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SuperPower Inc. is a subsidiary of Furukawa Electric Co. Ltd.

Progress in production and performance of second generation (2G) HTS wire for practical applicationsYifei Zhang, T.F. Lehner, T. Fukushima, H. Sakamoto, and D.W. Hazelton

IEEE 2013 International Conference on Applied Superconductivity and Electromagnetic DevicesOctober 25-27, 2013 Beijing, China

ASEMD 2013 Beijing, China Oct. 25-27. 2013All Rights Reserved. Copyright SuperPower® Inc. 2013

Outline

• 2G HTS wire development and production – an overview• SuperPower Inc. and its 2G HTS wires• Wire quality and performance

– Uniformity (homogeneity) and piece length– In-field critical current– Electro-mechanical behaviors– Delamination strength

• Technology advancement in using 2G HTS wires• Application projects using 2G HTS wires• Summary

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R&D and production of 2G HTS wire

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World-wide developers and manufacturers – a glance at the technologies

• A limited number of commercial products providers• Piece length (without splice): 200 ~ 500 meter• Ic (77K, self field): 250 ~ 500 A/cm• Price: 150 ~ 350 $/kAm at 77K, self field • No commercial 2G-based electrical or electromagnetic devices


SuperPower Inc. – company history timeline

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• Formed within Intermagnetics (IGC) in 2000

2000 ~ 2006• Intermagnetics acquired by Royal Dutch Philips in 2006

2006 ~ 2012

• SuperPower Inc. acquired by Furukawa Electric in 2012

2012 ~ present

− Strategic Research Agreements with national labs (LANL, ORNL, ANL)

− Building up strong R&D team and IP− Supported by government funding

− Building up strong manufacturing and marketing teams

− Transition to pilot-scale manufacturing− Strategic Research Agreement with

University of Houston (TcSUH)

− Continuous improvements in quality and performance

− Steady growth in capacity to meet the market− Moving towards long-term sustainability

ASEMD 2013 Beijing, China Oct. 25-27. 2013All Rights Reserved. Copyright SuperPower® Inc. 2013 5

Voice of the customer provides our roadmap

• We have provided 2G HTS wires to over 230 customers in 31 countries

• Electric and electromagnetic devices applications include high-field magnets, MRI magnets, accelerator magnets, high-current power cables, superconducting fault current limiters (SFCL), superconducting magnetic energy storage (SMES), generators & motors, etc.


Architecture of SuperPower’s 2G HTS wireIBAD-MOCVD based REBCO wire on Hastelloy substrate

• Substrate (Hastelloy®

C-276) provides mechanical strength, electro-polished surface for subsequent layer growth

• IBAD-MgO provides template for growing epitaxial buffer layers

• Buffer layers provide: – Diffusion barrier

between substrate and REBCO

– Lattice match with REBCO

• REBCO layer – optimized composition with nanosized BZO & RE2O3 flux pinning sites for high in-field Ic

• Ag layer – provides good current transfer to REBCO layer and facilitates oxygen diffusion during oxygenation annealing

• Cu layer – provides stabilization (parallel shunt for electrical current) at transition


Specification of SuperPower’s 2G HTS wire

• Types of wires:– AP (Advanced Pinning) – for enhanced in-field performance for coil

applications in motors, generators, SMES, high-field magnets, etc.– CF (Cable Formulation) – for cables, transformers– FCL (Cable Formulation) – with tailored Ag layer and thicker substrate

• Variations in width, substrate thickness, SCS thickness, and insulation– Insulated wire: polyimide tape wrapped - 30% overlap or butt-wrap


Quality and performance of 2G HTS wire

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• Uniformity along length and across width (Ic and other attributes)• Ic(B, T, )

– engineering current density– field dependence– field orientation dependence– minimum Ic()

• Electromechanical properties (mechanical strength)– axial tensile (irreversible stress or strain limits)– transverse (c-axis) tensile (along tape surface normal)– transverse (c-axis) compressive (along tape surface normal)– transverse compressive (along width)– bending (with REBCO under compression or tension)– fatigue (in various stress states)

• Quench stability• Splice

– geometry– resistance (resistivity)– mechanical strength (tensile and bending)

Standards for 2G HTS wire characterization and testing are under development


Uniformity along length

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• Longer piece length is desired by most targeted devices− Enable device fabrication− Affect cryogenics and dielectric designs

Ic & n-value along length(Transport measurement)

• Uniformity (homogeneity) along length is required for almost every aspect of wire performance, including dimension (width, thickness), Ic(B, T, ), electro-mechanical behaviors, thermal properties, etc.

• Localized Ic dropouts – major reason for shorter piece length, depending on amplitude and dimension

• Section-by-section Ic (77K, s.f.) measured along length by transport method for each wire produced


Uniformity along length – cont.

