-tip, and 3) Region III, where crack-growth is controlled mainly by mechanical rupture and is relatively insensitive to the chemical environment.
Log10 crack-velocity
Figure 2.2: Schematic crack-velocity/stress-intensity diagram. K0 is the stress corrosion limit and KIC is the fracture toughness; experiments yet to confirm K0 in rocks and minerals (Atkinson, 1984). 6
These diagrams have been used to: a) predict time-dependent fracture properties (Evans, 1972; Wiederhorn, 1974) and b) understand the micro-mechanism of subcritical crack growth under different environments (Wiederhorn, 1974; Atkinson, 1979a). 2.2 THERMODYNAMICAL BASIS Contemporary theories of the strength of brittle materials stem from the Griffith energy balance description of fracture processes (1920). Griffiths idea to model a crack as a reversible thermodynamic system (Griffith, 1920) coupled with his energy-balance concept (pertaining to crack propagation) and flaw hypothesis (pertaining to crack initiation) laid a strong foundation for a general theory of fracture. Griffith considered a static crack as a thermodynamical system and defined a criterion for crack propagation so as to minimize the total free energy of the system based on the first law of thermodynamics (law of energy conservation). The system energy (U) during crack propagation can be considered as a sum of mechanical-energy (UM) and surface-energy (US) terms. Mechanical energy consists of strain potential energy (UE) in the elastic media and the potential energy (UA) of the outer applied loading systems. Surface energy (US) is the free energy consumed in creating new surfaces by overcoming cohesive forces of molecular attraction. These can be mathematically expressed as U = U M + US , U = (U E + U A ) + US , Differentiating Equation 2.5 with crack length, we get (2.5) (2.6)
(2.7)
= free surface-energy per unit area. Mechanical energy terms generally decrease during crack propagation (dU M / dc < 0) and thus favor it. The surface energy term shall generally increase during crack growth and thus oppose it. Griffiths concept assumes crack-growth as a reversible process and proposes equilibrium condition as a criterion for predicting fracture behavior:
dU / dc = 0, Gc = 2 . (2.8) (2.9)
The crack should propagate or not according to whether the (dU/dc) term is negative or positive, respectively. Equation (2.4) provides an equivalence between mechanical-energy release rate and critical stress-intensity factor, KIC. Equation (2.4) and Equation (2.9) combined can be used to calculate free-surface energy or fracture-energy, as a function of KIC
US = 2 c
Equilibrium
Energy
c0
Crack length, c
UM = -
2
2E
c2
U=U M + US
Figure 2.3: a) Griffith crack system b) energetic of Griffith crack in uniform tension, plane stress (adapted from Lawn, 1993).
2 K IC E'
(2.10)
Simpson (1973) proposed that in a porous material, the stress intensity in the solid will be elevated because of the reduction in load-bearing area. KIC should be divided by (1 ) to take porosity into account. Thus, the fracture energy normalized for porosity should be
N =
(1 2 )
(2.11)
where N is normalized fracture energy. By invoking linear elasticity theory and using Inglis solution of the stress and strain fields, Griffith showed that the critical failure for an elastic plate with crack of length 2c subjected at infinity to the action of uniformly distributed stress tension, 1, occurs at
I = (2 E ' / c)1/ 2
where I is remotely applied stress
(2.12)
Irwin (1957) and Orowan (1949) independently proposed to add the work of plastic deformation, p to the specific surface energy related to a unit area of the newly formed surfaces, in the Equation (2.3). Plastic deformation zones are small zones in front of the crack. Poncelet (1965) challenged the basic Griffith Criteria (1920) assumption of isothermal behavior of freshly cleaved surface. From the statistical thermodynamic viewpoint, Poncelet (1965) argued that the surface energy of bodies is a free energy and not a potential energy as stated by Griffith (1920). The breaking of bonds which are not reformed, supplies the heat of sublimation of the solid to the surface and kinetic energy
terms. But still it didnt take the thermodynamics of slow-crack growth into consideration.
