U.S. Department of Energy Annual Peer Review
Arlington, VA
July 29, 2008
Presenters: Angelo Santamaria, Martin Rupich, Alex Malozemoff
American Superconductor, Devens MA
1

2007 Support for AMSC 2G Program
• DOE funding
-
ORNL: 2G Wire Initiative
-
With DOD: Title III
• Other outside support
-
DARPA – ONR
-
AFOSR
• AMSC internal funding
• Collaborative programs
-
DOE: ORNL CRADA
-
DOE: Wire Development Group
• LANL, ANL, ORNL CRADAs
• IRL, FSU, U. Houston
-
NRL, NIST-Boulder, NHMFL, BNL
2

Outline
• Production Scale-Up Overview – A. Santamaria
• Production Process and R&D Results – M. Rupich
• Practical Conductor for Applications – A. Malozemoff
• Technology Transfer and Collaboration, 2008 Results,
2009 Plans – A. Malozemoff
3

Production Scale-Up Overview
4

Approach
• Develop the ultimate low-cost high performance
HTS wire
-
Proprietary RABiTS/MOD
-
Innovative wide strip technology
• Transition to progressively wider strips to increase production capacity (more wires per strip) with minimal impact on capital expense and labor requirements
-
Presently working with 4-cm wide strip (7-8 x 4 mm wires per strip)
-
Will migrate to 10-cm wide strip (20-23 x 4 mm wires per strip)
• Customize wire properties by a low cost lamination process
-
Flexibility of 344 superconductors to address numerous applications
-
In particular, enables fault current limiting functionality
Major focus this year: scale-up to full-scale manufacturing equipment
5

Price-Performance Projection for
344 Superconductors (“2G” HTS Wire)
Gross Capacity & Pricing Timeline
$125
$100
$25
$20
$75
$15
$50
$25
0 2
* Assumes 200 A performance
$10
Assumes large volume commercial orders
4 6 8 10
$5
6

Full-Scale Production Equipment Implemented
Full-Scale
Equipment
10 cm Rolling Mill
Degreaser
Texture Anneal
Qualification
Complete
3
3
3
Implemented in Production
3
3
3
3 3 Texture Anneal
Multi-Line
Substrate
Inspection
Seed Deposition
3 3
Barrier Deposition
Cap Deposition
3
3
3
3
3
3
Full-Scale
Equipment
HTS Solution
Coater
Decomposition
Reaction
Qualification
Complete
3
3
3
3
Implemented in Production
3
3
3
3
Silver
Deposition
Oxygen
Slitter
Lamination
3
3
3
3
3
3
3
3
3 Implemented since 2007 Superconductivity Peer Review
7

Substrate Production
10-m Production Furnace
10-cm Wide Strip Rolling Mill
9
8
7
6
5
4
3
2
1
0
In-Plane Texture (Delta Phi)
Out-of-Plane Texture (Delta Chi)
0 2 4
Strip #
6 8 10
Capacity over 2 Mm/y of wire – roll 1200 m long, 10 cm wide, slit to 2x4 cm
8

Nanotech Surface and Buffer Deposition
9
Quality Metric: CeO
2
Layer
Texture
Average (deg)
In-Plane
Delta Phi
5.0
Out-of-Plane
Delta Chi
3.9
Std. Dev. (deg)
Std. Dev. (%)
0.22
4.4
0.46
11
Nine Production Strips

HTS Deposition:
Slot-Die Coating/Decomposition/Reaction
• Production equipment for YBCO coating, decomposition and reaction
-
Equipment designed to process strips in lengths up to 1 km
-
Designed for 1.4
μ m thick YBCO
4 cm
10 m
10

Maximum Piece-Length in Recent Runs
1200
1000
800
Slit into four
4 cm x 600 m strips
600
400
200
0
Finish Roll Texture
Anneal
Buffer
Deposition
HTS Coat and Dry
Reaction Ag Deposit Oxygen
Anneal
Slitting Laminate /
Test
440 m lengths produced through entire process
11

