Presented at: Radiation-Hard Insulation Workshop Fermi National Accelerator Laboratory April 2006...

Presented at:

Radiation-Hard Insulation WorkshopFermi National Accelerator Laboratory

April 2006

Radiation-Resistant Insulation For High-Field Magnet Applications

Presented by:

Matthew W. Hooker

2600 Campus Drive, Suite D • Lafayette, Colorado 80026 • Phone: 303-664-0394 • www.CTD-materials.com

NOTICEThese SBIR data are furnished with SBIR rights under Grant numbers DE-FG02-05ER84351 and DE-FG02-06ER84456 . For a period of 4 years after acceptance of all items to be delivered under this grant, the Government agrees to use these data for Government purposes only, and they shall not be disclosed outside the Government (including disclosure for procurement purposes) during such period without permission of the grantee, except that, subject to the foregoing use and disclosure prohibitions, such data may be disclosed for use by support contractors. After the aforesaid 4-year period the Government has a royalty-free license to use, and to authorize others to use on its behalf, these data for Government purposes, but is relieved of all disclosure prohibitions and assumes no liability for unauthorized use of these data by third parties. This Notice shall be affixed to any reproductions of these data in whole or in part.

Radiation-Resistant Insulation for High-Field Magnets2

“Engineered Material Solutions”

CTD is a unique company where the development of original materials is fused with incisive engineering to provide innovative solutions for our customers’ technology and system needs.

Electrical and Thermal Insulation

For CTD, development of new materials is an engineering toolFor CTD, development of new materials is an engineering tool

Elastic Memory Composites

Composite Pressure Vessels & Tanks


Insulation Development Goals

Mission Improve system-level performance Reduce cost Improve reliability Reduce manufacturing risk

Insulation Processes Vacuum pressure impregnation

(VPI) Wet-winding Prepreg High pressure laminates (HPL)

Applications Fusion energy High-energy physics Motors, generators, and transformers MRI, NMR Cryogenic adhesives

Testing & Validation

Insulation characterization• Processing characterization • Mechanical testing• Electrical testing• Thermal testing

Fabricate sub-scale test articles Environmental testing


Insulation Selection for VPI

• Design for manufacturability- Low viscosity- Long pot life- Thermosetting resins

• Enhanced performance- High mechanical strength at operating temperatures- High dielectric strengths- Thermal shock resistance- Radiation resistance

• Insulation systems for VPI processing- CTD-101 & 101K (epoxy)- CTD-528 (RT-cure epoxy)- CTD-403 (cyanate ester)


CTD-101 & 101K

• Widely used magnet insulation products

- Low viscosity

- Long pot life

- Excellent strength at cryogenic temperatures

- Thermal shock resistance

• Applications- High energy physics

- Fusion

- Commercial systems

NCSX coil, PPPL

HD-1 Magnet, LBNL

Commercial systems


CTD-403

• CTD-403 (Cyanate ester)- Excellent VPI resin- High-strength insulation from

cryogenic to elevated temperatures- Radiation resistant- Moisture resistance improved over

epoxies

• Quasi-Poloidal Stellarator- Fusion device- Compact stellarator- 20 Modular coils, 5 coil designs- Operate at 40 to >100°C- Water-cooled coils

0

20

40

60

80

100

0 10 20 30 40 50 60 70 80 90

Time (hrs)

Vis

co

sit

y (

cP

s)

CTD-403@50°C

QPS


Insulated Insulated Coil SectionCoil Section

Wind-and-ReactFabrication of Nb3Sn Magnets

ApplicationApplicationToTo

ConductorConductor

VPIVPI

Impregnate with organic

resin and cure

PyrolysisPyrolysis

650°C for

30 hours in N2

GreenGreenStateState

MonolithicCoil

CompletedCompletedCoilCoil

Hybrid Insulation


Braided Ceramic-FiberReinforcements

Use or disclosure of the data contained on this page is subject to the restriction on the cover page of this document.

