Status of HTS Projects at SuperPower: 2G HTS Wire and Cable

Transcription

1 superior performance. powerful technology. Status of HTS Projects at SuperPower: 2G HTS Wire and Cable Yi-Yuan Xie, Y. Chen, X. Xiong, Y. Xie, M. Marchevsky, A. Rar, Y. Qiao, R. Schmidt, A. Knoll, K. Lenseth, D. Hazelton and V. Selvamanickam Funded by Title III Program, DOE and AFRL Supported by CRADAs with Los Alamos, Oak Ridge, & Argonne National Laboratories Workshop on Superconducting DC Transmission and Distribution, PSFC, MIT, Feb 25, 29 SuperPower, Inc. is a subsidiary of Royal Philips Electronics N.V.

2 SuperPower s 2G wire is based on high throughput processes & superior substrate SuperPower 2G HTS wire is based on high throughput IBAD MgO and MOCVD processes High throughput is critical for low-cost 2G wire and to minimize capital investment Use of IBAD as buffer template provides the choice of any substrate Advantages of IBAD are high strength, low ac loss (non-magnetic, high resistive substrates) and high engineering current density (ultra-thin substrates) 2 μm Ag <.1 mm 2μm Cu 1 μm YBCO - HTS (epitaxial) ~ 3 nm LMO (epitaxial) ~ 3 nm Homo-epi MgO (epitaxial) ~ 1 nm IBAD MgO 1 nm 5μm Hastelloy substrate 2μm Cu YBCO LaMnO 3 MgO (IBAD + Epi layer) Y 2 O 3 Al 2 O 3 Hastelloy C-276 2

3 SuperPower s 2G pilot manufacturing facility has been operational since 26 Majority of investment already made for 1 km/year capability Pilot Substrate Electropolishing Pilot IBAD Pilot Buffer 5 m Test Rig Pilot HTS 3

4 Post-YBCO processing & extensive testing of wire prior to delivery YBCO, 12 mm Prepare for delivery Non-contact Ic Transport Ic Slit, 4 mm ~.1 mm Non-contact Ic Non-contact Ic LN2, 1 atm, 24 hr Copper Plate Non-contact Ic Transport Ic & dimensional tests Hermeticity Test 4

5 Use of high-strength 5 micron substrate yields thin-profile 2G wire with much higher tensile strain & critical tensile stress Conductor with 1 μm substrate Conductor with 5 μm substrate Stress (MPa) G with High-strength 5μm substrate 2G with 1μm substrate Strain (%) Tensile Stress (MPa) T = 76K Bare substrates (5 μm) Batch 1 Complete conductor (5 μm) Bare substrates (1 μm) Batch 3 Batch 2 Complete Conductor (1 μm) Tensile Strain (%) Ic/Ic() Ic/Ic() Versus Stress at 77K Tape ID # M BS54-569M Peak Stress 48 Unloaded Peak Stress 115 Unloaded Peak Stress 163 Unloaded Recommended Stress Limit Stress [MPa] 2G conductor made with Yield strength at 77 K* Critical tensile stress 1 micron substrate 65 MPa 35 MPa High-strength 5 micron substrate 12 MPa 7 MPa *Measurements by Y. Zhou and K. Salama (U.Houston) N. Cheggour, D. Van der Laan, J. Ekin (NIST), and R. Holtz (NRL) 5

6 In-house electromechanical test as routine product qualification procedure Bend test: minimum bend diameter of standard wire as small as 12 mm Room-temperature critical tensile stress test No degradation seen after a maximum load of 2 kg is applied to SCS45 wire (>55 MPa) Spiral winding test diameter 16 mm, pitch length 1 mm. 6

7 In 27, 3 m cable was manufactured by Sumitomo Electric with ~1, m of SuperPower 2G HTS wire 2G wire cable winding 3 core stranding Cu Stranded Wire Former Electric Insulation (PPLP + Liquid Nitrogen) Stainless Steel Double Corrugated Cryostat 135 mm 2G HTS wire (3 conductor Layers) 2G HTS wire (2 shield Layers) Cu Shield 7

8 2G cable shows excellent critical current performance in all layers 2 Conductor 2 Shield Electrical Field(uV/cm) Core-1 Core-2 Core-3 Ic Criterion (1uV/cm) Electrical Field(uV/cm) Core-1 Core-2 Core-3 Ic Criterion (1uV/cm) Current (A, DC) Current (A, DC) I c of conductor layers: ~ A (DC, 77K, 1μV/cm) I c of shield layers: ~24 25A (DC, 77K, 1μV/cm) 8