Large Volume Capacity Demonstrated Today with
4 cm Strip Process
2,000
1,500
0.8 micron
HTS Layer
1,000
500
ƒ
New magnet design in process for better Ag target utilization, plus longer lengths
0 se
Fi ni sh
Roll
De grea xtu
Te re
An ne al ed
PV
D Se
P
VD
Bar rie r
PV
D
Ca p d D ry
C oa t an
De co mpo sit io n
Re act ion
Ag D
O sit epo xy ge n
Ann ea l
Sl itt in g
La mi nat e
Installed capacity increases 2.5x as production transitioned to 10 cm wide
12

Production Operations and Infrastructure
Established
• Costed bill of materials (BoM) complete
• Raw materials and finished goods inventory complete
• Material handling
-
Motorized cart for handling heavy loads of substrate commissioned
-
End-effecters for loading into furnaces and PVD systems commissioned
-
WIP storage design for furnace and deposition area implemented
• Operating and maintenance documentation 95% complete
-
Work instructions
-
Preventative maintenance procedures and schedules
-
Job hazard analysis with requirements for personal protection equipment
-
Lock-out/tag-out procedures for equipment repair and PM
• Quality control of incoming materials
• SPC charts monitor individual processes
13

Example: Qualification and Quality Control of
Suppliers
Statistical Process Control Analysis
• TFA-Salts for HTS Solution
9 SPC evaluation of vendors for all salts in large batch size for production
9 Identified vendor-to-vendor variability
9 Working to qualify multiple vendors
9 Excellent I c achieved from commercially available salts
200
150
300
250
100
Mean = 237
Mean = 276
Alfa
Vendor 1
GFS
Vendor 2
14

High Resolution Production I c
Test Developed to
Evaluate Uniformity over Finer (4 cm) Length-Scale
100
90
80
70
60
50
40
30
20
10
0
0
2 systems
300 m/h each
100 cm Resolution
100
90
80
70
60
50
40
30
20
10
0
4 cm Resolution
1 system
150 m/h
(>1 Mm/y)
10 20 30 40
Position (m)
10 60 20 70 30 40
Position (m)
50 60
High resolution essential to characterize true uniformity and control quality
70
15

New Test Gives I c
Drop-Out Resolution and
Provides Tool to Better Track Down Root-Cause
100.00
90.00
80.00
70.00
60.00
50.00
40.00
30.00
20.00
10.00
0.00
14
15.11
15.73
15.43
16.05
16.35
16.68
Repeat Distance ~ 0.31 m
Corresponds to diameter ~ 4 in
Common roll diameter in 11 spooling systems
15 16 17
Position (m)
18 19 20
I c dropouts from point defects on reels, addressed by preventive maintenance
16

Initial Volume Production Summary
• High capacity manufacturing line commissioned
• 3 x 500 m production strip starts per week
• Demonstrated 10 cm x 1,200m through rolling
• Achieved 440 m final strip length
• Resolution of high production rate reel-to-reel I c testing enhanced significantly for defect identification
17

18

Improved Ni-W for Substrate – Development of
Supplier
• NiW substrate produced from first large scale (LS - 5000 lb) batch differed from pre-pilot (PP – 300 lb) batch in AMSC production
-
% cube texture was lower
-
Degree of twinning (high angle grain boundary) was significantly higher
-
I c was lower than expected
Cube (%)
δφ
( o )
δχ
( o )
LS 93-93.5
6.7-7.2
7.2-7.9
Twins
(#/area)
19-34
PP 94.3-95.1
6.6-7.3
7.2-7.8
<10
• Identified vendor processes/materials which affected performance
• Worked with vendor to produce new material meeting AMSC’s specifications
19

Improved NiW Properties in Second Large Batch
First Large Batch (Ic ~ 80 A)
Twin (422) and retained roll texture
Regular
(200) pole
Second Large Batch (Ic ~ 100 A)
90% cube;
δφ
=6.9
o
High Twin Density
Low Twin Density
93.5% cube;
δφ
=6.4
o
Very Low Twin Density pole figures – no background correction
20

Performance Metric of Rolled and Annealed
Substrate
8
7
Pre-pilot
In-Plane Texture
First Large Batch
6
Second Large Batch
8
Out-of-Plane Texture
First Large Batch Pre-pilot
5
0 5 10 15
Run No
20 25 30
7
Second Large Batch
6
0 5 10 15
Run No
20 25
Substrate exhibits consistent texture run-to-run with improved production process
30

