Production of 2G HTS Conductor at SuperPower: Recent ...MEM13_SP_FINAL_Web+Ver.pdfProduction of 2G...

superior performance. powerful technology.

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

Production of 2G HTS Conductor at SuperPower: Recent Progress and Ongoing ImprovementsTraute F. Lehner, Sr. Director of Marketing

7th MEM Workshop (Mechanical and Electromagnetic Effects in Superconductors)March 12-14, 2013 Aix-en-Provence, France

Topics

• Evolution of SuperPower’s approach to the market• Listening to the Voice of the Customer• Technology and manufacturing program• Current status and continuous improvement activities• Summary

2All Rights Reserved. Copyright SuperPower® Inc. 2013 MEM13 March 12-14, 2013 Aix-en-Provence, France

SuperPower’s evolution from years of experience• 2000-2006: The Intermagnetics Years

– 2G HTS technology development– Production scale-up – Demonstration projects – energy focus

• 2006-2012: The Philips Years– Transition from scale-up to commercialization– Exploration of wide range of commercial markets– Buildup of broad customer base

• From 2012 onward: The Furukawa Years– Continuous manufacturing improvements over established

baseline capabilities … to address market needs– Steady expansion of production to meet market requirements– Focus on long-term sustainability in a slowly evolving market


4MEM13 March 12-14, 2013 Aix-en-Provence, France

Three core materials across five business segments

MetalsPhotonics

Metal Polymer

Telecommunications

Energy/Industrial Products:

Electronics/Automotive

Systems

Light Metals

SuperPower benefits from Furukawa’s strengths

All Rights Reserved. Copyright SuperPower® Inc. 2013

CORPORATE PHILOSOPHYDrawing on more than a century of expertise in the development and fabrication of advanced materials,we will contribute to the realization of a sustainable society through continuous technological innovation.

CORPORATE PHILOSOPHYDrawing on more than a century of expertise in the development and fabrication of advanced materials,we will contribute to the realization of a sustainable society through continuous technological innovation.

Market expectation: at 20-30% of device cost, significant growth expected for HTS wire market by 2017


Global Market for S/C Materials ($M)2012 2017 CAGR

LTS Materials $353.70 $441.80 4.50%HTS* Materials $12.30 $370.00 97.50%Total $366.00 $811.80 17.30%

Superconducting Magnet Market ($M)2012-2017 Growth: HTS* vs. LTS

$0.00

$50.00

$100.00

$150.00

$200.00

$250.00

$300.00

$350.00

$400.00

$450.00

S/C Device Market in 2017 ($M)

HTS Wire Market ($M)

Superconducting Device Market ($M)HTS Wire

Source: Superconductors: Technologies and Global Markets, BCC Research, Oct. 2012

Type of Wire 2012 2017 CAGRLTS 353.6 425.6 3.8HTS* 6.6 39.6 43.1

Total 360.2 465.2 5.2* HTS = MgB2, BSCCO and YBCO

The Voice of the Customer provides our roadmap

Application-specific requirements:• Performance: critical current, in-field performance, engineering current

density, low ac losses, piece length• Mechanical properties: wire strength, joint options• Finishing options: insulation, stabilization, multiple geometries• Quality: uniformity, delivery time, price optimization, reliability

All Rights Reserved. Copyright SuperPower® Inc. 2013 6MEM13 March 12-14, 2013 Aix-en-Provence, France

SuperPower® 2G HTS wire: Thin film deposition on robust, flexible substrate• Routine, high quality production established –

fast, high throughput, automated, reel-to-reel


We are meeting today’s needs

• High Ic: 100A standard; 110-150+ A premium (4 mm width)

• Uniform Ic over long lengths

– Good, repeatable bandwidth

– Good 2D uniformity (across width)

• High engineering current density (very thin substrate and stabilizers)

• Chemistry: two formulations

– AP (Advanced Pinning) (enhanced performance for in-magnetic field applications)

– CF (Cable Formulation) (77K, low fields)

• Flexible, robust architecture– Multiple widths and thicknesses (substrate, stabilizers)

• Superior mechanical properties– Yield strength up to 700 MPa with superalloy-based coated conductors

– Excellent joints and solderability

• Long piece lengths: routine 100-300 m lengths


Further progress planned with Continuous Improvement Programs …Higher critical current (Ic)


Am

pere

s

0

200

400

600

800

1000

1200

2011 2012 2013 2014 2015 2016

Ic (77K, 0T)

In-field Ic (30K, 2T)

*4mm equiv.