Zone boundary
crack
dc
Figure 2.4: Irwin-Orowan extension of the Griffith concept: small-scale zone model Two major works to advance the understanding on thermodynamical aspects of crack propagation came from Pollet and Burns (1977) and Rice (1978). Pollet and Burns (1977) expressed the crack extension force, neglecting thermodynamic surface energy of the material, as sum of two components: an athermal and a thermal component. Pollet and Burns (1977) proposed that the athermal component corresponds to the value of the applied crack extension force below which crack propagation does not occur and is required to overcome long-range, high-energy obstacles that cannot be activated by thermal fluctuation, whereas the thermal component is used to assist thermal activation of short-range barriers. The value of athermal component should correspond to the value of crack extension force at which the crack velocity is zero. Rice (1978) included the concept of irreversible thermodynamics in the formalism of crack-propagation and proposed an extended Griffith criteria. Basing his arguments on the second law of thermodynamics, i.e. non-negative entropy production, Rice extended Griffith criterion to be
10
(G 2 ) c 0 where G = elastic energy release rate, 2 = reversible work to separate the fracture surfaces,
.
(2.13)
= crack speed.
It was shown that the reversible work of separation (in vacuum) must lie in the range between the critical levels of G for rapid growth (G+) and rapid healing (G-), i.e.
G 2 G + .
(2.14)
Thus, it paved the way for a thermodynamically unstable condition, which described the crack propagation as stable within two extremes of applied stress-condition. It was further shown that for crack growth in a reactive environment, which can adsorb on the newly-created fracture surfaces, inequality remains valid when is interpreted as a surface energy as altered appropriately to account for adsorption. Thus, Rices extension of the Griffith criterion (Figure 2.5) helped to explain lattice trapping of atomistic model (Thomson, Hsieh and Rana, 1971) and stress corrosive effects (Charles and Hillig, 1962) within the theoretical formalism of thermodynamics. Rice criterion provided a fundamental rationale for the construction of v-G or v-K diagrams.
11
Figure 2.5: Thermodynamically admissible kinetic relations: a) thermally activated crack growth in vacuum; lattice trapping, b) environmentally assisted crack growth, c) three typical stages, d) environment is surface active but unable to reach separating crack tip bonds, e) strongly surface active environment makes negative but unable to reach tip (Rice, 1978).
12
2.3
Understanding the effect of chemically-active environment on mechanical properties of rocks is paramount to application in oil and gas industry. Operations on subterranean reservoir rocks include use of acidic media (matrix acidization), basic media (Alkaline-Surfactant-Polymer Flooding) and surfactants (ASP Flooding, Hydraulic fracturing and Drilling). The effect of chemistry on polycrystalline-polyphase rocks is difficult to analyze because of the complexity imposed due to the presence of microstructures, cements, fabrics etc. There are various reversible and irreversible mechanisms at work during fast and slow crack growth and it is imperative to understand the role of each of them, before extrapolating the experimental results to macro-scale application. The interdisciplinary nature of this field of study warrants integrating the complicated interplay of variables arising out of chemistry of the rock constituents and environment, physics of the surface of the rock and mechanics of rock-engineering. Different phenomena contributing to critical and subcritical crack growth have been identified and various models have been proposed to incorporate these mechanisms at work. Rebinder (1928; cited in Rebinder and Shchukin, 1973) and Orowan (1944) were among the earliest to identify the role of chemistry in brittle fracture. Rebinder (1928) proposed reduced strength and plastic flow during deformation and failure of solids under a definite stress-state in presence of surface-active media. The reversible physicochemical action of the media lowers the specific free surface energy of the solid and therefore, the work of formation of new surfaces during deformation and failure processes. Orowan (1944) observed a reduction by a factor of about three in the strength of glass specimens in moist air relative to that in a vacuum under sustained loading. He proposed that environmental molecules enter the crack and get adsorbed onto the walls in 13
the adhesion zone, lowering the surface energy of the solid. Another approach to explain reversible effect of the presence of surface-active agent on mechanical strength of materials came from Westwood (1974). He proposed that the environments which tend to bring zeta-potential to zero have the highest effect on lowering the mechanical strength of materials. In particular, Mills and Westwood (1980) cited that the addition of 10-3 to 10-4 moles l-1 of cationic surfactant DTAB (dodecyl trimethyl ammonium bromide) to cutting fluids increases drilling rate in quartz and westerly granite.