Improved Texture from New Batch Significantly
Improves I c
120 300
100
80
60
40
20
New Ingot
First Ingot
250
200
150
100
50
0
20 40 60 80 100
0
Length (m)
Understanding and controlling materials properties is critical for performance
22

7
6
5
4
3
2
1
0
Improved Seed Deposition – Production Equipment
Allows Broad Control of Y
2
O
3
Texture
Out-of plane
In-plane
Processing Temperature
Y
2
O
3 texture improved with increased deposition temperature; however, a new texture component develops at high temperature, giving lower than expected I c
Goyal, Specht, Lee - ORNL
Identified process parameters to significantly improve seed texture
23

Identified Process Window for Seed Deposition –
“Axiotaxy” - Source of Secondary Texture
Y
2
O
3
<100> || NiW<110>
Aggressive Y
2
O
3 deposition conditions for maximum texture enhancement resulted in axiotaxy in seed layer, reducing cube texture by >5%
Goyal, Specht,
Lee - ORNL
Seed deposition conditions modified to eliminate axiotaxy while maintaining desired texture enhancement
See ORNL talk – Goyal
Appearance of axiotaxy sets an upper limit to deposition temperature
24

2
1
0
4
3
0
Early Production Wires had Low, but Uniform I c
120 300
Slit #4
Slit #5
100 250
80
60
200
150
Low I c correlated to poor texture in initial large-scale
NiW ingot
40 100
20
0
0 20 40 60
Length (m)
80
50
100
0
2 0
No data
4 0 6 0
L e n g t h ( m )
8 0 1 0 0
Contour I c map shows I variation between even c and odd slits
3 0 4 0 5 0 6 0 7 0 8 0 9 0 1 0 0 1 1 0 1 2 0

4
3
2
1
0
0
Initial Long Length Production Runs Showed
Significant Non-uniformity across Width and Length
1 2 0 3 0 0
S lit 3
S lit 4
2 5 0 1 0 0
8 0
6 0
2 0 0
1 5 0
Analysis of tape showed incorrect texture in buffer deposition along one edge of 4-cm strip resulting in formation of randomly textured YBCO and large I c variations in remainder of strip
4 0 1 0 0
2 0
0
0 5 0 1 0 0 1 5 0 2 0 0
L e n g th (m )
2 50 3 00
5 0
0
35 0
5 0 1 0 0 1 5 0 2 0 0
L e n g t h ( m )
2 5 0 3 0 0 3 5 0
Randomly textured YBCO
3 0 5 0 7 0 9 0 1 1 0 1 2 0

4
3
2
1
0
0
Ic Level, Uniformity Improved with New Large NiW
Batch and Modification of Web Transport
120 300
250
100
100 250
Strip #2
200
80
200
80
150
60 150
60
100
40
I c
20
100
40
20 50
50
0
0 20 80 100
0 0
1 2 6 7
0
40 60
Length (m)
3 4 5
Slit Number
2 0 4 0
No data
6 0
L e n g th (m )
8 0 1 0 0
Material and equipment modifications resulted in a significant improvement in I c and across-strip uniformity
3 0 .0 0 5 0 .0 0 7 0 .0 0 9 0 .0 0 1 1 0 .0
1 2 0 .0
Process modifications being confirmed in long length production runs

Nearing 110 A (275 A/cm-width) Average I c
μ m HTS Layer with Production Process in 0.8
140
120
100
80
60
40
Tracking Problem
In PVD system
20
0
0 20 40 60
Position
80 100 120
Foundation for >120 A with 1.4 micron double-coat HTS layer
28

R&D Results
• Wire Development Group Activities
• New Pathways for High Ic
• New Characterization Techniques

1000 A/cm-w (77K, sf) - Possible with
MOD-YBCO Process
1000
750
400 A/cm-w in
0.8
μ m (1-coat)
1000 A/cm-w
5 MA/cm
2
3.4 MA/cm
2
735 A/cm-w in 2.3
μ m
(multi-coat) – ISTEC
560 A/cm-w in 2
μ m (3-coat)
500
500 A/cm-w in 1.5
μ m (2-coat)
250
Multi-coat or innovative single layer development
0
0 1 2
Film Thickness ( μ m )
3
R&D focused on increased Ic, pinning and uniformity in MOD-YBCO/RABiTS

