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Presented at:
Radiation-Hard Insulation WorkshopFermi National Accelerator Laboratory
April 2006
Radiation-Resistant Insulation For High-Field Magnet Applications
Presented by:
Matthew W. Hooker
2600 Campus Drive, Suite D • Lafayette, Colorado 80026 • Phone: 303-664-0394 • www.CTD-materials.com
NOTICEThese SBIR data are furnished with SBIR rights under Grant numbers DE-FG02-05ER84351 and DE-FG02-06ER84456 . For a period of 4 years after acceptance of all items to be delivered under this grant, the Government agrees to use these data for Government purposes only, and they shall not be disclosed outside the Government (including disclosure for procurement purposes) during such period without permission of the grantee, except that, subject to the foregoing use and disclosure prohibitions, such data may be disclosed for use by support contractors. After the aforesaid 4-year period the Government has a royalty-free license to use, and to authorize others to use on its behalf, these data for Government purposes, but is relieved of all disclosure prohibitions and assumes no liability for unauthorized use of these data by third parties. This Notice shall be affixed to any reproductions of these data in whole or in part.
Radiation-Resistant Insulation for High-Field Magnets2
“Engineered Material Solutions”
CTD is a unique company where the development of original materials is fused with incisive engineering to provide innovative solutions for our customers’ technology and system needs.
Electrical and Thermal Insulation
For CTD, development of new materials is an engineering toolFor CTD, development of new materials is an engineering tool
Elastic Memory Composites
Composite Pressure Vessels & Tanks
Radiation-Resistant Insulation for High-Field Magnets3
Insulation Development Goals
Mission Improve system-level performance Reduce cost Improve reliability Reduce manufacturing risk
Insulation Processes Vacuum pressure impregnation
(VPI) Wet-winding Prepreg High pressure laminates (HPL)
Applications Fusion energy High-energy physics Motors, generators, and transformers MRI, NMR Cryogenic adhesives
Testing & Validation
Insulation characterization• Processing characterization • Mechanical testing• Electrical testing• Thermal testing
Fabricate sub-scale test articles Environmental testing
Radiation-Resistant Insulation for High-Field Magnets4
Insulation Selection for VPI
• Design for manufacturability- Low viscosity- Long pot life- Thermosetting resins
• Enhanced performance- High mechanical strength at operating temperatures- High dielectric strengths- Thermal shock resistance- Radiation resistance
• Insulation systems for VPI processing- CTD-101 & 101K (epoxy)- CTD-528 (RT-cure epoxy)- CTD-403 (cyanate ester)
Radiation-Resistant Insulation for High-Field Magnets5
CTD-101 & 101K
• Widely used magnet insulation products
- Low viscosity
- Long pot life
- Excellent strength at cryogenic temperatures
- Thermal shock resistance
• Applications- High energy physics
- Fusion
- Commercial systems
NCSX coil, PPPL
HD-1 Magnet, LBNL
Commercial systems
Radiation-Resistant Insulation for High-Field Magnets6
CTD-403
• CTD-403 (Cyanate ester)- Excellent VPI resin- High-strength insulation from
cryogenic to elevated temperatures- Radiation resistant- Moisture resistance improved over
epoxies
• Quasi-Poloidal Stellarator- Fusion device- Compact stellarator- 20 Modular coils, 5 coil designs- Operate at 40 to >100°C- Water-cooled coils
0
20
40
60
80
100
0 10 20 30 40 50 60 70 80 90
Time (hrs)
Vis
co
sit
y (
cP
s)
CTD-403@50°C
QPS
Radiation-Resistant Insulation for High-Field Magnets7
Insulated Insulated Coil SectionCoil Section
Wind-and-ReactFabrication of Nb3Sn Magnets
ApplicationApplicationToTo
ConductorConductor
VPIVPI
Impregnate with organic
resin and cure
PyrolysisPyrolysis
650°C for
30 hours in N2
GreenGreenStateState
MonolithicCoil
CompletedCompletedCoilCoil
Hybrid Insulation
Radiation-Resistant Insulation for High-Field Magnets8
Braided Ceramic-FiberReinforcements
Use or disclosure of the data contained on this page is subject to the restriction on the cover page of this document.
• Minimizing cost- Lower-cost fiber reinforcements for
ceramic-based insulation (CTD-CF-200)- CTD-1202 ceramic binder is 70% less than
previous inorganic resin system
• Improving magnet fabrication efficiency- Textiles braided directly onto Rutherford
cable (eliminates taping process)- Wind-and-react, ceramic-based insulation
system
• Enhancing magnet performance - Insulation thickness reduced by 50%
• Closer spacing of conductors enables higher magnetic fields
- Robust, reliable insulation• Mechanical strength and stiffness• High dielectric strength• Radiation resistance
Radiation-Resistant Insulation for High-Field Magnets9
Enhanced Strain in Ceramic-Composite Insulation
Graceful Failure
Brittle Failure0
50
100
150
200
0 0.2 0.4 0.6 0.8Percent Strain (%)
Str
ess
(MP
a)
S-2 Glass Reinforcement Brittle Failure
CTD-CF-200 ReinforcementGraceful Failure
Tensile Test, ASTM D303977 K
Use or disclosure of the data contained on this page is subject to the restriction on the cover page of this document.