2.3.1 Rebinder Effect
The reversibility of physico-chemical effect and obligatory participation of mechanical stress distinguishes Rebinder Effect from other chemical or electrochemical processes such as stress-corrosion or dissolution of the solids in the surrounding media, which are typically irreversible. It incorporates the idea of thermodynamically stable interfaces between the given solid phase and the medium and therefore partial cancellation of the intermolecular forces on the newly produced surfaces. This effect is manifested both due to an adsorption monolayer and a liquid-phase layer, which can lead to still stronger changes in the mechanical properties corresponding to very low values of the inter-phase energy. Rebinder Effect proposes reduction in materials strength due to combined action of a reduction in surface energy of the material, a reduction in the bonding forces (causing healing of the fracture) across the developing crack or fracture and a chemomechanical wedging pressure exerted by the surfactant on the flanks of existing cracks in the form of osmotic pressure. Parameters affecting these actions can be expressed in terms of contact angle , wetting energy w, wedging pressure Pw and capillary pressure Pc in order of importance. The contact angle is defined as, 14
cos =
SV SL , LV
(2.15)
SL = Interfacial tension between solid-liquid interfaces, LV = Interfacial tension between liquid-vapor interfaces.
Contact angle is a measure of wetting (ease of spread of liquid over solid surface). Complete wetting occurs at a contact angle of zero; non-wetting means that the angle is greater than zero and complete non-wetting occurs at a contact angle of 1800. Wetting energy is defined as the difference between the solid-vapor and solid-liquid surfacetensions. Wetting energy is also a measure of wetting and the ability of liquid to penetrate irregularities. Wedging pressure is related to the liquid-vapor surface tension and the crack dimension. The effect of wedging pressure is to increase the tensile stress perpendicular to the tip of a crack or fracture. Capillary pressure is the pressure that drives a wetting fluid into a crack or fracture.
2.3.2 Westwood Approach
Westwood (1974) proposed that the chemo-mechanical effects in the presence of surface-active agents are result of electrostatic interaction between the adsorbed monolayer of species from the chemical environment and the bulk fluid. Westwood (1974) further proposed that, even if propagation of fast moving cracks in ceramic solids is not affected by presence of surface active agents, slow-crack growth is affected. The nucleation and mobility of dislocation near the crack tip are affected by a type of surface electrostatic potential called the zeta-potential (). The zeta potential is the electrostatic potential between the monolayer of adsorbed ions and molecules from the surfactant and the bulk-fluid. The sign and magnitude of the zeta-potential are dependent on the concentration of the surfactant in the fluid medium. 15
If the zeta-potential is zero ( = 0), the mobility and nucleation of near-surface dislocations are minimized. Westwood (1974) noted that the stresses required to propagate a crack are reduced because all energy is directed toward breaking the bonds at the tip of the crack. In a highly positive or negative zeta-potential environment, the nucleation and mobilization of near-surface dislocations are enhanced. Energy is consumed in the process of nucleation and mobilization of dislocations, which blunt the tip of the crack or fracture and inhibit propagation of the crack Any deformation that involves plastic deformation would be inhibited at = 0 and enhanced at 0. Plastic deformation invariably involves the processes such as surfacedislocations in the deformation-zone, which result in crack-tip blunting. The presence of dislocations would result in stored elastic strain energy around the crack and therefore an increase in the amount of work required propagating the crack. Westwood (1974) noted that dislocation mobility in ionic solids such as MgO is considerably influenced by dislocation extrinsic point defect interactions and the state of ionization of these defects will be influenced by surface potential. For covalent solids such as alumina and certain crystalline silicates, dislocation-lattice interactions dominate dislocation mobility and therefore, they might be immune to any chemo-mechanical effects. Wu et al. (1978) showed that the linking of microcracks is a significant mechanism of crack growth in crystalline brittle materials and therefore, application of Westwood approach alone to explain the effect of dislocation-mobility during crack propagation might be insufficient. The electrical potential (potential) is measured at the slipping plane, i.e. the plane at which relative motion takes place. Dunning (1984) postulated possibility of enhanced penetration of a liquid into cracks or flaws in a material at zero-zeta ()
16
potential due to absence of any shearing resistance between the bulk fluid and the adsorbed species on the solid material. Westwood (1974) related an increasing rate of penetration during drilling through silicate materials in presence of cationic surfactants to zero potential as compared to silicates in water, which exhibit negative potential. Dunning, Lewis and Dunn (1980) have linked changes in hydrofracture strength and microfracturing rate in orthoquartzite to potential. Ishido and Mizutani (1980) showed that maximum reduction of strength in quartz diorite is around zero potential. However, Dunning et al. (1980) showed that Westwood (1974) and Rebinder et al. (1944) do not accurately predict the crack-propagation behavior in quartz. Freiman (1984) raised question whether zeta potentials measured on bulk solids or powders will be similar in any way to those within the small confines of a crack tip. During subcritical crack growth in rocks, various other mechanisms are also at work, which are irreversible in nature, as opposed to the reversible effects of the environment discussed in preceding paragraphs. Atkinson (1984) identified stress corrosion, dissolution, diffusion, ion-exchange and microplasticity as the major mechanisms, all of which are effected by chemical effects of the pore fluid. Various phenomenological approaches using the theory of reaction rates in conjunction with continuum mechanics description of tip geometry (Hillig and Charles, 1965; Wiederhorn et al., 1980) have been taken to incorporate variables such as temperature, pressure and concentration (activity). Yet, the fundamental understanding of chemical interactions at the crack-tip is not complete. A complete description is yet to be formulated so that data from one system could be used to predict the response of another.
