Low Mass Magnesium Based Conductors

Today’s electrical grid capacity must expand to support the anticipated growth of wind power and solar power generation in the coming decades.Most renewable power generation sites in the U.S. generally are distant from the more densely populated regions and require new transmission systems. The US expects to require as much as $200B in utility investments over the next decade. Reducing the cost of installing new, and expanding existing power lines can provide substantial benefits to the US. A high strength, high conductivity magnesium composite conductor can increase the tieback distances for undersea cables, and the tower distances for suspended transmission cables. Under this SBIR, Terves will demonstrate the scalable production of nanocomposite magnesium composite conductor materials. These conductors are based on adding carbon nanotubes and other high electrical conductivity phases to magnesium alloys to produce a low density, high strength magnesium conductor that offers 30-40% or higher weight savings over aluminum. This program will prepare nanocomposite Magnesium alloys and develop tape, wire, and scalable rod production techniques leading to the production of aligned fibrous magnesium nanocomposite structures with high strength and electrical conductivity 20-50% higher than aluminum. Processes will be demonstrated at the 2-5Kg scale in phase I, and sufficient nanocomposite magnesium conductor lengths will be fabricated to demonstrate feasibility and enable key technical and economic for conductor cable to be identified. A 200% increase in the strength to weight and amperage to weight ratios in electrical conductors could potential double the span between transmission line support towers, reducing grid costs by 30%, or alternatively enabling installation of lower resistance (larger) wires to cut transmission losses by 30-50%. Magnesium-CNF conductors could also displace copper in high current motor and generator applications, such as hybrid cars, aircraft actuators, and wind generators, reducing cost and energy use in these applications.