Radiation-Resistant Insulation for High-Field Magnets10
LARP Insulation Requirements
Design Parameter Design ValueCTD-1202/CTD-CF-200
Performance
Compression Strength* 200 MPa 650 MPa (77 K)
Shear Strength 40-60 MPa 110 MPa (77 K)
Dielectric Strength 1 kV 14 kV (77 K)
Mechanical Cycles 10,000Planned testing to
20,000+ cycles
Relative Cost** 1.00 0.20-0.30
*200 MPa is yield strength of Nb3Sn
**Relative cost as compared to CTD-1012PX
Use or disclosure of the data contained on this page is subject to the restriction on the cover page of this document.
Radiation-Resistant Insulation for High-Field Magnets11
CTD Irradiation Timelines
1988CTD Founded
ProposedCeramic/Polymer Hybrids
SBS & Gas Evolution at 4 K
2005-2007DOE SBIRMIT-NRL
Resins & Ceramic/Polymer HybridsSBS, CompressionAdhesive StrengthGas Evolution
1992-1998ITER
Garching/ATI
2000-2003DOE SBIR
ATI
Epoxy-Based InsulationsSBS, Compression
Shear/Compression at 4 K
Epoxies & Cyanate EstersSBS, Compression
Gas Evolution
Epoxy-Based InsulationsSBS
E-beam Irradiated at 4 K
2008-2009DOE SBIR
NIST
1992-93SSCGA
Fu
sio
nH
EP
Radiation-Resistant Insulation for High-Field Magnets12
MIT Irradiation Facility
• MIT Reactor (MITR)- 5 MW experimental fission
reactor- Radiation exposures at various
locations- Irradiations to 100 MGy
• Insulation test specimens- Short-beam-shear
• Fiber-reinforced composites• Copper/insulation adhesion
- Compression- Gas evolution
• Irradiation test considerations- Specimen size & type- Facility- Cost
Radiation-Resistant Insulation for High-Field Magnets13
Insulation Irradiations
• Fiber-reinforced VPI systems- CTD-101K (epoxy)- CTD-403 (cyanate ester)- CTD-422 (CE/epoxy blend)
• Insulation performance- Shear strength most affected
by irradiation- Compression strength largely
un-affected by irradiation
• Ongoing irradiations- Ceramic/polymer hybrids- CTD-403- 20, 50, & 100 MGy doses- Expect to complete by 8/07
0
500
1000
1500
2000
0 20 40 60 80 100 120
Radiation Dose (MGy)
Co
mp
res
sio
n S
tre
ng
th (
MP
a)
CTD-101K
CTD-403
CTD-422Test Temperature: 77 K
0
20
40
60
80
100
120
0 20 40 60 80 100 120
Radiation Dose (MGy)
Sh
ort
-Bea
m-S
hea
r S
tren
gth
(M
Pa)
CTD-101K
CTD-403
CTD-422
Test Temperature: 77 K
Radiation-Resistant Insulation for High-Field Magnets14
Valve
Feed-through
Vacuumgauge
Specimenlocation
Valve
Feed-through
Vacuumgauge
Specimenlocation
Radiation-Induced Gas Evolution
• Gas evolution in polymeric materials
- Attributed to breaking of C-H bonds, releasing H2 gas
- Gas causes swelling of insulation
• Gas evolution measurements- Composite specimens sealed in
evacuated quartz capsules- After irradiation, capsule fractured
in evacuated chamber- Gas evolution correlated to
pressure rise in chamber- Dimensional change measured
Use or disclosure of the data contained on this page is subject to the restriction on the cover page of this document.
Radiation-Resistant Insulation for High-Field Magnets15
Proposed 4 K Irradiation
• Low-temperature irradiations- Linear accelerator facility
- CTD Dewar design
• Insulation characterization- Short-beam shear
- Gas evolution
- Dimensional change
• Insulations to be tested- Ceramic/polymer hybrids
- Polymer composites
- Ceramic insulations
Dewar
Window
SpecimenPosition
Dewar
Window
SpecimenPosition
Use or disclosure of the data contained on this page is subject to the restriction on the cover page of this document.
Radiation-Resistant Insulation for High-Field Magnets16
Continuing Insulation Development & Application
• Insulation Expertise- Material selection- Processing procedures and
specifications- Numerous successes
• Magnet Insulation Needs- Materials- Testing- Processing- Application
• Cooperative Research- Industry worldwide- US national laboratories- US government
“Enabling Technology for the Superconductor Industry”