Wire Development Group
• WDG’s primary focus is R&D of Ex-Situ (MOD) HTS layer for performance improvement
• This year, WDG results summarized briefly here and in more detail in separate CRADA and other presentations:
-
LANL AMSC CRADA
-
ORNL/ANL joint presentation
-
ANL CRADA
-
FSU presentation
• WDG continues as a very active collaboration, capitalizing on synergies between the various institutions
-
Next year, expect a separate WDG presentation
• This year – important results which open paths to major breakthrough in performance

FY2008 WDG Plans and Achievements
• Expand the fundamental material science for maintaining constant properties in 2-3
μ m YBCO films with the goal of establishing new processing paradigms for obtaining
• 700 A/cm-w in FY2008, 1000 A/cm-w by FY2010
9
Critical nucleation parameters characterized and optimized
9
Multiple paths demonstrated for eliminating interface in thick, multi-coat YBCO films
9
Thick crack-free single-coat precursors demonstrated
• Chart the field-temperature crossover between bulk pinning and grain boundary current- limiting regimes and correlate with dissipative mechanisms in RABiTS/MOD
9
Parallel and perpendicular field orientations studied; novel vortex flow identified in parallel orientations
9
Dissipative mechanisms identified and characterized
• Improve irreversibility behavior of MOD-based YBCO through systematic studies of oxygen loading as a function of film composition and hybrid architecture
9
Detailed oxygenation study in YBCO films; process enhancements incorporated into AMSC production
• Develop an improved predictive model for vortex pinning in MOD YBCO as a function of temperature, field magnitude, and field orientation
9
Record Fp in MOD-YBCO/RABiTS conductors
• Characterization of the current uniformity, flux flow and stability of 2G wire in relation to performance requirements for cables and FCL applications
9
Current uniformity in production wire characterized at 10-m to < 1-cm length scale

High I c
: Interface Layer in Multi-coat Films
Limits Through-Thickness J c
700
600
500
Through-thickness of hybrid YBCO film - 2006
3.4 MA/cm
2
400
Multi-layer interface
300 Interface
200
Top layer has reduced texture and lower Jc
100
0
0.0
Lower layer has consistent texture and Jc
0.5
1.0
1.5
Film Thickness ( μ m)
2.0
Decreased performance attributed to
• Poor texture transfer across multi-layer interface(s)
• Poorly controlled YBCO nucleation and growth
Tilted YBCO grain

High I c
: Improving Nucleation and Growth in Thick,
Double-Coat MOD Films
Island-like YBCO nucleation and growth identified as detrimental for thick MOD films
ANL-ORNL collaboration has shown:
• improved growth can be achieved through process modifications
• growth mode is influenced by variations in local chemistry
YBCO low H
2
O
Island (“domed”) YBCO nucleation and growth high H
2
O
Lamellar (“pancake”) nucleation and growth
New process and chemistry modifications for thick film, long-length MOD-based conductors are being tested
Miller- ANL, Feenstra - ORNL
34

High I c
: Characterizing YBCO Nucleation and Growth
  = YBCO Optical and Raman imaging methods used to map phase evolution patterns during conversion of fluoride- based precursors to
YBCO
200 300 400 500 600
Detailed studies of nucleation and growth mode require complementary measurements techniques at ANL
D. Miller, V. Maroni - ANL

Breakthrough Technology for Thick Single-Coat
MOD-Based YBCO Films
Precursor films up to 2.5
μ m (equivalent YBCO) deposited in single process step with no increase in time decomposition
2.5
μ m
3-layers
Triple Layer:
560 A/cm-w in
2.2
μ m final YBCO
(2.5 MA/cm 2 )
2.5
μ m 2.5
μ m
2-layers 1-layer
Double Layer:
500 A/cm-w in
1.4
μ m final YBCO
(3.5 MA/cm 2 )
Single Layer:
390 A/cm-w in
1.4
μ m final YBCO
(2.8 MA/cm 2 )
[IRL with WDG]
Long
Strickland
Single layer process has significant cost-advantage

LTLSM Imaging of Grain Boundaries Shows
Remarkable Field Orientation Effects
B
1T
I
Full Lorenz force
B I
5T,
90º
5T,
75º
B
Force free
50
β m
I
0.04
β
V 1.55
β
V
B I
5T
5T,
55º
™ GBs are lesser obstacles with B parallel to the tape plane – and obstacles appear again in the nominal force-free geometry
Larbalestier, Abraimov - FSU

Oxygen Annealing – Control of ab plane Pinning
Tetragonal YBCO Orthorhombic YBCO Y 124 Intergrowths
Standard
Modified
Standard
Modified
Novel phase modification step allows enhanced tuning of intergrowths, improving
YBCO field performance and reducing wire-to-wire and within-wire variability
-30 0 30 60 90 120 -30 0 30 60 90 120
Fundamental science by WDG leads to improved wire performance

Enhanced Pinning: 10 GN/m 3 Achieved with BZO
Nanoparticle Addition in Non-Fluorine MOD-YBCO
Fp = ~10 GN/m 3 77K, ~2T
Non-fluorine MOD-
YBCO film on YSZ single crystal
Significance: Higher I c in field
E. Hellstrom - FSU

Enhanced Pinning by Nanoparticle Addition Plus
Irradiation in MOD(TFA) YBCO/RABiTS
• Dy
2
O
3 nanodots give enhancement for perp field (flat “background”)
• Perpendicular ion tracks give further enhancement with c-axis peak
• Decrease in self-field I c
(significant for 3x10 11 cm -2 )
• Perp-field pinning force up to 8.3 GN/cm 2 at 1.5T
180
160
140
Nanodot film
unirradiated (360 A/cm)
3x10
10
ions/cm
2
(326 A/cm)
1x10
11
ions/cm
2
(288 A/cm)
3x10
11
ions/cm
2
(145 A/cm)
120
8
6
100
80
60
40
20
0
0
Heavy ion irradiation
30 60 90 120
Field angle (deg)
150
N. Long
N. Strickland
Record F p
180 210
4
2
0
0 500
77K perp field
unirradiated (360 A/cm)
3x10
10
ions/cm
2
(326 A/cm)
1x10
11
ions/cm
2
(288 A/cm)
3x10
11
ions/cm
2
(145 A/cm)
1000
Applied Field (mT)
1500 achieved in high I c
MOD-YBCO on RABiTS template

80
Current Uniformity: Intrinsic Properties of YBCO and Defects Characterized Along Wire Length
Slit #4
60
40
20
0
0
Observation:
Directional pinning varies slightly at x=0, 79, & 117cm
Conclusion:
Low I c region is probably cross section related
sf [AMSC 4-cm CITS]
200 400 600
Position (cm)
1.3
1.2
1.1
1.0
B||ab
B||c
0.9
0.8
0.7
0.6
0
I c
scaled to mean
I c
for orientation
50 100
Position x (cm)
150 200
800 1000
Characterization tools and techniques developed at
LANL for 4 mm – 4 cm wide wires and insert strips
Powerful tools for non- destructively identifying defect and variability mechanisms
Coulter, Civale - LANL
Similarity of self-field and in-field data indicates blocking defect mechanism

100
80
60
I c
40
20
0
0
Low-Cost Manufacturing: MOD Buffers
Demonstrated on 4-cm Production Line
4 mm wide strips
1 2
Length (m)
3 4
100
80
60
40
20
0
0 1 2 3
Length (m)
Strip3
Strip4
Strip5
4
Goyal, Paranthaman - ORNL
MOD-LZO performance comparable to PVD-YSZ in 344 superconductors

Summary of R&D Results 2008
• Major new paths for I c increase identified
-
IRL thick crack-free decomposition
-
ORNL/ANL optimized nucleation
• Powerful new tools established
-
LTLSM for uniformity and current limiting mechanisms - FSU
-
In-field wire scanning, low atomic number probes - LANL

FY2009 WDG Plans and Expectations
• Increase critical current (77k, self-field) in MOD-YBCO/RABiTS conductors
• 700 A/cm-w in R&D wire in FY2009
• 1000 A/cm-w in R&D wire in FY2010
• Improved current uniformity in 2G wire for cable and FCL applications
• Identify dissipative mechanisms as a function of length scale
- 1 cm – 1 meter (LANL)
- < 1 cm (FSU)
• Characterize vortex flow in parallel and perpendicular field orientations through
LTLSM measurements
• Optimize pinning in MOD-YBCO films
• Achieve a F p
> 7GN/m 3 in a 1
μ m MOD-YBCO on RABiTS
• Demonstrate F p
>15 GN/m 3 in MOD-based YBCO films

Practical Conductor for Applications
45

Major Applications of 344 Superconductors in Progress
• Cable applications with Nexans
-
Initial 30 m transmission-level 2G cable demonstrated
-
LIPA2 - DOE SPE program for 600 m in-grid 2G transmission cable
• Stand-alone fault current limiter with Siemens
-
Initial 13 kV-class 2.25 MVA demonstration
-
DOE SPE program for 2G 110 kV in-grid FCL with SCE
• Fault-current-limiting cable
-
Secure Super Grids TM system
-
With Con Edison, Southwire, DHS
-
Initial demonstration of fault current limiting achieved
46

Flexibility in Width and Lamination Enables
Tailored Wire for Specific Applications
Width
Laminate
Copper: conduction cooled coils
Brass
Stainless: fault current limiting
4 mm 1 cm 4 cm
Coils
Cable wire,
DOE LIPA2
Hydra
ATP –
Wind generator
DOE HV FCL
Roebel cable precursor
Width flexibility by slitting
Stabilizer flexibility by lamination
Demand for 344 superconductors continues to grow as applicability demonstrated
47

Example: 2G Brass Stabilized Wire:
344B Superconductors for Cable Applications
150
μ m thick brass stabilizer both sides
- Form-fit-function for 1G
- Excellent stabilization
- Robust – resistance to buckling goes as cube of thickness
Brass stabilizer, both sides
2G Insert Wire
Solder
48

“Symmetrical” Splice for Cable Applications
Using 344B Superconductors
Side View
Thin Lamination Reinforced HTS Strap
HTS Film Face To Face Across Joint
Reinforcement Metal Backing Strip
HTS Reinforced Tape Joined By Splice
Top View
Taper on Each Tape End
To mitigate kinking in bend
• Tapered transition, displaced strap edges to distribute stress
• Low electrical resistance
• Preserves 2G wire layer orientation through the splice
49

HTS Wire and Splice Reliability Qualification for Cable Application
Cable stranding and installation
Test 1: Mechanical reliability in stranding
Test 2: Former configuration reliability
Operation
Test 3: Thermal cycling
Test 4: Pressurized LN2
Four tests developed specifically for cable applications
50

Test 1: Stranding Reliability
Back Tension
4.5 kg
Bend
200 mm
Twist
360º in 0.6 m
Reverse Bend
200 mm
Cable Wind
150 mm pitch on 38 mm former
Pay-off
Test parameters in red
Take-up
• Long length HTS wire with multiple splices
• Sequence of bends, axial twist, winding
- to simulate cable stranding
• >1000 m tested
Photo of Test Set Up
Result on 344B superconductors with splices: no I c degradation
51

Test 2: Former Configuration Reliability
• 1 m wire (with splice) wound on various former diameters, tension and pitch varied
• Tests: I c
, dimensions, splice resistance Several 100’s wires tested
110
Retained Ic for 344B Spliced Wire Versus Former Dia and Pitch
344B Test Cable on 16 mm diameter former,
130 mm pitch, 4.5 kg tension
120
Final / Initial Splice Resistance In Cable Versus Former Diameter
110
100
100
90
90
80
70
14
80
Retained Ic (%) - 130 mm pitch
Retained Ic (%) - 65 mm pitch
Resistance Ratio (%), 13 cm pitch
Resistance Ratio (%), 6.5 cm pitch
16 18
Former Diameter (mm)
20 22
70
14 16 18
Former Diameter (mm)
20
Result: no I c degradation or substantial splice resistance change
22
52

Test 3: Thermal Cycling
• 1 m wire around former, including splice
• I c
, resistance tested each 25 cycles in situ
• Several 100 wires tested
120
100
80
60
40
20
LN2 Dunk 293K - 77K Thermal Cycles
(38 mm former, 150 mm pitch, 4.5 kg tension)
Average Retained Ic (%)
97.7% Confidence Level
0
Initial As Cabled 25 LN2
Thermal
Cycles
Thermal cycling apparatus
Result: no I c degradation or splice resistance change
50 LN2
Thermal
Cycles
75 LN2
Thermal
Cycles
100 LN2
Thermal
Cycles
53