• Minimizing cost- Lower-cost fiber reinforcements for

ceramic-based insulation (CTD-CF-200)- CTD-1202 ceramic binder is 70% less than

previous inorganic resin system

• Improving magnet fabrication efficiency- Textiles braided directly onto Rutherford

cable (eliminates taping process)- Wind-and-react, ceramic-based insulation

system

• Enhancing magnet performance - Insulation thickness reduced by 50%

• Closer spacing of conductors enables higher magnetic fields

- Robust, reliable insulation• Mechanical strength and stiffness• High dielectric strength• Radiation resistance


Enhanced Strain in Ceramic-Composite Insulation

Graceful Failure

Brittle Failure0

50

100

150

200

0 0.2 0.4 0.6 0.8Percent Strain (%)

Str

ess

(MP

a)

S-2 Glass Reinforcement Brittle Failure

CTD-CF-200 ReinforcementGraceful Failure

Tensile Test, ASTM D303977 K



LARP Insulation Requirements

Design Parameter Design ValueCTD-1202/CTD-CF-200

Performance

Compression Strength* 200 MPa 650 MPa (77 K)

Shear Strength 40-60 MPa 110 MPa (77 K)

Dielectric Strength 1 kV 14 kV (77 K)

Mechanical Cycles 10,000Planned testing to

20,000+ cycles

Relative Cost** 1.00 0.20-0.30

*200 MPa is yield strength of Nb3Sn

**Relative cost as compared to CTD-1012PX



CTD Irradiation Timelines

1988CTD Founded

ProposedCeramic/Polymer Hybrids

SBS & Gas Evolution at 4 K

2005-2007DOE SBIRMIT-NRL

Resins & Ceramic/Polymer HybridsSBS, CompressionAdhesive StrengthGas Evolution

1992-1998ITER

Garching/ATI

2000-2003DOE SBIR

ATI

Epoxy-Based InsulationsSBS, Compression

Shear/Compression at 4 K

Epoxies & Cyanate EstersSBS, Compression

Gas Evolution

Epoxy-Based InsulationsSBS

E-beam Irradiated at 4 K

2008-2009DOE SBIR

NIST

1992-93SSCGA

Fu

sio

nH

EP


MIT Irradiation Facility

• MIT Reactor (MITR)- 5 MW experimental fission

reactor- Radiation exposures at various

locations- Irradiations to 100 MGy

• Insulation test specimens- Short-beam-shear

• Fiber-reinforced composites• Copper/insulation adhesion

- Compression- Gas evolution

• Irradiation test considerations- Specimen size & type- Facility- Cost


Insulation Irradiations

• Fiber-reinforced VPI systems- CTD-101K (epoxy)- CTD-403 (cyanate ester)- CTD-422 (CE/epoxy blend)

• Insulation performance- Shear strength most affected

by irradiation- Compression strength largely

un-affected by irradiation

• Ongoing irradiations- Ceramic/polymer hybrids- CTD-403- 20, 50, & 100 MGy doses- Expect to complete by 8/07

0

500

1000

1500

2000

0 20 40 60 80 100 120

Radiation Dose (MGy)

Co

mp

res

sio

n S

tre

ng

th (

MP

a)

CTD-101K

CTD-403

CTD-422Test Temperature: 77 K

0

20

40

60

80

100

120

0 20 40 60 80 100 120

Radiation Dose (MGy)

Sh

ort

-Bea

m-S

hea

r S

tren

gth

(M

Pa)

CTD-101K

CTD-403

CTD-422

Test Temperature: 77 K


Valve

Feed-through

Vacuumgauge

Specimenlocation

Valve

Feed-through

Vacuumgauge

Specimenlocation

Radiation-Induced Gas Evolution

• Gas evolution in polymeric materials

- Attributed to breaking of C-H bonds, releasing H2 gas

- Gas causes swelling of insulation

• Gas evolution measurements- Composite specimens sealed in

evacuated quartz capsules- After irradiation, capsule fractured

in evacuated chamber- Gas evolution correlated to

pressure rise in chamber- Dimensional change measured



Proposed 4 K Irradiation

• Low-temperature irradiations- Linear accelerator facility

- CTD Dewar design

• Insulation characterization- Short-beam shear

- Gas evolution

- Dimensional change

• Insulations to be tested- Ceramic/polymer hybrids

- Polymer composites

- Ceramic insulations

Dewar

Window

SpecimenPosition

Dewar

Window

SpecimenPosition



Continuing Insulation Development & Application

• Insulation Expertise- Material selection- Processing procedures and

specifications- Numerous successes

• Magnet Insulation Needs- Materials- Testing- Processing- Application

• Cooperative Research- Industry worldwide- US national laboratories- US government

“Enabling Technology for the Superconductor Industry”

Presented at: Radiation-Hard Insulation Workshop Fermi National Accelerator Laboratory April 2006...

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Transcript of Presented at: Radiation-Hard Insulation Workshop Fermi National Accelerator Laboratory April 2006...