Recent Developments in 2G HTS Wire and Its Application in Superconducting Power Equipment

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1 superior performance. powerful technology. Recent Developments in 2G HTS Wire and Its Application in Superconducting Power Equipment Yi-Yuan Xie, D. Hazelton, J.C. Llambes, Y. Chen, X. Xiong, A. Rar, K. Lenseth, Y. Qiao, A. Knoll J. Dackow, and V. Selvamanickam Nov. 2-4, Tsukuba, Japan SuperPower, Inc. is a subsidiary of Royal Philips Electronics N.V.

2 SuperPower develops advanced 2G HTS technology and manufactures commercial wires < 0.1 mm Surround Copper Stabilizer: by electroplating; electric stability, hermetic seal and solder temp. up to 250 o C HTS layer (biaxially aligned): by MOCVD, high dep. rate + large dep. zone area high throughput Buffer stack: IBAD-MgO based, biaxial texture formation with ~ 10 nm film high throughput; wide range of substrate selection; Substrate: High strength, thin and highly resistive high J e and low ac loss 20 µm HTS grain orientation 2 µm 1 µm ~0.2 µm 50 µm c b a 20 µm

3 World-class results demonstrated in SuperPower s 2G program in last three years G wire Pilot-scale production established First largest delivery of 2G wire from pilot operations ~ 10,000 m delivered to Albany Cable project Production of m splice-free piece lengths with Ic of 200 A/cm 2007 Crossed 500 m splice-free piece lengths and 100,000 A-m Kilometer-long fully buffered tapes at 360 m/h* and uniform in-plane texture of Crossed 1,000 m splice-free piece lengths and 200,000 A-m Ic > 810 A/cm over 1 m (repeated) 340 A/cm at 65 K & 3 T (perpendicular field) and 267 A/cm (minimum Ic) and 229 A/cm at 77 K & 1 T (perpendicular field) using Zr-doped (Y,Gd)BCO World s first demonstration of device made with 2G wire in the power grid. Low ac loss of 0.34 W/m/phase Over 33,000 m of customer wire orders *4mm wide equivalent 3

4 Key areas of advancement in 2G HTS and its applications in power equipment in 2009 Manufacturing of long length wires at high processing speeds In-field performance Enhancement via Zr-doping and transfer from R&D to production Demonstration in high-field coils HTS generator work Fault current limiter application Summary

5 High throughput manufacturing routine in 2009 Routine electropolishing of two tapes simultaneously doubled throughput to 16,800 meters* a week Simultaneous deposition of alumina & yttria layers sequentially using two chambers available in Pilot Buffer system - combined two process steps into one, eliminating one set-up time. Speed of 750 m/h* of 4 mm wide tape to deposit both alumina & yttria; deposition time is only 6 hours! Simultaneous deposition of homo-epi MgO & LMO processes after IBAD-MgO # ( # at 360m/h*, 12.6 km* weekly) 4 buffer layers deposited on 1,400 m tapes routinely with one pilot buffer system. Weekly production* : 8,400 m. Substrate planarization is being introduced to eliminate of vacuum deposition of alumina and yttria; buffer throughput will double to 16,800 m/week Cu Cu *4 mm equivalent Hastelloy substrate LMO Homo-epi MgO IBAD MgO Yttria Alumina alumina yttria Pilot buffer Sputtering These 2 layers deposited simultaneously in Pilot Buffer These 2 layers deposited simultaneously in Pilot Buffer

6 High quality, five-layer buffered tapes manufactured in kilometer lengths More than 60 fully-buffered tapes produced to date in lengths > 1 km Over 50% of fully-buffered tapes are 1,200 to 1,400 m long Over 90% of tapes have in-plane texture of 5 to 7 o FWHM with excellent uniformity 6

7 IBAD-MgO-based MOCVD 2G HTS wire is produced in kilometer lengths 450 Kilometer Long 2G HTS Wires Ic (A/cm-w) Jul-08 Aug Aug K, I c measured every 5 m using continuous dc currents over entire tape width of 12 mm (not slit) Voltage criterion: 0.2 microvolt/cm Position (m) Minimum current (I c ) = 282 A/cm-w over 1065 m 2009 new world record: I c Length = 300,330 A-m 7

8 Critical Current * Length (A-m) Remarkable progress in 2G HTS wire scale-up over the last 7 years 320, , , , , ,000 80,000 40,000 0 Nov-01 Jul A-m to 300,330 A-m in seven years Mar-03 Nov-03 Aug-04 Apr m 322 m 427 m 1 m 18 m 97 m 206 m 158 m 62 m Dec-05 Aug-06 Apr-07 1,065 m 282 A/cm 1,030 m 227 A/cm 935 m 790 m Jan-08 Sep-08 May-09 World Records 8

