Moldable Ceramic Composites for High Field Magnet Applications

75399S High field magnets, such as those used in High Energy Physics facilities, require precision placement of the superconducting cables to achieve high performance. However, current 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 demonstrated that moldable ceramic compounds can be easily formed to the desired shape or packed into small gaps within a magnet structure. Characterization included strength measurement, thermal expansion, and dimensional control. Phase II will focus on the optimization of the composition and processing to further increase strength and to control other properties such as thermal expansion. Evaluation of the mixing, drying, and firing processing stages will be performed. Compressive strength, thermal expansion, and electrical properties will be measured at room temperature and cryogenic temperatures. 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.