Wrap-able, Radiation-Resistant Electrical Insulators for Superconducting Magnet Applications

The Department of Energy, Office of Fusion Energy Sciences program requires advancements in superconducting magnet relevant radiation-resistant electrical insulators for coils used in fusion energy reactor systems. These insulators must: (1) exhibit low gas generation under irradiation, (2) have higher pot life, and (3) exhibit high bond, high strength and flexibility in shear. These insulators must demonstrate considerable cost reduction. In the planned project, the company aims to validate application-specific metal-oxide nanoparticle- enhanced organic polymer composites designed for use as flexible, radiation-resistant electrical insulators. The focus will be on developing superconducting wires and electronic products coated with this polymer composite for the commercial market. The proposed technology is expected to enhance the performance of superconducting magnet wires in fusion reactors and polymer-coated electronic products for space applications. During initial Phase II, the polymer composite samples were exposed to cobalt-60 gamma radiation of 50 MRad and ionizing radiation of 1 x 1016 neutrons/cm2. Polymer composite samples showed: (1) long pot life over 20 months, (2) excellent film forming properties, (3) excellent flexibility and adhesion/bonding strength to different metal surfaces, (4) high thermal stability up to 300 °C, (5) storage modulus values of 1.4 x 108 Pa at 70 °C, (6) dielectric strength values of 30ľ56.5 kV/mm in liquid nitrogen, and (7) resistance to radiation. Dielectric strength displayed an increasing trend with increasing doses of radiation. In Phase IIB, the company plans to: (1) optimize and scale up composite formulations, (2) develop polymer-coated magnet wires and microcircuit boards, (3) evaluate their properties and performance under high voltage and ionizing radiation at room and cryogenic temperatures, and (4) finalize opportunities for commercial deployment. The polymer composites can be used as a conformal coating on microcircuits for protecting sensitive spacecraft/satellite electronic parts from unwanted radiation damage and electrostatic charges. Polymer composites can also be used in medical devices for cancer therapy, medical imaging systems, and high- field accelerator magnets/motors/generators in extreme conditions. Summary for Members of Congress: This project supports developing radiation-resistant insulator materials, which align with political objectives related to national security, technological advancement, scientific exploration, economic development, and international cooperation in space exploration and research. The DOE also aims to develop such materials at a reduced cost for superconducting magnet coils used in fusion energy reactor systems to achieve a safe, reliable, economic and environmentally benign fusion energy system.