Test 4: Accelerated Pressure Cycling –
“Hermeticity” Reliability Test
• Inner tank pressurized to 30 atm in LN
2
Long length wire with splices
- Hold 16 hours, depressurize, remove, warm up, repeat 6x
• Test for dimensions, I c
, splice resistance
• >2000 m tested
Pressure test apparatus
Result: no I c degradation or splice resistance change
54

Summary Slides
• Results
• Research Integration
• GFY2008 Goals
• Concluding Remarks
55

Summary of 2008 Results Compared to Goals
9
Complete qualification of manufacturing processes on full-scale equipment for initial volume production at 720,000 m/year in
December 2007
-
All manufacturing equipment commissioned
-
Capacity consistent with >720 km/year (except Ag at 550 km/year)
-
Deliveries to customers under way
-
New conductor and splice configurations developed (344B superconductors)
-
Extensive reliability tests successful
9
Extend production piece-length to 250-500 m range
-
Production strip lengths up to 440 m processed; substrate up to
1200 m
-
Progress in eliminating defects; 4 cm I c tool for root cause studies resolution powerful new
56

2008 Results Compared to Goals (cont.)
– Implement 1.4 micron thick HTS layer in production to exceed the electrical performance commercial threshold of 120 A in 344 superconductors
-
Initial production focused on 0.8 micron single coat process, up to
110 A average I c achieved
-
Double-coat (1.4
μ m) insertion in progress
– R&D demonstration of 650 A/cm-width in short samples
-
R&D focus on production support
-
Key knowledge base for higher I c developed with WDG collaborators
• Crack-free single-coat films up to 2.5
μ m: new pathway to high I c
• Significant progress in thick-film MOD pinning force
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Technology Transfer, Collaboration, Partnerships
• ORNL CRADA – RABiTS focus (Goyal, Paranthaman, List, Specht)
-
Characterization of template, identification of “axiotaxy”, MOD buffers
• Wire Development Group – MOD HTS focus
-
LANL CRADA (Civale, Holesinger, Maiorov, Matias) – novel uniformity testing, microstructure of decomposed precursors
-
ANL CRADA (Miller) – TEM of nucleation process in MOD double layers
-
ORNL CRADA (Feenstra) – nucleation process in MOD double layers
-
FSU (Larbalestier, Hellstrom) – LTLSM uniformity and pinning mechanism studies, high pinning in MOD BZO-doped films
-
U. Houston (Salama, Jacobson) - multi-coat MOD, BZO pinning
-
IRL (Strickland, Long) – thick crack-free decomposition process demonstrated
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• NIST-Boulder (Ekin, van der Laan, Cheggour) – Mechanical characterization
• BNL (Solovyov) – Nucleation and growth studies of thick, ex-situ HTS films
• NRL (Holtz, Goswami, Osofsky, Claassen, Spanos) – TEM analysis, electrical and mechanical characterization of wire and coils
• AFOSR (Barnes, Harrison) – Development and characterization of novel pinning centers
• Industrial Partnerships
Dynamic collaborations with leaders in industry and science around the world
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GFY2009 Plans
Scale-up
• Demonstrate consistent >500 m production at >720,000 m/year
• Demonstrate production I c
(77 K, sf) > 125 A in 344 superconductors
R&D (with Wire Development Group)
• Demonstrate 700 A/cm-width in short samples
• Characterize local dissipation mechanisms
• Demonstrate 15 GN/m 3 pinning strength in MOD films
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Concluding Remarks
• High capacity 2G wire production line now operating!
-
>20X increase in capacity over earlier pre-pilot production
-
Major advances toward 1 Mm/year capacity
• Volume manufacturing infrastructure in place
-
High resolution I c to improve yield testing critical for quality control to identify defects and
• Low-cost vision is being realized
-
10-cm strip technology enables ultra-high wire output speed
-
1,200 m rolled strip demonstrated
-
RABiTS TM and MOD fundamental to low-cost manufacturing
-
Lamination customizes wire for wide array of applications
• High reliability of wire and splices demonstrated
• Deliveries to key programs and customers underway
2G HTS wire production is coming of age as the foundation for the HTS industry!
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