superior performance. powerful technology.
SuperPower Inc. is a subsidiary of Furukawa Electric Co. Ltd.
Production of 2G HTS Conductor at SuperPower: Recent Progress and Ongoing ImprovementsTraute F. Lehner, Sr. Director of Marketing
7th MEM Workshop (Mechanical and Electromagnetic Effects in Superconductors)March 12-14, 2013 Aix-en-Provence, France
Topics
• Evolution of SuperPower’s approach to the market• Listening to the Voice of the Customer• Technology and manufacturing program• Current status and continuous improvement activities• Summary
2All Rights Reserved. Copyright SuperPower® Inc. 2013 MEM13 March 12-14, 2013 Aix-en-Provence, France
SuperPower’s evolution from years of experience• 2000-2006: The Intermagnetics Years
– 2G HTS technology development– Production scale-up – Demonstration projects – energy focus
• 2006-2012: The Philips Years– Transition from scale-up to commercialization– Exploration of wide range of commercial markets– Buildup of broad customer base
• From 2012 onward: The Furukawa Years– Continuous manufacturing improvements over established
baseline capabilities … to address market needs– Steady expansion of production to meet market requirements– Focus on long-term sustainability in a slowly evolving market
3All Rights Reserved. Copyright SuperPower® Inc. 2013 MEM13 March 12-14, 2013 Aix-en-Provence, France
4MEM13 March 12-14, 2013 Aix-en-Provence, France
Three core materials across five business segments
MetalsPhotonics
Metal Polymer
Telecommunications
Energy/Industrial Products:
Electronics/Automotive
Systems
Light Metals
SuperPower benefits from Furukawa’s strengths
All Rights Reserved. Copyright SuperPower® Inc. 2013
CORPORATE PHILOSOPHYDrawing on more than a century of expertise in the development and fabrication of advanced materials,we will contribute to the realization of a sustainable society through continuous technological innovation.
CORPORATE PHILOSOPHYDrawing on more than a century of expertise in the development and fabrication of advanced materials,we will contribute to the realization of a sustainable society through continuous technological innovation.
Market expectation: at 20-30% of device cost, significant growth expected for HTS wire market by 2017
5All Rights Reserved. Copyright SuperPower® Inc. 2013 MEM13 March 12-14, 2013 Aix-en-Provence, France
Global Market for S/C Materials ($M)2012 2017 CAGR
LTS Materials $353.70 $441.80 4.50%HTS* Materials $12.30 $370.00 97.50%Total $366.00 $811.80 17.30%
Superconducting Magnet Market ($M)2012-2017 Growth: HTS* vs. LTS
$0.00
$50.00
$100.00
$150.00
$200.00
$250.00
$300.00
$350.00
$400.00
$450.00
S/C Device Market in 2017 ($M)
HTS Wire Market ($M)
Superconducting Device Market ($M)HTS Wire
Source: Superconductors: Technologies and Global Markets, BCC Research, Oct. 2012
Type of Wire 2012 2017 CAGRLTS 353.6 425.6 3.8HTS* 6.6 39.6 43.1
Total 360.2 465.2 5.2* HTS = MgB2, BSCCO and YBCO
The Voice of the Customer provides our roadmap
Application-specific requirements:• Performance: critical current, in-field performance, engineering current
density, low ac losses, piece length• Mechanical properties: wire strength, joint options• Finishing options: insulation, stabilization, multiple geometries• Quality: uniformity, delivery time, price optimization, reliability
All Rights Reserved. Copyright SuperPower® Inc. 2013 6MEM13 March 12-14, 2013 Aix-en-Provence, France
SuperPower® 2G HTS wire: Thin film deposition on robust, flexible substrate• Routine, high quality production established –
fast, high throughput, automated, reel-to-reel
7All Rights Reserved. Copyright SuperPower® Inc. 2013 MEM13 March 12-14, 2013 Aix-en-Provence, France
We are meeting today’s needs
• High Ic: 100A standard; 110-150+ A premium (4 mm width)
• Uniform Ic over long lengths
– Good, repeatable bandwidth
– Good 2D uniformity (across width)
• High engineering current density (very thin substrate and stabilizers)
• Chemistry: two formulations
– AP (Advanced Pinning) (enhanced performance for in-magnetic field applications)
– CF (Cable Formulation) (77K, low fields)
• Flexible, robust architecture– Multiple widths and thicknesses (substrate, stabilizers)
• Superior mechanical properties– Yield strength up to 700 MPa with superalloy-based coated conductors
– