2G HTS Wire Produced in Pilot-scale Manufacturing at
Transcript of 2G HTS Wire Produced in Pilot-scale Manufacturing at
Providing HTS Solutions for a New Dimension in Power – TODAY!
2G HTS Wire Produced in Pilot-scale Manufacturing at SuperPower and Application in Prototype Devices
Partially funded through Title III Program & DOE (UT-Battelle), AFRL & AFOSRSupported by CRADAs with Los Alamos, Oak Ridge, and Argonne National Laboratories
ACASC, Xi’an, China ● Dec. 2 – 4, 2007
Yi-Yuan Xie, Y. Chen, X. Xiong, X. Zhang, Y. Qiao, A. Rar, J. Reeves, K. Lenseth, R. Schmidt, M. Martchevskii, D. Hazelton J. Herrin, and V. Selvamanickam
ACASC 2007 – 2 –
SuperPower’s 2G wire is based on high throughput processes & superior substrate
High throughput is critical for low cost 2G wire and to minimize capital investmentSuperPower’s 2G wire is based on high throughput IBAD MgO and MOCVD processesUse of IBAD as buffer template allows us the choice of any substrate• Advantages of IBAD are high strength, low ac loss (non-magnetic, highly
resistive substrates) and high engineering current density (ultra thin substrates)
2 μm Ag
20μm Cu
20μm Cu50μm Hastelloy substrate
1 μm HTS~ 30 nm LMO
~ 30 nm Homo-epi MgO~ 10 nm IBAD MgO
< 0.1 mm
ACASC 2007 – 3 –
SuperPower’s 2G Pilot Manufacturing facility has been operational since 2006
Pilot IBAD
Majority of investment already made for 1000 km/year capability
Pilot HTS
Pilot Substrate Electropolishing Pilot Buffer
5 m Test Rig
• Producing marketable 2G HTS wire: high performance, large quantity and low cost • Focus on three key metrics: high Ic, high throughput and long length
ACASC 2007 – 4 –
Pathway to commercialization of 2GMetric 1 : Higher Currents
Thick film MOCVD technology continues to advance Demonstrated 300 A conductor in 4 mm width, 50% better than today’s best 1G.
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Jc (M
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2006 Ic (Y,Sm)BCO2007 Ic (Y,Gd)BCO2007 Jc (Y,Sm)BCO2007 Jc (Y,Gd)BCO
Critical current measured across entire tape width of 12 mm (no patterning)
Microstructural problems increase with increasing film thickness.
Can high currents be achieved in thinner films ?
In a 2.8 micron film made in 4 passes, achieved Ic of 740 A/cm (Jc = 2.64 MA/cm2) over reel-to-reel processed 12 mm wide, 10 cm long tape.
Ic measurement using continuous dc current (no pulsed current) across entire tape width of 12 mm No patterning
Ic = 888 A = 740 A/cm
ACASC 2007 – 5 –
Pathway to Commercialization of 2GMetric 2: Higher Throughput
180345345360Speed of 4 mm wide tape (m/h)
June 07
Oct. 06
Month
1440
360
IBAD MgO
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Homo-epi MgO
1380
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LMO
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MOCVD YBCOProcess
Production Capacity (km/yr)(if 45% uptime)
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Position (m)
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Minimum Ic = 201 A/cm over 130 mUniformity = 3.5%
Min Ic
Oct. 06: High currents demonstrated over 200+m with all processes at high speedsall processes at high speeds
June 07: High currents over 130+m with all processes at even higher speedsall processes at even higher speeds
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Minimum Ic = 227 A/cm over 201 mUniformity = 2.7%
ACASC 2007 – 6 –
Higher currents in 100+ m lengths at higher HTS processing speeds