9 Longer and higher in 2009! 600+ m lengths with I c > 300 A/cm m lengths with I c > 250 A/cm 9

10 Excellent in-field performance makes a wide range of real-world applications possible J e (KA/cm 2 ) Low Field Medium Field High Field 1E Magnetic Field B (Tesla) Ultra-High Field Ic(B//ab)/Ic(77K,0T) - 4.2K Ic(B//c)/Ic(77K,0T) K Ic(B//c)/Ic(77K,0T) - 14 K Ic(B//c)/Ic(77K,0T) - 22 K Ic(B//c)/Ic(77K,0T) - 33K Ic(B//c)/Ic(77K,0T) - 50K Ic(B//c)/Ic(77K,0T) - 65 K Ic(B//c)/Ic(77K,0T) - 72K Ic(B//c)/Ic(77K,0T) - 77K I c (B)/I c (77K,0T) High Temp, Low Fields: Cable SFCL Transformer Motor/generator Plasma Confinement Xtal growth magnet Magnetic separation Medium Temp, Medium Fields: Motor/generator Plasma Confinement Xtal Growth Magnet Magnetic separation Maglev SMES Low Temp, High Fields: SMES High-Field MRI High-Field Insert NMR * J e is calculated based on I c (77 K, 0T) = 100 A/4 mm (surr. copper stabilized) and scaling factors measured by D. Larbalestier, et al at FSU and E. Barzi, et al. of Fermi Lab.

11 Ic (A/cm) 2008: Zr doping was demonstrated in MOCVD to achieve dramatic improvements in in-field performance micron SmYBCO micron GdYBCO micron Zr:GdYBCO K, 1 T Angle between field and tape (degrees) 97% increase in minimum I c to 186 A/cm corresponds to J e of 28,500 A/cm 2 (no copper) 85% increase in I c (B tape) to 229 A/cm corresponds to J e of 35,200 A/cm 2 (no copper) : 3.33 μm Zr:(GdY)BCO 2008: 3.15 μm Zr:(GdY)BCO 2007: 2.8 μm (GdY)BCO Angle (deg) 65 K, 3 T 67% increase in minimum I c to 267 A/cm corresponds to J e of 41,000 A/cm 2 (no copper) 88% increase in Ic (B tape) to 340 A/cm corresponds to J e of 52,300 A/cm 2 (no copper) In 2009, Zr-doping chemistry successfully transferred to production line Selvamanickam, Xie and Dackow, 2009 DOE HTS Program Review Data from Y. Zhang, M. Paranthaman, A. Goyal, ORNL

12 Two coils made with Zr-doped 2G wire Identical size, same quantity of Zrdoped wire with similar critical current performance at 77 K, zero field. Repeatable enhanced coil performance demonstrated with Zr-doped 2G wire 12

13 Zr doping provides enhanced performance in nitrogen cooling Coil 2008 Coil 2009 Coil SN2:LN2 boundary Linear (2009 Coil) Linear (2008 Coil) LN T (K) B 0 (T) Central Field, Bo (T) SN & 2009 coils with Zr:(GdY)BCO wire 2007 Coil with (SmY)BCO wire 30% Temperature (K) % higher field in coils with made with Zr-doped chemistry and 2009 coils have larger winding I.D. and lower coil constant

14 2009 high field insert coil achieves record performance Insert coil tested in NHMFL s unique, 20 T, 20 cm wide-bore, Bitter magnet Temperature (K) Coil ID Winding ID Winding OD Coil Height 12.7 mm (clear) 19.1 mm ~ 84 mm ~ 73.6 mm # of Pancakes 16 (8 x double) 2G wire used ~ 600 m # of turns ~ 3696 Coil J e Coil constant Wire I c (77 K, sf) ~155.3 A/mm 100A ~ 51.8 mt/a 120 A 180 A (non Zr-doped) Patrick Noyes, Ulf Trociewitz, Huub Weijers, Denis Markewicz, David Larbalestier Central field self field (T) Total Central Field in background field (axial) (T) With Background field (T)

15 Proof of concept - 2G conductor for SFCL shows consistent, excellent performance 12 elements, 40 cm long with four 2G wires in parallel per element Current [ka] Voltage across HTS elements [kv] Time [ms] Iprospective I_total_KEMA I_HTS Ish V_total_KEMA High-power SFCL test Prospective current Limited current Peak current through element Response time Element quality range 2G 90 ka* 32 ka 3 ka < 1 ms Narrow Fast response time Current [ka] Quench speed around 0.5 ms Time [ms] I_total_KEMA I_HTS Ish V_total_KEMA Voltage across HTS elements [kv]

