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FY2007 Superconductivity for Electric Systems Peer Review Project Summary J
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Project Title:
Scale-up of 2G HTS Wire Manufacturing at American Superconductor
Organization:
American Superconductor Corporation
Presenters:
Steven Fleshler, Alexis Malozemoff and Martin Rupich

The overall purpose of this project is to develop the base technology and an initial manufacturing
line for volume production of low-cost 2G HTS wire for commercial and military applications.
To achieve the mission of this program, AMSC has developed a reel-to-reel process for
manufacturing wide HTS strips using RABiTS
TM
for the template and Metal Organic Deposition
(MOD) for the HTS layer. AMSCs wide strip process is designed to produce 2G wire at very low
cost since multiple industry standard 4.4 mm wide wires are produced in a single manufacturing
pass by slitting the wide strip to narrower width in the last stage of the manufacturing process.
The wires are then laminated with copper, stainless steel or any other material to tailor the wire
properties for specific applications. The laminated, 4.4 mm wide wires are known as 344
superconductors.

Essential elements of this program include the following objectives: 1) achieving high electrical
performance wire above the commercial threshold for applications, 2) developing a low-cost,
reel-to-reel process for manufacturing 2G wire with a high production rate, 3) producing and
providing wire for prototype applications and 4) qualifying a production facility with full-scale
manufacturing equipment as part of the DOE and DOD Title III partnership.
The status relative to specific objectives set for GFY2007 is the following:


Increase the consistency of I
c
above 100 A in the production of 344 superconductors.
I
c
of 109 A achieved in production 344 superconductors with 0.8 micron thick HTS layer.

Deliver 10,000 m of 344 superconductors for development of HTS power equipment.
11,500 m delivered to 26 customers in eight countries in AMSCs fiscal year ending
March 2007.

Commission the full-scale manufacturing equipment to meet 720,000 m/year capacity in
December 2007.
All full-scale production equipment for initial volume production installed and 75% of
the processes qualified to stay on track for 720,000 m/year capacity in December 2007.

Increase process rates to facilitate further capacity expansion to 1,000,000 m/year.
Demonstrations of significant rate enhancements of texture anneal and oxygen anneal in
full-scale manufacturing equipment.

R&D demonstrations of higher electrical performance: 650 A/cm-width (77 K) in short
strip and 500 A/cm-width in 4 mm insert wire over 5 m (200 A in 344 superconductors).
560 A/cm-w R&D demonstration in short lengths with a 2.0 micron thick HTS layer.
150 A demonstration in a 5 m length of 344 superconductors using production equipment
with a 1.4 micron thick HTS layer.
August 7-9, 2007

Arlington, Virginia

Project Title:
Progress in Scale up of 2G Conductor at SuperPower
Organization:
SuperPower
Presenters:
V. Selvamanickam, Y. Xie, & J. Reeves

The overall purpose of this project is to scale up second-generation (2G) HTS wire technology
and implement Pilot-scale manufacturing operations. A high priority for SuperPower in FY07
was to complete delivery of nearly 10,000 meters of 2G wire to Sumitomo Electric to construct a
30 m cable for the Albany Cable project. An important objective of this project in FY07 was to
improve the cost/performance metric of 2G to be competitive with that of 1G. In order to achieve
competitive cost/performance metrics, long lengths, high I
c
, and large production capacity i.e.
high throughput have to be all demonstrated with 2G. Hence, these were the primary areas of
focus in SuperPowers 2G program in FY07. Our effort in FY07 was fully aligned with the June
2008 milestones of the Title III program which include 1,000 m piece lengths, with critical
current of 500 A/cm and an annual production capacity of 1,000 km.


Project Title:
Wire Development Group: Understanding and Engineering the
Performance of 2G HTS Wire
Organization:
Los Alamos National Laboratory, Argonne National Laboratory, Oak
Ridge, National Laboratory, Florida State University, University of
Houston, and American Superconductor Corporation
Presenters:
Martin Rupich (AMSC), Terry Holesinger (LANL), David Larbalestier
(FSU), Dean Miller (ANL)

The Wire Development Group (WDG) project is focused on advancing the materials science of
second generation (2G) high temperature superconductor wires for energy and magnet
applications in the US and international marketplace. During the past year, the WDG has focused
on three critical issues needed for a successful commercial 2G wire technology: (1) understanding
the key processing parameters controlling the growth of thick, high Ic YBCO films; (2)
characterizing key microstructural features that enhance vortex pinning and developing
processing routes to engineer specific pinning properties into the YBCO films; and (3)
characterizing grain-boundary and bulk-pinning limited regimes for both H//ab and H//c.
Significant progress was made in these areas during the year in leading to a more comprehensive
understanding of key factors controlling the nucleation and growth of thick YBCO films and the
introduction of pinning defects in MOD-based YBCO films. This new understanding led to the
development of improved processes that are being implemented into AMSCs 2G manufacturing
process. Key results and accomplishments in FY2007 include:

Studies of the nucleation and growth of thick YBCO films identified key issues in maintaining a
high Jc through the film thickness

Extensive characterization of pinning mechanisms and microstructures based on nanoparticle
additions and Y-124 stacking faults resulted in the development of new processing techniques
that allow independent control of pinning in parallel and perpendicular fields

August 7-9, 2007

Arlington, Virginia
Visualization of grain-boundary and bulk-pinning current-limited regimes was correlated to
processing variations of YBCO films resulting in an improved understanding of dissipation
mechanisms in MODbased YBCO films

New results on pinning near Tc reveal surprising temperature dependences for different kinds of
defects probed with fields along different directions

During the coming year, the WDG will continue to focus on understanding the fundamental
materials science of high temperature superconductors, specifically mechanisms for enhancing
current transport and vortex pinning in thick YBCO films, with the goal of overcoming barriers
and enhancing the performance of RABiTS-based 2G wire.


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Project Title:
ORNL-AMSC CRADA: Development of RABiTS-Based 2G Wires
Organization:
Oak Ridge National Laboratory, American Superconductor
Presenters:
A. Goyal (ORNL), M. Paranthaman (ORNL), X. Li (AMSC)

The overall purpose of this project is to support the development of a low-cost, high throughput,
high yield manufacturing process for American Superconductors (AMSC) commercial
manufacturing of 2G wire. This goal is pursued through the development of improved materials
and manufacturing processes leading to yield improvements and manufacturing cost reductions.
During the past year, this project has focused on three key areas that can result in a significant
cost reduction for the 2G wire manufacturing: (1) development of a low-cost, solution-based
process for the deposition of buffer layers, (2) development of thinner, high strength substrates
and (3) understanding of buffer layer texture evolution in comparison to the texture of the base
alloy substrate. The program has also addressed detailed characterization of long length wires
produced at AMSC and correlation of properties with specific process variables, leading to
improvements in both performance and wire yield.

The ORNL-AMSC CRADA combines the expertise in the RABiTS
TM
template technology and
processing capabilities at ORNL with the process development and manufacturing expertise at
AMSC to continuously reduce the costs and improve the performance of the RABiTS/MOD-
YBCO technology. These combined capabilities allow the project team to explor