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• Uniformity in quality and performance along length is achieved by process control with various techniques, real-time and off-line

Surface roughness of electro-polished substrate, real-time

XRD in-plane texture of cap layer (LMO), off-line


Uniformity along length – cont.

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• Uniformity (homogeneity) along length inspected by various techniques for each wire produced

Thickness along length of fully processed wire, off-line

Ic(77K, s.f.) along length, Hall probe (TapeStar)Position along length (meter)

Position along length (meter)Wire

Thi

ckne

ss (µ

m)

Ic (A

/4m

m, 7

7K, s

.f.)


Doping of REBCO to improve in-field performance

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• Introduction of nanoscale defects into REBCO starts with adjusting chemistry of MOCVD precursor− Zr content, RE substitution, RE:Ba:Cu ratio− Effects on formation of BaZrO3 (//c) and RE2O3 (//a-b) nanorods and nanoparticles

• Nanostructure also depends on MOCVD growth condition− Effects on density, size, orientation & distribution of defects

• Optimization of chemistry and MOCVD deposition condition to meet performance requirements from different applications (lower-field & higher-temperature or higher-field & lower-temperature)

TEM cross-sectional image of REBCOIc versus magnetic field orientation at 40K, 3T

Measured at University of Houston

H//a-b H//c


Ic(B,T,) - critical performance to high-field applications

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• Ic(B,T) at a certain angle (e.g. B//c) is usually the limiting factor for high field applications

• Ic(B,T,) – basic to coil and magnet design and applications• Lift Factor is defined as Ic(B,T, )/Ic(77K, s. f.)• Ic(B,T,) at high field & low temperature lacks good correlation with Ic(77K, s.f.)• Ic(B,T,), in addition to Ic(77K, s.f.), needs to be measured for quality control

Courtesy of D. Abraimov & M. Santos, NHMFLData measured at Tohoku University


IcBT measurement system under construction for routine production sampling

Target operating conditions – Temperature: 30K – 77K– Field: 0 - 2T (65K)

• Higher field operation at 4K – Field //c and //ab (rotatable 0-225°)– Sample length in field – min 25 mm– Maximum sample current 800-1200A

• Full width samples to 4mm wide – Maximum coil current 400A

• 2G HTS background coils– Enables testing of production material

in Schenectady (77K-30K, 0-2T) to evaluate consistency of lift factor


Tensile stress (strain) limits of 2G HTS wire

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• Stress-strain relationship under axial tensile load (at room temperature and at operating temperatures) – basic behaviors

• Tensile stress (strain) limit: critical stress (strain) above which Ic < 95% of zero-stress Ic(0)

• Tensile stress (strain) limits – intrinsic behavior of REBCO film, strongly dependent on substrate and affected by stabilizer

• Tensile stress (strain) limits measurements- Ic measured after applying stress at RT,

compared with zero-stress Ic(0)- Ic measured WHILE applying stress at

a cryogenic temperature, e.g., 77K, compared with zero-stress Ic(0)

- Ic measured AFTER applying stress at a cryogenic temperature, e.g., 77K

- Increase stress level WHILE applying a constant current, e.g., at 95% of the zero-stress Ic(0)

50µm Hastelloy/100µm Cu

50µm Hastelloy/40µm Cu


Addressing the delamination question• Multilayer structure - prone to

delaminating under transversal tensile stress

• Performance degradation of epoxy impregnated coil observed, due to thermal stress in radial direction through thermal cycling

• Cohesive, adhesive or mixed mode delamination observed

• Testing methods developed to measure delamination strength (c-axis tensile strength)

Cu

REBCOBuffer

Hastelloy

Cu

Cohesive delamination (within a layer)

Adhesive delamination (at an interface)

Mixed mode delamination (interlaminar)

Ag

Ag

• Conductor engineering and process modification to reinforce the wire• Techniques developed to mitigate the thermal stress in a coil

VI curves of an experimental coil

Dry Winding

Wet Windingw/ epoxy

77K


P

17

Anvil Cleavage (RIKEN)

Stud-Pin Tension(Fujikura)Peel Test

(SuperPower)

Anvil Tension (NHMFL)

Anvil Tension (Andong U.)

