For more than five decades, hydraulic fracturing has been widely used to enhance oil and gas production. Hydraulic fracturing in solid materials (e.g., rock) has been studied extensively. The main goal of this thesis is a comprehensive study of the physical mechanisms of hydraulic fracturing in cohesionless sediments. For this purpose, experimental techniques are developed to quantify the initiation and propagation of hydraulic fractures in dry particulate materials. We have conducted a comprehensive experimental series by varying such controlling parameters as the properties of particulate materials and fracturing fluids, boundary conditions, initial stress states, and injection volumes and rates. In this work, we suggest principle fundamental mechanisms of hydraulic fracturing in particulate materials and determine relevant scaling relationships (e.g., the interplay between elastic and plastic processes). The main conclusion of this work is that hydraulic fracturing in particulate materials is not only possible, but even probable if the fluid leak-off is minimized (e.g., high flow rate, high viscosity, low permeability). Another important conclusion of this work is that all parts of the particulate material are likely to be in compression. Also, the scale effect (within the range of the laboratory scales) appears to be relatively insignificant, that is, the observed features of fractures of different sizes are similar. Based on the observed fracture geometries, and injection pressures we suggested three models of hydraulic fracturing in particulate materials. In the cavity expansion or ??e driving model, the fracturing fluid is viewed as a sheet pile (blade) that disjoints the host material, and the cavity expansion occurs at the fracture (blade) front. The shear banding model is also consistent with a compressive stress state everywhere in the particulate material and explains the commonly observed beveled fracture front. The model of induced cohesion is based on the fluid leak-off ahead of the fracture front. The induced cohesion may be caused by the tensile strain near the fracture tip (where the stress state is also compressive), which, in turn, induces the cavitation of the leaked-off fluid and hence capillary forces.

Oriented thermoplastics offer interesting opportunities for making structural automotive components due to their higher strengths. A new process, referred to as the axial feed hot oil tube forming (AF-HOTF) process, has been developed and studied for the forming of oriented thermoplastic tubes. The starting material for AF-HOTF process is an oriented polypropylene (OPP) tube produced by the solid state extrusion process. AF-HOTF was used to study forming and fracture behaviour of OPP tubes at large strains. Mechanical properties and molecular orientation of starting and post-formed materials were investigated to gain a better understanding of structure-property-process relationships during solid state extrusion and subsequent forming of OPP tubes. The development of molecular orientation and other microstructural changes and damage development in extruded and bulged OPP tubes during solid state extrusion and AF-HOTF processes were studied with optical microscopy, wide-angle X-ray diffraction (WAXD) and field emission scanning electron microscope (FE-SEM) techniques. Also, the development of large strains during AF-HOTF of OPP samples were experimentally studied in the form of spatial strain maps, strain/stress state and forming limit strains using an on-line strain mapping method based on digital image correlation (DIC). In addition, tensile tests have been carried out at room temperature on samples machined from the extruded and bulged tubes along the axial and hoop directions. Experimental quantitative relationships amongst molecular orientation parameters and extrusion and AF-HOTF process parameters such as draw ratio, strain and strain state have been obtained. These relationships in the form of White and Spruiell biaxial orientation factors provide a useful insight into molecular reorientation that occurs during extrusion and subsequent forming of OPP tubes. Also, an analytical model for forming limit prediction that takes into account OPP tube properties, tube dimensions and AF-HOTF process parameters was developed based on existing model of tube hydroforming in the literature. In addition, a new biaxial ball stretching test (BBST) system was developed and utilized to subject the thermoplastic tube to biaxial stretching. The design of the test-rig and results were presented for polypropylene (PP) tubes subjected to BBST at various temperatures. The BBST system was combined with an available on-line imaging and strain analysis system (ARAMIS® system from GOM) to observe the development of strains in the biaxial tensile region during the test. BBST samples were studied with wide angle X-ray diffraction (WAXD) pole figures. Three different hot forming processes (Solid-state extrusion, AF-HOTF and BBST) were used in this research. The structure of the extruded samples at draw ratio 5 and higher was completely changed to fibrils structure, and the yield strength and elastic modulus increased by 50%. Also the crystallinity increased from 47% to 68% with an increase in draw ratio. An increase in axial feed during the hot forming process resulted in higher formability (strains values of 0.55 major strain and -0.25 minor strain) and delayed failure. The analytical model prediction of bursting shows good agreement with the experimental results. The results provide an understanding of the orientation development in solid state extrusion of PP tubes as well as an understanding of tube formability, flow localization and fracture characteristics of PP tube from AF-HOTF process and other related processes. / Thesis / Doctor of Philosophy (PhD)