9 Ac loss measurement, mechanical & high voltage test in 2G cable Cable: 2.5 meter single core Current loading by go & return through conductor and shield Ac loss measurement using lock-in amplifier with electrical 4 terminals 1 AC loss (W/m/phase) Measured value.34 8 Arms Almost same result as previous 1 meter test 2G cable Loading Current (Arms, 6Hz) Bend Test (18D: bend dia. = 2.4 m) No Ic degradation No defect was found at dismantling inspection Voltage tests (Based on AEIC): AC 69kV for 1 minutes, Impulse ±2kV, 1 times 9

10 Fault current testing of 2G cable was successful Fault Current Testing at Nissin Electric, Kyoto 1 m cable segment tested Current: 23 ka Duration: 8 38 cycles Cooling: Open bath (77K) Generator (5V) Maximum Temperature Rise [K] Lg L1 L2 L SW BSCCO Conductor BSCCO Shield YBCO Conductor YBCO Shield Transformer (66V/55V) Test Samples Shield Conductor Duration [cycles, 6Hz] Even with much less stabilizer, 2G cable fault current performance was similar to 1G cable 1

11 2G cable was installed, connected to 1G cable section and fully tested by end of 27 Installation at Albany Cable site (Aug. 5, 27) Joint made between 32 m 1G cable & 3 m 2G cable 2.5 Complete 35 m cable tested Ic = at 23 A, same as factory test performance of 2G cable section Electric Field [uv/cm] C ore-1 C ore-2 C ore-3 C able M ean Tem p :73K Ic critrion (1μV/cm ) 69K Current [A, DC] 11

12 Demonstration of the world s first device using 2G HTS wire in a live power grid 1.2 Temperature Deference between Outlet and Inlet of Cable 2 Temperature Deference [K] Jan Transmitted Electricity [MVA] Transmitted Electricity 1/7 1/21 2/4 2/18 3/3 3/17 3/31 Date (28) Cable made with 2G HTS wire was energized in the grid in January 28 & performed as expected, without any issues 12

13 Our main objective in 28 was to meet market requirements for 2G wire Replace 1G wire in large HTS device demonstration projects in the U.S. and around the world Key requirements: Long length, availability, I c, price Supply large volumes of 2G wire to customers who have been waiting to take advantage of the superior performance of 2G Key requirements: Long length, I c, additional performance metrics such as in-field Ic, ac losses, joints, insulation, FCL performance Advance towards mid-term goal of replacing copper wire in commercial HTS projects and challenge LTS wire in high-field applications Key requirements: Long length, availability, I c, price, in-field performance and other additional performance metrics 13

14 High current metric: Capability of ~1 A in 12 mm widths achieved! Critical current (A/cm-width) (GdY)BCO 26 Sm YBCO 25 Sm YBCO 27 GdYBCO Thickness (μm) Jc (MA/cm 2 ) (GdY)BCO 25 Sm YBCO 27 GdYBCO 26 Sm YBCO Thickness (μm) Over 1+ m length, I c = 976 A = 813 A/cm Ic measurement using continuous dc current (no pulsed current) across entire tape width of 12 mm. No patterning 3.3 μm film made in 1 passes: I c = 976 A = 813 A/cm (Jc = 2.44 MA/cm 2 ) 2.1 μm film made in 6 passes: I c = 929 A = 774 A/cm (Jc = 3.68 MA/cm 2 ) All achievements using production buffer tapes 14

15 High current technology is being transferred to pilot MOCVD I c (A/cm-w) 5 Minimum I c > 4 A/cm-w over 55 m length Position (m) Over 55 m length, Minimum I c = 481 A = 41 A/cm At.2 μv/cm voltage criterion Voltage (V/cm) 2.E-7 1.5E-7 1.E-7 5.E-8.E+ -5.E-8 Ic = 454 μv/cm voltage criterion Current (A/cm-w) Over 1 m length, I c = 544 A = 454 A/cm At.1 μv/cm voltage criterion MOCVD process speed 9 m/h (4mm equivalent) Potential of supplying high-current wires to the market. All Workshop achievements on Superconducting DC using Transmission production & Distribution, MIT, 2/25/29 buffer tapes. 15

16 In-field performance metric: tailoring angular dependence by changing film chemistry Ic (A/cm) micron SmYBCO.7 micron GdYBCO.7 micron Zr:GdYBCO Angle between field and tape (deg) Ic (A/cm) 77K, 1T 5 77K, 1 T Data from Y. Zhang, M. Paranthaman, A. Goyal, ORNL 3.5 micron SmYBCO 2.8 micron GdYBCO 3.3 micron Zr:GdYBCO Angle between field and tape (degrees) Gd substitution results in strong pinning parallel to the tape Zr doping strongly enhances pinning perpendicular to tape & at intermediate angles Precursor solution-based MOCVD provides advantage for tailoring in-field performance by adjusting precursor composition 16