16 SFCL modular system design components integration Module Design Specification and criteria 2G tape J c, J/cm/tape, RUL Arms/tape, mechanical, thermal and electrical properties LN2 Bath Shunt Coils Zsh = Rsh + jxsh, X/R ratio, EM force withstand, thermal and electrical properties, connectors, size, weight, over-banding, ease of assembly and manufacturablity HTS assembly Tape per element, RUL per element, element energy capability, connectors, size, cooling orientation, failure mechanisms and mitigation, losses and their effects on cryogenics design HV design LN2 and GN2 design stress criteria, spacing between tapes, elements and modules, stress shield dimensions, using solid barriers or not, bushings and assembly integration, assembly supporting structure (post insulators), overall assembly to cryostat spacing and integration Cryogenics - LN2 flow control, LN2 and GN2 interface, pressurizing, safety issues, thermal handling of fault and steady state losses Modular Matrix Assembly Complete Transmission / Distribution System Design Boundaries Instrumentation, control and condition monitoring of SFCL system Systems issues - SFCL device testing, systems study and utility interfaces

17 2G modular RUL capabilities tested at FSU-CAPS Module #1 Module #2 Module #3 Module #4 Test conditions evaluated: 2 SFCL tapes configurations ( standard and new configuration) are evaluated with 2 types of modules Follows AEP sequence Module current scalable in multiples of 500 A peak Module voltage scalable from 400 V - 1 kv peak Prospective fault currents scalable from 5-10 ka peak Photo of 4 modules in test dewar ready for test

18 RUL vs. Fault Duration / Occurrence. 3 x Base-Line Voltage

19 HTS generator project Funded by US Office of Naval Research (ONR) Target operation: 36.5 MVA Partners: SuperPower, Baldor Electric, General Dynamics-Electric Boat, Naval Surface Warfare Center (Philadelphia), Naval Research Lab, Oak Ridge National Lab Current Phase: Conceptual design / risk reduction studies Smaller / lighter weight tradeoff studies vs. efficiency vs. cost HTS windings development Rotor / stator design / development Fabrication of test articles

20 Ic/Ic(0) SuperPower 2G HTS wire tolerates high axial stress ~700 MPa Ic/Ic(0) Versus Stress at 77K Tape ID # M BS M Peak Stress 0048 Unloaded Peak Stress 0115 Unloaded Peak Stress 0163 Unloaded Recommended Stress Limit Stress [MPa] Data from R. Holtz, NRL I c drops by up to 10% reversibly under peak stress up to 700 MPa (about 0.6% strain) Above 700 MPa (0.6% strain) I c degrades irreversibly N-value does not change with peak stress up to 700 MPa N-value degrades irreversibly coincident with irreversible I c degradation Define σ IcRL (ε IcRL ) = I c Reversiblity Limit = Peak monotonic stress (strain) for >98% reversibility of I c σ IcRL (ε IcRL ) = 700 MPa (0.6%) Fatigue strength also found to be equivalent to I c reversibility limit

21 2G HTS coil for thermal cycle testing at NRL Terminal Blocks 1018 Carbon Steel Case (Top Plate Removed) 2G HTS / Kapton / Epoxy / Glass Windings

22 NRL thermal cycling results: Quench stability Coil Voltage (b) Typical Voltage vs Time Curves 50% 95% 100% 105% 115% 110% 120% 90% 80% Various currents as a percentage of the quench instability current Time [sec] (b) Typical voltage-time curves for the same HTS coil. For each value of current, the voltage is monitored for some period of time to determine if it is stable. The highest current at which the voltage exhibits long term stability is designated the quench instability limit current. Data from R. Holtz, NRL

23 NRL thermal cycling test results on Coil 1: No degradation of quench instability current 1.2 Normalized Current (b) Quench Instability Current Thermal Cycles (b) The quench instability current of coil NRL-1 vs thermal cycles. Results are normalized to the average values. Data from R. Holtz, NRL

24 Summary SuperPower routinely produces 2G HTS wire in manufacturing line. New world record performance of I c L = 300,330 A-m achieved in km long wires In-field performance enhancement at all field angles achieved via Zr-doping; technology has been transferred into production line High-field coils with consistently improved performance demonstrated with SuperPower 2G wire. Self field was increased from 0.73 Tesla to above 1 T at 77 K and more than 2 T at 65 K. At 4.2 K, maximum fields of 10.4 T and 27.4 T were achieved in self-field and with 19.9 T background, respectively Proof of concept for resistive 2G SFCL demonstrated. Developed generalized SFCL module specification: Module current scalable in multiples of 500 A peak Module voltage scalable from 400 V - 1 kv peak Prospective fault currents scalable from 5-10 ka peak Model coils for HTS generator fabricated and demonstrated reliable performance

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