AMSC has established a Second Generation (2G) High-Temperature Superconductor (HTS) wire manufacturing technology based on the Rolling Assisted Biaxially Textured Substrate and Metal Organic Deposition processes. AMSC's 2G wire (Amperium) has been used by a wide range of customers for development and testing of initial commercial HTS-based applications. Although the Amperium wire properties and quantities satisfy the requirements for these initial projects, improvements in critical current, field performance, and cost are beneficial for large-scale commercial and military applications. As Amperium wire manufacturing continues to ramp up, AMSC's R&D program has focused on increasing critical current, and the development of nonmagnetic substrates. The R&D process developed for a single-coat, 1.2 μm YBCO film has been transferred to production-scale equipment, resulting in the first Amperium wires with critical currents reaching 500 A/cm-w (77 K, self-field) in production length. A nonmagnetic substrate, which minimizes ferromagnetic substrate losses in ac cable applications, has been produced in R&D lengths and demonstrated in an Amperium cable wire.

Second Generation Wire Development at AMSC

This study introduces 600-km/h wheel-type railway concept propelled by linear synchronous motor (LSM) and deals with the conceptual design for LSM system. The LSM is designed to be of a coreless type, which uses high- Tc superconducting electromagnet (SC-EM) as on-board field magnet. From tentative train parameters, we suggest a conceptual LSM model and its design parameters to achieve the train performances. As high- Tc SC material, we use currently available YBCO tape in designing the SC coil. We produce three SC coil models and estimate tentative design values of each model. The feasibility study described herein provides informative design ranges of LSM for 600-km wheel-type railway.

Conceptual Design of Superconducting Linear Synchronous Motor for 600-km/h Wheel-Type Railway

High temperature superconducting (HTS) generator was promising in the wind power applications for its advantages in the weight, size and thermal stability against load fluctuations, especially in the “direct-driven” design. A 100 kW generator was proposed for the demonstration of the feasibility of using HTS in 10 MW wind turbine generators. The electromagnetic design and optimization of the rotor were done using finite element method (FEM). The excitation coil of the rotor was designed considering variable working conditions. According to the numerical results, a number of suggestions in the design and winding techniques of the superconducting rotor were proposed.

Design of a High Temperature Superconducting Generator for Wind Power Applications

We explored high magnetic field superconducting properties and stability at 4.2 K of Second Generation High Temperature Superconductors using both short conductors and small pancake coils. Short lengths of conductor were tested at 4.2 K and 0-25 T in parallel and perpendicular fields, demonstrating an overall critical current of 420 A/mm2 in a parallel field of 25 T. A 56 m length of wire was carefully characterized for performance along the length in self-field at 77 K, and in 10 m lengths at 75 K and a 0.52 T field oriented parallel and perpendicular to the face of the conductor. These characterized lengths were made into small pancake coils which were equipped with a central heater, voltage taps and taps for thermocouples. We report on the stability testing at 4.2 K of one of these coils.

Stability of Second Generation HTS Pancake Coils at 4.2 K for High Heat Flux Applications

This paper presents a novel high-speed alternating current (AC) homopolar motor/generator design using stationary ReBCO excitation windings. Compact, lightweight, high-efficiency motors and generators are sought for a multitude of applications. AC homopolar synchronous machines are an ideal choice for such applications as these machines enable very high rotational frequencies. These machines include both AC armature winding and direct current (DC) excitation winding within the stationary part of the machine. The stationary excitation winding magnetizes a solid steel rotor, enabling operating speeds limited only by the mechanical stress limit of the rotor steel. The operating speeds are many multiples of conventional power 50/60 Hz machines. Significant cooling requirements limit machines of this type utilizing copper excitation windings to only a few kilowatts. However, megawatt ratings become possible when superconductor coils are used. This paper describes the design and analysis of an AC homopolar machine in the context of developing a 500 kW flywheel system to be used for energy recovery and storage in commuter rail subway systems. Different approaches are discussed for an AC armature employing conventional copper coils. Challenges of building and cooling both armature and field coils are discussed and preferred approaches are suggested. Calculations of the machine performance are then made.

https://www.mdpi.com/1996-1073/12/1/86/pdf

Superconducting AC Homopolar Machines for High-Speed Applications

American Superconductor Corporation (AMSC) has developed the base technology and a manufacturing line for initial volume production of low-cost second generation high temperature superconductor (2G HTS) wire for commercial and military applications. The manufacturing line is based on reel-to-reel processing of wide HTS strips using rolling assisted bi-axially textured substrate (RABiTS™) for the template and Metal Organic Deposition (MOD) for the HTS layer. AMSC’s wide strip process is a low cost manufacturing technology since multiple wires are produced in a single manufacturing pass by slitting the wide strip to narrower width in the last stage of the manufacturing process. Industry standard 4.4 mm wide wires are produced by laminating metallic foils, such as copper, stainless steel or any other material, to the HTS insert wire, and are chosen to tailor the electrical, thermal and mechanical properties of the wire for specific applications. The laminated, 4.4 mm wide wires are known as “344 superconductors.” In this paper, we summarize the status of AMSC’s manufacturing capability, the performance of the wire presently being produced, as well as the cost and technical advantages of AMSC’s manufacturing approach. In addition, future direction for research and development to improve electrical performance is presented.

Scale-up of 2G wire manufacturing at American Superconductor Corporation

We have studied the thermal conductivity of several 2G HTS coated conductor wires produced by AMSC's RABiTSTM/MOD processes. The measurements employed a non-steady state method in which the sample is connected to a cold head on one end and a copper block on the other end. The heat capacity of the copper block is used to determine heat flow through the sample as the cold head slowly warms up. Measurements were done at temperatures ranging from 10 K to 130 K on 2G wires made with a Ni 5at%W substrate and different lamination architectures. The focus of the investigation was on the effects of lamina material type, thickness of the silver layer and alloyed silver. The data show that 2G wires can be 3 times less thermally conductive when compared to 1G BSCCO wires with a Ag-Au matrix, making them excellent candidates for use in current lead applications.

https://iopscience.iop.org/article/10.1088/1742-6596/234/2/022015/pdf

Thermal conductivity of 2G HTS wires for current lead applications

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Scale-up of 2G wire manufacturing at American Superconductor Corporation

Thermal conductivity of 2G HTS wires for current lead applications