17
2.3.3
Stress Corrosion
Stress corrosion presumes that the chemical reaction between strained bonds and an environmental agent produces a weakened state which can be broken at lower stresses than the unweakened states. The general expression for weakening for silicate glasses and quartz in water environments is proposed as (Scholz, 1968, 1972; Martin, 1972; Atkinson, 1979; Martin and Durham, 1975):
H O H + [ Si O Si ] Si OH HO Si 2 [ Si OH ] .
Charles (1958) proposed following expression for corrosion of silica glasses in basic environments: Si O Si + OH Si O + Si OH . Michalske and Freiman (1982) approached the molecular interaction problem from an electron orbital viewpoint. They postulated that for crystalline silicates and silicate glasses, the strained Si-O bonds at crack tips can react more readily with the environmental agents than unstrained bonds because of a strain induced reduction in the overlap of atomic orbitals. It was envisaged that the incoming water molecule interacts with the Si-O-Si crack-tip bond in three stages (Figure 2.6): 1) Step A involves attachment and alignment of water molecule with the bridging bond, 2) Step B involves reaction where water molecules donate an electron to the silicon and a proton to the oxygen, in the stretched linkage unit and 3) Step C involves rupture of a weak hydrogen bond and creation of a fracture surface saturated with hydroxyl groups.
18
Figure 2.6: Interaction between water molecules and strained crack-tip bond in glass: (A) adsorption, (B) reaction and (C) separation (Michalske and Freiman, 1984). Stress-corrosion of Si-O-Si bonds has been attributed to both ionized water (Wiederhorn et al., 1980) and to molecular water (Michalske and Freiman, 1982). Freiman (1984) correlated the rate of stress-corrosion to activity of the corrosive agent. Stress-corrosion reactions in calcite rocks are even less understood. Possible chemical reactions that accompany stress corrosion crack growth in the complex silicates biotite and feldspar has been indicated by Barnett and Kerrich (1980), but these complex reactions were also not well characterized.
2.3.3.1 Chemical Reaction Rate Theory
The thermodynamic formulation of reaction rate theory is based on the assumption that reactants are in a state of equilibrium with an activated complex formed during the reaction and which in turn decomposes to form the reaction products:
A + B ( A B )* C
The reaction rate, kr for such a single-step reaction is given by: 19
(2.16)
kr =
kT [ A] [ B] exp ( G * / RT ) h
(2.17)
where k is Boltzmanns constant, T is the absolute temperature, h is Plancks constant, R is the gas constant, [A] and [B] are the concentrations of the reactants, and G* is the change in partial molar free energy between the initial and activated state of reaction. G* can be expressed as: G * = T S * + E * + PV * (2.18)
where S* is the activation entropy, E* is the activation energy, V* is the activation volume and P is the pressure at the crack-tip. Entropy (S) is a measure of the extent of randomness or disorder in a system. The difference between the entropy of the transition state and the sum of the entropies of the reactants is activation entropy S*. The temperature dependence of the rate constant, kr is characterized by the activation energy of the experiment. The pressure dependence of the chemical reactions is characterized by the activation volume V* (d (ln kr)/P = V*/RT). The Charles-Hillig model (Charles and Hillig, 1962; Hillig and Charles, 1965) proposes that catastrophic delayed failure is triggered by the interaction between thermodynamics and chemical kinetics of a chemical corrosion process on a glass that is subjected to a tensile stress. Wiederhorn et al. (1980), on the basis of the Charles-Hillig model, treated the rupture process at crack tips as a chemical reaction. By assuming that 1) the crack tip can be modeled as an elastic continuum, 2) the crack tip has an elliptical shape with a curvature equal to , 3) the pressure term in the Equation (2.17) can be replaced by negative crack-tip stress (I = 2KI/()), and 4) the chemical potential of reactants should be modified to include surface curvature, Wiederhorn et al. (1980) obtained the following expression for the free energy of activation:
20
2 K * ( *V * V ) I G = T S + E V ( )1/ 2
* * *
(2.19)
where KI is the applied stress intensity factor and V is the partial molar volume of the material undergoing reaction. Wiederhorn et al. (1980) further suggested that the experimental crack-growth data in region I can be expressed by the following empirical relationship
E * + bK I v = vo exp RT
(2.20)
where vo, E*, and b are empirical constants of the fit. Here, vo is approximately proportional to the activity of the reactive species, E* is the related to the stress-free activation-energy and b is related to the activation volume. For chemical reaction rate theory to be consistent with the empirical relationship, the term containing the stress intensity factor in Equation 2.19 must be equal to the terms containing the stress intensity factor in Equation 2.20 V * = b . 2 (2.21)
Therefore by assuming a crack-tip radius and by measuring the slope of the v-K curve, the activation volume of the reaction can be determined. The limitations of the above model are the approximation of the the crack-tip profile as a smooth, rounded ellipse. Further, only linear term for crack-tip stress has been introduced into the energy barrier for activated crack-growth. Thus, the linearity expressed between the logarithmic stress-intensity factor and the crack-velocity loses sound physical basis. Further, there is no provision for crack-healing.
21
To overcome these limitations, Lawn (1975) developed a model to explore crackmotion kinetics at atomistic level, based on the lattice trapping theory of Thomson and coworkers (Thomson 1973, Thomson et al. 1971). This model was further developed by Cook et al. (1993) to derive atomistic variables from macroscopically measured variables.
2.3.3.2 The Lawn-Cook Model
Lawns atomistic model (Lawn, 1975) considers an ideally brittle fracture crack in which sequential bond rupture occurs via the lateral motion of atomic kinks (considering each atomic-scale jump as an energy-barrier), which are enhanced by thermal fluctuations. Chemically enhanced subcritical cracking is a two stage process: transport and reaction. Reactive species must be transported to the crack-tip before reactions can occur that facilitate crack extension. The slower of these two steps will control the rate of the overall process. By considering as the sum of a linear reversible surface energy term and a nonlinear trapping term approximated by a harmonic function with atomic periodicity, including statistical thermodynamics of a Maxwell-Boltzmann distribution to characterize bond-rupture frequency and incorporating chemical potential term to modify surface energy function, Lawn (1975) attempted to explain crack-growth on the atomic scale and while incorporating the effect of some key control variables such as applied loading, chemical concentration of reactive species and temperature on crack-velocity.
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Activated diffusion
Adsorptive reaction
Solute diffusion (liquids)
Figure 2.7: Schematic of potential rate-limiting phenomena (Lawn, 1993). The fundamental basis of this model is that the frequency of bond-rupture and bond-healing in a reactive environment is modified by the magnitude of the energy release rate. The net frequency of bond-rupture is represented by Maxwell-Boltzmann statistics (Lawn, 1975) as:
U * U * f = f o exp + exp kT kT f o = kT / h where fo = characteristic lattice vibration frequency, k = Boltzmanns constant, T = absolute temperature, h = Plancks constant.
