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© Center for Novel High Voltage/Temperature Materials and Structures, www.HVTcenter.org 1

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Research on Advanced Materials and Structures in HVT I/UCRCenter

Dr. Maciej Kumosa

Center Director University of Denver

[email protected]

IEEE Power & Energy Society General Meeting July 26-30, 2015

Denver, Colorado

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Disclaimer • The National Science Foundation (NSF) Industry/University Cooperative Research Center

(I/UCRC) for Novel High Voltage/Temperature Materials and Structures is a PUBLIC PROPERTY funded by the US Government (NSF) and several private and federal companies to provide research support and educate top class graduate students in the area of HVT materials and structures.

• We do not "sell any products or services" or support any "special companies“. Our only products are publications, theses and dissertations, and students’ degrees.

• The Center has been VERY closely monitored by the National Science Foundation to make sure that we follow strict federal I/UCRC guidelines and regulations.

• All US companies are welcome to participate in the Center as clearly mandated by NSF.

• We have invited MANY times most of your members to participate in this federally supported and monitored research and educational effort.

• This Center should be of great interest to your members considering the types of technologies we have been developing for the benefit of all of us, and, in particular, for the benefit of the HV transmission community.

mailto:[email protected]


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Why HVT Center? • General national needs for high quality HVT materials research

combining HV transmission Aerospace Other materials technologies

• Combined outstanding research capabilities of the University of Illinois Urbana-Champaign (UIUC), Michigan Technological University (MTU) and the University of Denver (DU) teams in the above areas

• M. Kumosa’s previous research projects GE90 for General Electric Aircraft Engines and Precision Cast Parts NCIs for EPRI, BPA, WAPA, APC, PG&E, NGK and others Carbon/ polyimide HT combustion chamber for NASA and AFOSR HTLS Polymer Core Composite Conductors (PCCC) for WAPA, BPA and Tri-State

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HV Composite Insulator Project; 1992-2005 • Widely used on transmission

lines and in substations all over the world

• In-service subjected to extreme combined mechanical, electrical and environmental stresses

• Catastrophic failures of the insulators used to occur quite frequently in-service in many regions of the world

•Explanation of 345 kV and 500 kV brittle fracture failures in 1992 and 1995 •Identification of acids responsible for brittle fracture •Simulation of brittle fracture with and without high voltage •Identification of several critical conditions leading to brittle fracture and

other mechanical and electrical failures •Development of a ranking of the commonly used GRP rod materials for their

resistance to brittle fracture and other failure modes (electrical, overcrimping, mishandling, etc.)

•Recommendation of numerous experimental and numerical procedures critical for insulator design

Research for EPRI, NSF, BPA, WAPA, APC, PG&E, NRECA, and several others


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HT Composite Combustion Chamber; 1992-2004

• High temperature PMCs and fabrication technologies were developed suitable for manifolds, thrust chamber supports and attachments

• Replacement of heavy metal engine components to provide a high thrust to weight ratio using carbon/polyimides (PMR-15 and many others)

• For NSF, AFOSR, NASA Glenn, Boeing and 24 other corporations; DU was only university involved

• The chamber passed hot fire test in 2004

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High Temperature Low Sag (HTLS) Conductors 2003 Blackout

• HV power line sagged to a tree in Ohio • Cascading electrical failures of major parts

of the national power grid • 55 million customer in eight states and

Canada affected • $6.5 billion in damages (or more) • 11 fatalities

Toronto; evening August 14, 2003 Since 2009 research for:

Bonneville Power Administration Western Area Power Administration

Tri-State Generation and Transmission National Science Foundation – GOALI

Since June 2014

HVT I/UCRC at DU, MTU and UIUC

http://upload.wikimedia.org/wikipedia/commons/f/f0/Toronto_ON_2003_Blackout.jpg

http://upload.wikimedia.org/wikipedia/commons/1/15/2003_North_American_Blackout_After.jpg

http://upload.wikimedia.org/wikipedia/commons/e/ec/2003_North_American_Blackout_Before.jpg


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HTLS Conductors

• Major contributions to HTLS conductor technology; critical bend radius, aging, corrosion, effects of fatigue and other dynamic loads, and many others

• Several PhDs (3) and MS (3) already defended; 5 in progress

• Explanations of 2008 (Warsaw, Poland) and 2011 (Utah, USA) PCCC conductor failures

ACCR ACCC ACSS ACSR

Aluminum Conductor Steel Reinforced

Aluminum Conductor Steel Supported

Aluminum Conductor Composite Reinforced

Aluminum Conductor Composite Core

<= Traditional designs => <= Novel designs =>

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HVT Center

• The Center was awarded by the National Science Foundation on March 15, 2014 after almost 3 years of competing at the national level (after six panel reviews!)

• Awarded to: University of Denver; main site

(Dr. Maciej Kumosa)

University of Illinois at Urbana-Champaign (Dr. Iwona Jasiuk and Dr. Martin Ostoja-Starzewski)

Michigan Technological University (Dr. Greg Odegard)



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Industry Advisory Board • Boeing • Bonneville Power Administration (Mr. Mike Staats,

Secretary) • BP • CTC Global • Composites Technology Development • General Cable (Dr. Srini Siripurapu, Chair) • John Crane • Lockheed Martin Corporation (Dr. Zach Loftus, Chair-

Elect • Southwire • Tri-State Generation and Transmission • US Bureau of Reclamation • Western Area Power Administration


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Progress so far • First Summit meeting on June 2-3, 2014 at DU; VERY

successful!

• Equally successful meetings at UIUC on November 17-18, 2014 and at MTU on May 19-20, 2015

• All meetings very closely monitored by NSF; electronic confidential evaluations and voting

• 12 full members in the first and second year

• Major INTEGRATION efforts in progress and working

• First NSF annual report approved by NSF in March 2015

• Nine second year research projects being conducted


Center Objectives Design of novel and evaluation of existing HVT energy

transmission/transfer multifunctional materials for next generation composite conductors, insulators, underground cables, towers and other electric power transmission structures

Failure prediction and prevention of HVT materials and structures under in-service conditions through state-of-the art multi-scale modeling and material performance evaluations

Development of new multi-field failure monitoring techniques and material repair methods in HVT materials under laboratory conditions and their subsequent transfer to the in-service inspection and repair

Design and development of novel advanced high temperature materials for aerospace and other industrial applications



More Specific Reasons for the Center • Urgent need to transport more

electrical power more efficiently – Rapidly increasing demand for

electrical power – Development of new sources of

energy

• Current all-metal high-voltage conductor materials suffer from line sag – Increased likelihood of contact with

ground or vegetation – Sagging increases with amperage

• New High Temperature Low Sag (HTLS) conductors based on Polymer Matrix and Metal Matrix Composites can significantly reduce sag, but are unproven in service

Our HVT expertise is also needed in other areas of HV engineering (HV insulators) , off-shore, civil, automotive,

military and other branches of engineering

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More Specific Reasons for the Center •New or improved composite

materials are needed for aircraft and space structures with:

– Increased electrical conductivity for lightning strikes and wiring

– Increased thermal conductivity for heat dissipation

– Increased resistance to aging due to temperature gradients, moisture, UV radiation


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HV < - > Aerospace Link

The center utilizes the most advanced aerospace technologies to design novel materials and structures for the next generation electrical grid

The aggressive environment of the high voltage grid drives innovations that benefit other industries such as aerospace, oil, transportation, and many others

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Key Areas of Research

A) Traditional and

Novel HV

Conductors,

Insulators, Towers,

Substations, and

others

B) Aging of HV/T

Materials and

Structures under

Extreme Service

Conditions

F) Structural

Health Monitoring

C) Fundamental

Aspects of

Nanotechnology

of HV/T Materials

D) Novel HV/T

Metals,

Composites,

NanoComposites

and Structures

E) Multiscale and

Multifield

Modeling of HV/T

Materials and

Structures


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Current Research Projects and Personnel

• 9 research projects are currently funded by the IAB

• Approximately $600k/year from participating industries

• $250k/per year from NSF

• Several other major complementary projects from Air Force, Navy, NASA Glenn and NSF

• Approximately 30 graduate students and 8 senior faculty

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Quality of Graduate Students

• All three sites have top class graduate students involved in the Center

• Dr. Odegard, PhD in ME with Kumosa in 2000, endowed Chair, MTU site director

• Dr. Zach Loftus, Lockheed Martin Fellow, PhD with Kumosa in 2013, Chair Elect of the IAB, will start in May 2016

• Eva Hakansson, PhD in 2016, world record holder (see next slide)

• Joe Hoffman, deputy director, PhD almost completed with Kumosa, major managerial experience

• Chrissy Daniels, US Bureau of Reclamation, first year PhD student with Kumosa, member of IAB

• And many, many others We are only as good as our students!


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Eva Hakansson • The world’s fastest electric

motorcycle at 270.224 mph (official two-way record 240.726 mph).

• The world’s fastest sidecar motorcycle.

• The world’s fastest female motorcycle rider

• Preparing for 300 mph next month

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Current Research Projects • Corrosion of Transmission Conductors (DU)

• Impact Damage to HTLS Conductors, Insulators, Transformers, Substation (DU)

• Diagnostics of RTV HV Silicone Rubber Components, Nanocoatings and Silicone Rubber Nanocomposites for HV and other Applications (DU)

• Glass and Basalt Fibers and their Polymer Based Composites under Excessive Corrosion, UV and Temperature Conditions (DU)

• Physical and Chemical Aging of Carbon/Epoxy Composites (MTU)

• Nanotechnology of HTLS Polymer Core Conductor Materials for Aging Prevention (DU and MTU)

• Multiscale Characterization and Modeling of Metal Matrix (Nano)Composites (UIUC)

• Development of Advanced Aluminum Alloys and Composites for HT and Low Galvanic Corrosion Applications (MTU)

• Electro-Thermo-Mechanical Multiscale Modeling of HV Transmission, Aerospace and other HVT Structures (UIUC)

• Electrically Conductive Polymer Matrix Composites for Static Dissipative, Semi-conductive, or Conductive Applications (UIUC and MTU)


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Examples of Specific Projects

Most applicable to this audience

If you would like to receive more information about other equally outstanding more

aerospace related projects, please contact Drs. Iwona Jasiuk at [email protected]

and Dr. Gregory Odegard at [email protected]

or browse through WWW.HVTCENTER.ORG

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Mishandling of HTLS Conductors

Dan Waters (PhD) and others at DU and UIUC

Goals:

• Design and build an impact fixture to evaluate the impact response of different HTLS conductors as a function of impact energy, impact angle, projectile shape, axial tension/no tension loading conditions and two or three different boundary conditions

• Perform a series of impact tests on the most important HTLS conductor types • Determine their residual strength and damage type • Simulate the impact performance numerically

Overhead conductors can be severely damaged during transportation, installation or in-service Failure modes of HTLS conductors by mishandling (including high velocity impacts) are not entirely understood with some exceptions; Burks, Kumosa et al (2008-2012) - critical bend radius, cyclic loads of ACCC and others


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Impact Damage to HTLS Conductors

We have performed successful impact tests supported by numerical simulations on one type of PCCC with different boundary conditions, including free ends, constrained ends and different amounts of tension simulating impacts during installation and in-service.

0 0.5 1 1.5 20

100

200

300

time (sec)

Ene

rgy (lb

-ft)

0 0.5 1 1.5 2

-100

-80

-60

-40

2580 lb Axial Tension

time (sec)

()

Impact

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Chemical and Physical Aging Prevention in HTLS Polymer Core Composite Conductors

Joe Hoffman (PhD) and others at DU and MTU Goals:

• To use nanotechnology to prevent both physical and chemical aging of HTLS Polymer Core Composite Conductors and other applicable polymer based structures with a variety of reinforcements (multiscale testing, manufacturing and modeling from ab-initio to full scale FEM)

• Life prediction of PCCCs subjected to

temperature cycles up to 200°C, 1% ozone, high cycle (aeolian vibrations), low cycle (galloping), complex manufacturing and installation stresses, nitric and other acids, corona/partial discharges, vandalism/terrorism, for 50-60 years!


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Chemical Aging Prevention in HTLS PCCC by Surface Coating of Composite Rods

Publications Middleton, J., Hoffman, J., Burks, B., Predecki, P., Kumosa, M., 2015. Aging of a polymer core

composite conductor: Mechanical properties and residual stresses. Composites Part A: Applied Science and Manufacturing 69, 159–167

Hoffman, J., Middleton, J., Kumosa, M., 2015. Effect of a surface coating on flexural performance of

thermally aged hybrid glass/carbon epoxy composite rods. Composites Science and Technology 106, 141–148

Hoffman, J., Kumosa, M. Thermal Aging Reduction in Polymer Matrix Composites. Proceedings of 20th International Conference on Composite Materials, Copenhagen, 19-24th July 2015

Significant Difference at 12 Months!! (coated: blue, uncoated: red)

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Chemical Aging Prevention in HTLS PCCC by Other Means Such as:

MAJOR research in progress at DU and MTU on thermal and mechanical properties of cycloaliphatic and other

epoxies utilizing silica, carbon black, graphene and other nanoparticles

Finite elements model of heating and cooling of PCCC subject to convection, emissivity, and wind

A. Increasing surface emissivity

B. Designing new HVT polymer nanocomposites with embedded nanoparticles


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Aging of Silicone Rubbers for HV Applications Goals: To develop experimental and numerical methodologies for aging prevention

and diagnostic of silicone rubber components and nanocoatings for a variety of applications

Environmental Stresses Electrical Stress

Heat

Chemical:

Water,

Acid,

Salts,

Ozone

Ultraviolet

Radation:

UVA,

UVB

Depolymerization

(Chain Scission, Oxidation)

CoronaDry-Band

Arcing

Loss of Elasticity

Surface Changes:

Chalking,

Cracking,

Erosion,

Roughness,

Pasty

Loss of LMW

Material

Surface Change:

Hydrophobicity

Decrease of

Mechanical StrengthDecrease in Electrical Strength

“Investigation into the Effects of Environmental Stressors on RTV-1 Silicone-Based Caulk Materials" by Allen B., Bleszynski, M., Willis, E., and Kumosa, M., IEEE Transactions on

Dielectrics and Electrical Insulation, should appear next month, August 2015

We have examined individual and combined effects of UV, temperature, moisture, nitric acid and salt on aging of three RTV1 caulk materials from a major manufacturer ---- and • determined most damaging conditions • ranked the caulks for in-service aging resistance

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Aging Study of RTV1 Silicone Materials Subjected to Salt

• M. Bleszynski and M. Kumosa, IEEE TDEI, submitted

0

1

2

3

4

5

6

1 2 3 4 5 6 7 8 9 10

STR

I Hyd

rop

ho

bic

ity

HC

RTV1 Sample (Weeks aged)

STRI hydrophobocity Test Before vs. After Sample Aging

Hydrophobocity Before Aging Hydrophobocity After Aging

0

5

10

15

20

25

30

35

40

45

1 2 3 4 5 6 7 8 9 10

Du

rom

eter

Sh

ore

A H

ard

ne

ss (H

A)

RTV1 Sample (Weeks aged)

Hardness Test Before and After Sample Aging

•Aging of RTV-1 materials can be estimated in service by relating changes in their hardness with their surface conditions such as hydrophobicity •An entirely NEW chemical aging model based on molecular dynamics simulations is proposed which explains aging of RTVs in salt solutions


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Synergistic Effects in Environmental Aging of HV GRPs Dr. E. Solis-Ramos, T. Lu and others

Goals:

• Investigate combined effects of acids, salt, temperature, UV, moisture, mechanical loads and time on structural integrity of GRPs based on E-glass, ECR-glass and basalt fibers in the presence of protective nanocoatings

• Provide models of synergistic aging of GRPs

E-glass and ECR-glass fibers in hot strong acids; effect of fiber composition on SCC; Resistance of ECR fibers to SCC very strongly dependent on their chemical composition

– major discovery!

Boron fibers (left, after exposure to very strong nitric acid) seem to be more resistant to SCC than ECR Could replace ECR in HV transmission applications Major research in progress

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Synergistic Effects in GRP Aging • Individual and combined effects of UV, water condensation, temperature

and time on HV glass reinforced polymer composites; experimental and numerical studies of aging by Tayler Lu (PhD candidate)


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Corrosion (Galvanic) of HTLS PCCCs Eva Hakansson (PhD candidate) and others

A) B)

C) D)

Goals: • Understand fundamental

corrosion mechanisms in HV conductors in general

• Develop standardized testing methods for evaluation of galvanic corrosion in HTLS and traditional conductors

• Develop service-life prediction models

• Develop monitoring systems for in-service corrosion in Polymer Core HTLS conductors

No galvanic corrosion with intact

barrier

Papers: Hakansson, E., Predecki, P. and Kumosa, M., Comparison of GalvanicCorrosion Performance of HTLS ACCC and Conventional ACSR Conductors, IEEE Transactions on Reliability, Vol. 99 (2015) E. Hakansson, P. Predecki, M. Kumosa, Numerical Model of Galvanic Corrosion in a Polymer Composite Core Conductor, Proceedings of ICCM20, Denmark, July 2015

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Corrosion of HTLS PCCCs

• Developed the first numerical model of galvanic corrosion in a PCCC with damaged corrosion barrier

• Good agreement with laboratory measurements

• The FE model shows that the corrosion is highly localized to the area near the cathode, which agrees with common knowledge of galvanic corrosion under atmospheric conditions

• Future improvements include the effect of oxide layer from manufacturing and build-up of corrosion products over time

Aluminum

(metal dissolution)

CFRP

(oxygen

reduction)

Electrolyte

layer

thickness

(<90 μm)

Thin film of electrolyte

Air at varying relative humidity

Glass fiber

reinforced PMC

(insulator)

98 mm 1.5 mm 3.5 mm

e-

OH-

Al3+

B)

10 mm 1.5 mm

3.5 mm

98 mm 1.5 mm

3.5 mm

A) A)

(~1:3 area ratio) (1:28 area ratio)


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Advanced Aluminum Alloys for High Conductivity and

Strength Denise Freeman (PhD), Paul Sanders and Greg Odegard at MTU

Major Conclusions so far: • Identified a possible alloying strategy for new Al ternary alloys based on

Al-Zn -Zr • Investigated compositional space with DFT and CALPHAD • Successfully cast compositions and made wire by drawing • Assessed initial heat treatments, measured mechanical and electrical

properties, and compared properties to baseline alloys • So far, their latest Al-Zn-Zr alloy system has not been shown to

outperform currently used 1350 Al (but they keep trying!)

Goals: Design new aluminum conductor alloy with improved strength and corrosion resistance while maintaining conductivity and low cost by

•Computational survey via VASP DFT •Production protocol

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New Research Project in the HVT Center

Novel Protections Against Physical

Damage to HV Power Grid

We are designing, testing and numerically simulating HV ballistic barriers against terrorist attacks on HV transformers and others based on:

advanced nanocomposites ballistic fabrics ballistic coatings biological materials


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Thank you • Thank you for allowing me to present the

HVT Center and some of its research projects at this very important IEEE meeting

• Thank you for your past support; I have given many presentations at your previous IEEE annual meetings since 1992 in The Dalles, Oregon

• Please join the Center and become a member of its prestigious IAB

research on advanced materials and structures in hvt i ... · research on advanced materials and...

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