superior performance. powerful technology. Production of 2G HTS Conductor at SuperPower: Recent Progress and Ongoing Improvements Traute F. Lehner, Sr. Director of Marketing 7 th MEM Workshop (Mechanical and Electromagnetic Effects in Superconductors) March 12-14, 2013 Aix-en-Provence, France SuperPower Inc. is a subsidiary of Furukawa Electric Co. Ltd.
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 2
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 3
SuperPower benefits from Furukawa s strengths Three core materials across five business segments Metals Photonics Telecommunications Metal Polymer Light Metals Energy/Industrial Products: CORPORATE PHILOSOPHY Drawing 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. Electronics/ Automotive Systems 4
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 Type of Wire 2012 2017 CAGR LTS 353.6 425.6 3.8 HTS* 6.6 39.6 43.1 Total 360.2 465.2 5.2 $450.00 $400.00 $350.00 $300.00 $250.00 $200.00 $150.00 $100.00 $50.00 $0.00 Superconducting Device Market ($M) HTS Wire S/C Device Market in 2017 ($M) HTS Wire Market ($M) * HTS = MgB 2, BSCCO and YBCO Source: Superconductors: Technologies and Global Markets, BCC Research, Oct. 2012 5
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 6
SuperPower 2G HTS wire: Thin film deposition on robust, flexible substrate Routine, high quality production established fast, high throughput, automated, reel-to-reel 7
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 8
Further progress planned with Continuous Improvement Programs Higher critical current (Ic) 1200 1000 800 Amperes 600 Ic (77K, 0T) In-field Ic (30K, 2T) 400 *4mm equiv. 200 0 2011 2012 2013 2014 2015 2016 9
Continuous Improvement Programs Longer piece lengths 1200 Average Length (m) 1000 800 Meters 600 Average Length (m) 400 200 0 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 10
Continuous Improvement Programs Uniformity: Tighter bandwidth 11
Continuous Improvement Programs Mechanical properties: stronger wire 800 600 SP 2G HTS High Je Stress (MPa) 400 High Strength 1G HTS Low Je 200 0 Low Strength 1G HTSModerate Je 0 0.1 0.2 0.3 0.4 0.5 Strain (%) Nb3Sn Moderate Je 12
Continuous Improvement Programs Faster delivery time Orders from inventory: 1-2 days after acceptance of order Custom orders: Reducing lead time from months to weeks 13
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 14
Quality drives success: major focus on product quality and performance certification 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 15
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) All Rights Reserved. Copyright SuperPower Inc. 2012 16
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 All Rights Reserved. Copyright SuperPower Inc. 2012 17
Technology development programs focused on next level of product improvements Critical current (A/12 mm) 3000 2500 2000 1500 1000 500 0 30 K, B wire State of the art HTS wire ARPA E REACT Improved HTS wire 68% improvement in wire performance at wind generator operating condition of 30 K, 2.5 T 0 1 2 3 4 5 6 7 8 9 Magnetic field (T) Increase base Ic Increase lift factor Increase wire strength Reduce ac losses With structured, well-timed process to transfer advancements into production 18
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: www.superpower-inc.com tlehner@superpower-inc.com 19