Ultra-Fast Processing of MOD-based YBCO Films for Low Cost 2G Conductors

In addition to performance, a critical requirement for the successful commercialization of second generation (2G) high temperature superconductor (HTS) wires is the reduction of manufacturing costs. Lower costs would ensure broad market penetration into key power utility applications such as power transmission and distribution cables, fault current limiters, transformers, motors and generators. Recent work has identified novel, high-rate processing routes that can further reduce the manufacturing cost of superconducting layers based on Metal Organic Deposition (MOD). In particular, one of these process improvements has the potential to double the rate of one of the slower steps in the current process, which would double manufacturing capacity with no added capital cost. This project will demonstrate an improved equipment design and process that will significantly shorten the time required to process MOD-based high temperature superconducting films. In Phase I, Computational Fluid Dynamics (CFD) modeling will be used to engineer novel equipment configurations, in order to achieve an ultra-fast rate for a critical MOD process. The modeling work, along with further process optimization, will be tested using pilot-scale reel-to-reel equipment. Phase II will develop and implement equipment modifications required for carrying out the new process. Commercial Applications and other Benefits as described by the awardee: The development of ultra-fast manufacturing processes for 2G HTS wire should result in a significant decrease in cost and increase near term and future production capacity, thus making more wire available for commercial sale. This will enable the introduction of 2G wire in a broader range of commercial and military applications, resulting in a more efficient and secure electric power grid, as well as enabling critical military applications and enhancing national security.