17 Wires with different film chemistry from Pilot MOCVD Crtical current (A) (Y,Sm)BCO (Y,Gd)BCO (Y,Sm)BCO with Zr (Y,Gd)BCO with Zr Angle between magnetic field & tape (degrees) Data from Y. Zhang, M. Paranthaman, A. Goyal, ORNL This tailored performance is being realized in routine long-length production 17

18 Continued routine manufacture of kilometer lengths of fully buffered tape in CY 28 8 In-plane texture (degrees) Tape position (m) Routine fabrication of long tapes with complete 5-layer buffer stack has been in place since 27 Lengths: 1,3-1,5 meters In-plane texture: 5-7 degrees Uniformity: ~2% 18

19 Challenges in fabrication of complete, kilometerlong 2G wire Ic (A/cm) Ic (A/cm) Position (m) Position (m) Ic (A/cm) Position (m) Kilometer lengths limited by a few bad regions in an otherwise uniform wire. Major sources of problems identified: MOCVD instability Mechanical damage Substrate defects 19

20 July - Aug. 28: Crossed the km threshold! Ic (A/cm) m Ic > 35 A/cm 4 mm : 14 A 77 K, Ic measured every 5 m using continuous dc currents over entire tape width of 12 mm (not slit) Voltage criterion =.2 microvolt/cm 32 m Ic > 35 A/cm 4 mm : 14 A Position (m) 31 m Ic > 35 A/cm 4 mm : 14 A Except for three spots, Ic of rest of 1,3 m > 3 A/cm 4mm: 12 A Length (m) Minimum Ic μv/cm I c Length (A-m) , , ,98 2

21 Remarkable progress in 2G HTS wire scale-up over the last 6 years 24, 1,, 1, 1, 1, 1 1 May-2 Oct-2 Mar-3 Aug-3 Jan-4 Jun-4 Nov-4 Apr-5 Sep-5 Feb-6 Jul-6 Nov-6 Apr-7 Sep-7 Feb-8 Jul-8 Critical Current * Length (A-m) 2, 16, 12, 8, 4, Nov-1 Jul-2 Mar-3 Nov-3 Aug-4 Apr-5 Dec-5 Aug-6 Apr-7 Jan-8 Sep-8 Critical Current * Length (A-m) 1 m Growth in last year 1 m to 1,3 m in 6 years 26 m 18 m 62 m 97 m 158 m 1,311 m 935 m 595 m 427 m 322 m 79 m World Records 21

22 Great strides made in 28 in all key metrics Metric I c (A/cm) over 1 m Improvement in past year 37% I c (A/cm) at 77 K, 1 T % I c (A/cm) at 65 K, 3 T % I c over 2 m (A/cm) * 378* 67% Length with Ic > 2 A/cm (m) % I c over 5 m (A/cm) % Length with I c > 3 A/cm (m) % Completed 2G wire Piece Length (m) ,311 12% I c L (A-m) 7,52 12, ,81 127% Coil: Field at 77 K (T) % *at 1 to 2% higher speed than in 26 22

23 Development of Practical Conductors: Joints Ic (A) Position (m) Location of joints Per customer s requirement, a 12 m long wire (4 mm wide) was produced with 11 splices in a production operation. Arrangement of the 12 segments along the length was decided based on customer communication to ensure that the Ic profile would fit the coil winding requirements 23

24 Excellent resistance measured in all joints and mechanical robustness also demonstrated Voltage (Volt) 6.E-5 5.E-5 4.E-5 3.E-5 2.E-5 1.E-5 Joint#1: 7-75m Joint#2: m Joint#3: m Joint#4: m Joint#5: m Joint#6: m Joint#7: m Joint#8: m Joint#9: m Joint#1: m Joint#11: m Voltage (Volt) 4.E-5 3.5E-5 3.E-5 2.5E-5 2.E-5 1st test After running thru 4" roller 3 times After running thru 2" rollers 6 times.e+ 1.5E-5-1.E Current (A) 1.E Current (A) All but one of the joints showed resistance around 33 nω; one joint showed a resistance of 1 nω, still within specs Wires with joints run through reel-to-reel Ic test rig with 4 and 2 rollers. No trace of degradation was shown in I-V curves 24

25 Customer-driven development of insulated wire Multiple inquiries for insulated 2G wire, primarily for coil applications System procured for in-house fabrication of insulated wire System in place and providing both 4 and 12 mm wide insulated wire Preliminary test show no breakdown at 1 V with.25 mm polyimide film Deliveries of insulated wire now routine 25

26 Acknowledgement Albany Cable Project: The Team and Government Support Project Manager; Site infrastructure, Manufacture of 2G HTS wire Host utility, conventional cable & system protection, system impact studies Design, build, install, and test the HTS cable, terminations, & joint Design, construct and operate the Cryogenic Refrigeration System, and provide overall cable remote monitoring and utility interface Supported by Federal (DOE) and NY State (NYSERDA) Funds 26