Moldable Ceramic Composites for High Field Magnet Applications

75399-High-field magnets, such as those used in High Energy Physics facilities, require precision placement of the superconducting cables to achieve high performance. However, existing coated metal insulators used for end shoes and spacers have sharp points that can easily damage the cable insulation during installation. When assembling the magnet, these spacers can be pushed through the fabric, damage it, and potentially flake off the coating. Electrical shorts can result that require rework. This project will develop novel moldable ceramic insulators for use in accelerator and fusion magnets, in order to minimize the potential for insulation damage and shorting. The material can be used in place of the sharp tips or wherever small gaps exist. The insulators will be capable of withstanding the high mechanical loads at cryogenic temperatures, surviving the high temperature heat treatments, and resisting radiation. Phase I will formulate ceramic compounds that can be shaped and molded into the appropriate dimensions. Two different ceramic-based compositions will be examined. The flow and formability of the materials will be evaluated under processing. Characterization will include strength measurement, thermal expansion, and dimensional control. Commercial Applications and Other Benefits as described by the awardee: The ceramic insulators should be more robust and reliable than existing materials used in high field accelerator and fusion magnet systems. More robust insulators would lower magnet production cost, which will help enable future devices to be constructed within budgetary restrictions. Commercial magnets could also benefit from molded insulator components, increasing their reliability at lower cost.