Anvil Tension (SRL/ISTEC)

Testing methods for measuring delamination strength


Addressing delamination question – cont.• Various pull tests used to measure the c-axis tensile strength, values vary

between several MPa to up to 80 MPa – results good for relative comparison• Effects of processing conditions on delamination strength found using pull test

(e.g., N. Sakai et al, ISS2012)• Peel test measures wire’s sensitivity to peel (cleavage) stress, results in

combination with microscopic analysis used to study delamination mechanism• Peel strength can be improved from near 1 N/cm up to 8 N/cm by modification

of wire processing

Load-displacement curves from peel test on experimental wires

• Calculation helps understand stress level and distribution

• Coil winding techniques developed to address delamination issue− Selection of different bobbin

material (Siemens)− Selection of different epoxy

(KIT, RTRI)− Advanced technique for wire

insulation (RIKEN)


Technology advancement with 2G HTS wire

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CORC (Conductor on Round Core) Cable− Fabricated by winding multiple 2G HTS wires in a

helical way around a small former− High current (7500A at 10mm in LN2)− Flexible − Developed by Advanced Conductor Technologies− Wire strength under complex stress desired

Roebel Cable− Fabricated by winding of mechanically punctured

meandering tapes− Low AC loss, high critical current (~nkA)− Major developers include IRL (Callaghan) and KIT− Wire 2D uniformity highly desired

D C van der Laan et al, SUST , 24(2011)042001

W. Goldacker et al, IEEE TAS , 17(2007)3398


Technology advancement with 2G HTS wire

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Twisted Stacked-Tape Cable (TSTC)− Fabricated by stacking multiple tapes

together and twisting at a pitch length− High current, compact, and flexible− Developed by MIT− Wire strength under complex stress desired

Ultra-thin Insulation− Ultra-thin (~4µm) polyimide film coated by

electrodeposition, scalable process− Coil PF up to 90% (high current density)− Improved coil stability− By RIKEN

M. Takayasu et al, SUST , 25(2012)014011

8µm 8µm4µmY. Yanagisawa et al, Physica C, 495(2013)15


Continuous R&D needed, driven by customers and applications• Further improvement in in-field performance

– Hirr at 77K of 15%Zr tapes increased to 14.8T, from 10.2T of 7.5%Zr tape

– Ic(2.5T, 30K) is expected to increased to 1,250 A/cm– Chemistry tailored for devices with different operation conditions– Deposition condition optimized for best pinning– Thicker REBCO layer

• Wire filamentization to reduce AC loss– High throughput, cost-effect and scalable technique

• Stabilizer and interfacial resistivity optimization for stability• Simplification of architecture and processing • Methods to fabricate superconducting splice (joint) • Capability of inspecting uniformity reel to reel, along length for quality

and performance characteristics (e.g., in-field Ic)• Processing modification to improve robustness (mechanical strength)

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• “Superconducting Magnetic Energy Storage System with Direct Power Electronics Interface”− DOE ARPA-E REACT project (Rare Earth Alternatives for Critical Technologies)− Starting from October 2010, 3 years, $4.2 million− Develop a SMES device that has instantaneous response and nearly infinite cycle

life (2MJ)− Partners

Application projects using 2G HTS wire

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• “High Performance, Low Cost Superconducting Wires and Coils for High Power Wind Generators”− DOE ARPA-E REACT project (Rare Earth Alternatives for Critical Technologies)− Starting in January 2012, 3 years, $3.1 million− Develop a low-cost superconducting wire for advanced wind turbine generators

that are lighter, more powerful, and more efficient− Partners

• “Fault Current Limiting Superconducting Transformer”− DOE Smart Grid Demonstration Program (SGDP) project− Starting from February 2010, 5 years, $21.5 million− Develop a SFCL transformer, 28MVA, 3-phase, 69kV/12.47kV class− Partners


• 275kV-3kA HTS cable project, Japan− 2008~2013, funded by NEDO MPACC Program − 2G HTS wire provided by SWCC, using Fujikura template− Highest voltage HTS cable in the world− Tested to demonstrate long-term reliability− Partners

• Cable specification− AC loss and dielectric loss <0.8 W/m at 3 kA, 275 kV − Electrical insulation: PD free at 310 kV, Impulse 1155 kV− Over-current (fault current): 63.0 kA for 0.6 s − Outer diameter <150 mm

• Model cable system testing− Including 30m cable, terminations, joint, cooling system − Ic = 6.8 kA for conductor; Ic = 7 kA for shield, at 77K − No PD at AC 310 kV for 10 min− One month testing at 210kV-3kA in Shenyang Furukawa

Cable Corp. in Dec. 2012, equivalent to 30 year operation

Application projects using 2G HTS wire – cont.

Courtesy of S. Mukoyama, FEC


Summary

• 2G HTS wire provides advantages of high current density, superior in-field performance, and high mechanical strength for various electrical and electromagnetic applications

• SuperPower’s 2G HTS wire production grows steadily, meeting performance and volume requirements for different applications, with continuous improvements in processing and quality underway

• Uniformity along length, in-field performance and mechanical strength (tensile strength and delamination strength) are key properties important to practical applications and being further improved with continuous R&D efforts

• Application development projects (e.g., SMES, FCL Transformer, and Wind Turbine Generator) are being pursued at SuperPower to demonstrate the technology and speed the adoption of the enabling material

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Thank you for your attention!谢谢!

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For more information: http://www.superpower-inc.comFor questions: [email protected]

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