Oct 2007: produced 155m long wire in Pilot MOCVD systemTape speed ~ 70 m/h*Minimum Ic over 155 m
= 320 A/cmUniformity over 155 m = 2.5%
In 2006, we demonstrated Ic ~ 300 A/cm over 100 m in MOCVD tape processed in Research MOCVD system. Tape speed = 15 m/h*Uniformity over 103 m = 6.8%
* 4 mm wide tape equivalent
Thicker film MOCVD technology successfully transitioned to Pilot system to produce long high current tapes at ~ 5x higher speeds
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ACASC 2007 – 7 –
Buffered tapes: produced kilometer lengths with complete 5-layer buffer stack and excellent & uniform in-plane texture
Ag
20μm Cu
20μm Cu50μm Hastelloy substrate
HTSLMO
Homo-epi MgO
IBAD MgO
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Tape Length Uniformity(m) Average Min Max
1 1,001 6.79 6.20 7.84 6.2%2 1,343 6.33 5.80 7.16 3.3%3 1,346 6.85 6.00 7.35 2.1%4 1,372 6.20 5.83 6.68 2.2%5 1,375 6.58 6.23 7.14 2.5%6 1,277 6.59 5.80 7.09 2.1%7 1,346 7.09 6.66 7.79 2.9%8 1,265 6.81 6.30 7.12 1.7%9 1,246 6.33 5.47 7.13 2.4%
10 1,369 6.18 5.95 6.26 1.2%
In-plane texture (°)
Pathway to commercialization of 2GMetric 3: Long Lengths
ACASC 2007 – 8 –
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Minimum Ic = 173 A/cm over 595 m
January 2007: crossed an important milestone of 100,000 A-m
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Sept. 2007: New long length record !
Minimum Ic = 190 A/cm Ic × Length (790 m) = 150,100 A-mUniformity over 790 m = 9.7%
We are getting very close to kilometer long 2G wire!
Speed of 4 mm tape (m/h)
Process (single pass)
360IBAD MgO345Homo-epi MgO345LMO
~ 100MOCVD
77 K, Ic measured every 5 m using continuous dc currents over entire tape width of 12 mm (not slit)
ACASC 2007 – 9 –
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* Le
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(A-m
)Remarkable progress in 2G wire scale-up over the last 5 years
62 m18 m1 m 97 m
206 m
1 m to 790 m in 5 years
Also, Ic doubled & speed
increased 12-fold to 180 m/h*
158 m
322 m427 m
595 m
World Record
*4 mm speed equivalent
790 m
ACASC 2007 – 10 –
Substantial improvements made in 2007 in all key metrics -Ic & speed, & piece lengths of 2G wire
Rapid progress with higher currents, higher speeds, and longer lengths are all leading the way to a lower-cost 2G wire
84%
85%
150%
Same Ic level with much higher speeds in all processes
33%
40 to 50%
30% higher Jc
Improvementin 2007
1,375550Buffered tape piece length (m)
790427Completed 2G wire Piece Length (m)
150,100
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180
345 to 360
740 in 2.8 micron film
2007
240Buffer speed* (m/h)
135MOCVD speed* (m/h)
227Ic over 100 m at stated speeds of Buffer & MOCVD
81,550Ic × L (A-m)
721 in 3.5 micron film
Ic (A/cm) – short, reel-to-reel processed
2006Metric
*4 mm wide tape equivalent, single pass
ACASC 2007 – 11 –
Progress being made both in Pilot Manufacturing of long lengths & technology development with shorter lengths
Next Steps:Manufacturing scale-up to reach 1000 m with Ic > 200 A/cm (almost there !)Manufacturing improvements to raise Ic level of 500+m Production lengths to that of short lengths of same film thickness i.e. 500 m and then 1000 m with Ic > 300 A/cmTechnology transition of higher-Ic conductors to Pilot manufacturing, i.e., 100 m, then 500 m and then 1000 m with Ic of 500 A/cm
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1 micron thick HTS Standard in Pilot MOCVDProduction system
2.8 micron thick HTS
1.4 micron thick HTS