* * and U terms The activation energies for kink advance and retreat are represented by U +
(2.22) (2.23)
which are modulated by the mechanical energy release rate to promote macroscopic crack motion. For a simple chemical reaction of the form
X + B B* ,
23
where X is the reactive environmental species, B and B* represent the unbroken and activated complex state, the rate of change of surface potential or the fracture resistance R, for an increment in crack area A (Cook and Liniger, 1993). dU s R = ( B* B ). N . X . N + R sin ( 2 NA ) dA where X = chemical potential of the environmental specie X, (2.24)
B = chemical potential of the reactant, B, B* = chemical potential of the activated complex, B*,
N = number of bonds per unit area, NA = total number of broken bonds. The last term is included to account for trapping and gives a periodic fracture surface energy term. On integrating the above equation, surface potential is obtained, which is periodic in bond-separation: U s = uo ( NA) u1 cos ( 2 NA ) , 2 (2.25)
where uo represents the energy required to break the bond in the reactive environment
uo = ( B* B ) . A ,
and u1 the intrinsic energy for bond rupture, R . u1 = N Cook et al. (1993) showed that for small departures from the equilibrium Griffith condition, the activation energy barriers can be expressed as a function of mechanical energy release rate, G as
G / N + uo * = u1 1 U 2u1
24
(2.26)
Further, the rate of increase of crack area, dA/dt can be expressed as f/N where f is given by the Equation (2.22). An expression for crack velocity can be obtained by combining Equation (2.21) and Equation (2.25): G 2 v = vo sinh (2.27)
Equation (2.26) can be used to fit the experimental v-G curves and the macroscopic crack velocity parameters (vo, , ) obtained can be related to the atomistic bond rupture parameters (fo, N, w, uo, u1) as
vo =
2 fo u exp 1 , Nw kT
2 = uo N ,
= 2 NkT .
Here, it can be noted that Equation 2.27 contains a zero and sign reversal at the equilibrium point G = 2. As discussed earlier, the energy per unit area 2 is the surface energy that is sensed experimentally. Cook et al. (1993) noted that Equation 2.27 has two terms: a local, kinetic term vo, containing information about the mechanism of bondrupture in the intrinsic activation barrier u1; and a global, thermodynamic constraint, the sinh function, containing information about the departure from equilibrium in (G-2). As noted earlier, uo represents the energy required to break the bond in the reactive environment (global term) and u1 the intrinsic energy for bond rupture (local term). Cook model is to be extended to the porous rock material.
2.3.3.3 Power Law vs. Exponential Law
Charles (1958) fit experimental static fatigue data of glass to a power law and proposed the following expression for subcritical crack growth velocity
25
' v = vo exp ( H * / RT ) K n
(2.31)
where v is crack-velocity, H* is activation enthalpy, R is the gas constant, T is temperature, vo and n are constants and n is called the subcritical index. Charles and Hillig (Charles and Hillig, 1962; Hillig and Charles, 1965) favored reaction rate theory for constitutive modeling of slow crack-growth. It was subsequently developed by Wiederhorn et al (1980). A brief synopsis of their model is discussed in Section (2.3.3.1). Equation (2.20) is a simple form of the exponential law. The Lawn-Cook model (Lawn, 1975; Cook and Liniger, 1993) proposed a hyperbolic sine functional relationship (Equation 2.27) between velocity and fracture-mechanics parameter. All these models fit quite well with the experimental data but diverge significantly outside the range of observations (Atkinson, 1987). Despite the sophistications involved in the reaction-rate theories and atomic theories, Charles power law is the most used method to characterize subcritical growth, particularly for geological materials. Costin (1987) noted that Equation 2.20 predicts a finite stress corrosion threshold, whereas Equation 2.31 does not. No stress-corrosion threshold has been observed for rock (Adefashe, 2006; Atkinson, 1984). The other advantage of using power-law model is that time to failure can be calculated more easily, as integration operation on a power-law model is easier. Various authors have presented v-K relationship in different mathematical forms. The bases of all these models are extension of empirical power-law relationship (Charles, 1958), exponential relationship from chemical reaction-rate theory (Charles and Hillig, 1962) or, relationship from atomistic model (Thomson, 1973; Lawn, 1975). A compendium of various models from literature is presented in Table 2.1.
26
Charles, 1958a Charles and Hillig, 1962 Hillig and Charles, 1965 Wiederhorn, 1967 Kies and Clark, 1969 Wiederhorn and Bolz, 1970 Evans, 1972 Evans and Wiederhorn, 1974
v = k ( m ) n exp( A / RT )
= o exp ( E * +bK I ) / RT
= o exp E * +V *
VM / RT
V = exp(H + K I ) / RT
3 dx d o = exp ( f * / kT + G / N o kT ){( p + )G N o f s } dt h
= o exp( E * +bK I ) / RT
V = ' K n exp(H / RT )
V = Vo K InT / To exp(H / RT )
Wiederhorn et al., 1974 Atkins et. al, 1975 Pletka and Wiederhorn, 1982 Cook and Liniger, 1993 Lockner, 1998
= o exp( E * +bK I ) / RT