Continuous Improvement Programs …Longer piece lengths


Met

ers

0

200

400

600

800

1000

1200

2011 2012 2013 2014 2015 2016 2017 2018 2019 2020

Average Length (m)

Average Length (m)

Continuous Improvement Programs …Uniformity: Tighter bandwidth


Continuous Improvement Programs …Mechanical properties: stronger wire


0

200

400

600

800

0 0.1 0.2 0.3 0.4 0.5

Strain (%)

Stre

ss (M

Pa)

SP 2G HTSHigh Je

High Strength 1G HTS Low Je

Nb3Sn Moderate JeLow Strength

1G HTSModerate Je

Continuous Improvement Programs …Faster delivery time


• Custom orders: Reducing lead time from months to weeks

• Orders from inventory: 1-2 days after acceptance of order

Engineering new wire innovations to address customer requests and meet application requirements

• Additional wire insulation methods– Today: Kapton®/Polyimide wrapped– Other options under development:

thinner profile, better coverage

• Additional wire architectures under development – Higher current carrying capability

• Multi-layer combinations, i.e. EuCARD• Cable on Round Core (CORC)• Plus others …

– Custom attributes• FCL – normal state resistance feature


Courtesy: Advanced Conductor Technologies

• Additional Quality Assurance initiatives introduced to ensure product quality and production improvements: – Kaizen, Six Sigma (continuous improvement plans)– Lean manufacturing (5S program)– SOP, TPM, SPC, Documentation/Measurement

• Performance certification at device operating conditions– Expansion of in-field performance testing

• In-house testing systems in place (up to 9T, 4.2K)• Additional system under development to allow

for production qualification (77-30K, 0-2T, angular dependence)

• Working with partners to expand testing in multiple field and temperature ranges

– Long-term reliability, consistency and uniformity of product

Quality drives success: major focus on product quality and performance certification


Coil programs support customer activities and build expertise


• New coil winding approaches examined and under implementation– Coil modeling– 2G winding process development– Various coil types: solenoid, racetrack,

pancake, and layer wound – Various coil testing techniques – Alternative insulation investigations

• Investigation of wire performance under stress– Tensile and compression strength testing– C-axis tensile/peel strength testing– Conductor characterization

(Ic vs. stress)

Applications development programs support wire manufacturing activities• SFCL Transformer: new wire architecture, FCL functionality, low ac

loss configuration• ARPA-E SMES: high current density for high field coil … also toward

price improvement• Army SMES for tactical micro-grid: adaptation of coil from utility medium

voltage interface to lower voltage military performance requirement• ARPA-E REACT Wind turbine generator: 4X improvement in current

density under operating conditions … directly leading to price improvement


Technology development programs focused on next level of product improvements …


0

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1000

1500

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0 1 2 3 4 5 6 7 8 9

Critical current (A

/12 mm)

Magnetic field (T)

State‐of‐the‐art HTS wire

ARPA‐E REACT Improved HTS wire

30 K, B ⊥wire

68% improvement in wire performance at wind generator operating condition of 30 K, 2.5 T

With structured, well-timed process to transfer advancements into production

• Increase base Ic• Increase lift factor• Increase wire strength• Reduce ac losses

• Increase base Ic• Increase lift factor• Increase wire strength• Reduce ac losses

Summary

• SuperPower’s wire production is stable and sufficient to meet today’s market

• Market requirements become more demanding• Manufacturing initiatives directed toward improvements to meet

application requirements and to speed adoption rate• Further wire development efforts are focused on meeting demands of

key applications

• For more information: [email protected]


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