Title III goal June 2008
~ 2.3 micron HTS in Pilot MOCVD Production system
ACASC 2007 – 12 –
2G wire cable winding 3 core stranding
Nearly 10,000 m of 2G wire in 43 m piece lengths and minimum Ic over 70 A was delivered by SuperPower in Dec. 2006, marking the single largest delivery of 2G wire
30 m 2G Cable has been manufactured & tested by Sumitomo with ~ 10,000 m of our 2G wire
Cu StrandedWire Former
Electric Insulation(PPLP + Liquid Nitrogen)
Stainless Steel DoubleCorrugated Cryostat
Cu Shield2G HTS(2 shield Layers)
2G HTS(3 conductor Layers)
135 mm
ACASC 2007 – 13 –
Excellent overall performance obtained in 2G cable
Ic of conductor layers ~ 2660 – 2820A (DC, 77K, 1μV/cm)
Ic of shield layers ~ 2400 – 2500A (DC, 77K, 1μV/cm)
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Measured value
0.34 W/m/ph @ 800 ArmsAlmost same result as previous
1 meter test 2G cable
No Ic degradation and No defect was found at dismantling inspection when bend to a diameter of 2.4 m
Cable withstood AC 69kV for 10 minutes and Impulse ±200kV, 10 times
ACASC 2007 – 14 –
2G Cable has been installed in grid at Albany Cable site
Installation at Albany Cable site (Aug. 5, 2007)
• Assembly of joint between 2G & 1G cables completed
• Terminated assembly completed• 2G cable cool-down began late Nov. 2007 and
will be energized soon thereafter
• World’s first in-grid cable, first underground HTS cable, first cable-to-cable joint, 350 m long
• On-grid operations began July 20, 2006• 30 m segment of 1G cable replaced by 2G cable
which is world’s first 2G device
ACASC 2007 – 15 –
New high field coil constructed with 2G wireTotal thickness of our 2G wire including copper stabilizer is only 0.095 mm which is ½ the thickness of 1G and other 2G wires. This is very useful for coil applications where higher number of amp-turns can be obtained.
In FY’06, we demonstrated a 2G coil that generated 1.1 T at 77 K and 2.4 T at 64 K
2006 2G coil• In FY07, we constructed a coil with 6 double
pancakes using 462 m of 2G wire.• The coil was tested in the National High
Magnetic Field Lab at FSU
2007 2G coil
ACASC 2007 – 16 –
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4.2 K, no background field
World record performance achieved with 2G coil
78 A in 4 mm width (77 K, self field)
Average Ic of tapes in coil
~ 44.46 mT/ACoil constant~1.569 A/mm2 per ACoil Je~ 2772# of turns
~ 462 m2G tape used
12 (6 x double)# of Pancakes
~ 51.6 mmCoil Height
~ 87 mmWinding OD
19.1 mmWinding ID9.5 mm (clear)Coil ID
World record field for HTS coil: 9.8 T
Coil tested by H. Weijers, D. Markewicz, & D. Larbalestier, NHMFL, FSU
9.81 T4.2 K Central field – self field
612,6124.2 K Amp Turns @ Ic -self field
221 A4.2 K Coil Ic - self field
ACASC 2007 – 17 –
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Current (A)C
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SuperPower 2G
OST Bi-2212 tape
Two concentric Hitachi Bi-2212 inserts
World record performance achieved with 2G coil
26.8 T4.2K Central Field – 19 T background (axial)
485,1004.2 K Amp Turns @ Ic – 19 T background (axial)
175 A 4.2 K Coil Ic – 19 T background (axial)
This demonstration extends the potential of 2G over a wider application range
World record field for LTS or HTS coil: 26.8 T
Coil tested by H. Weijers, D. Markewicz, & D. Larbalestier, NHMFL, FSU
23.425.126.8Total field achieved (T)
5.45.17.8Additional
field generated (T)
125/11286275Winding Je (A/mm2)
1.02.10.46Conductor length (km)
1999 Hitachi 2- insert
2003 OST
2007 SP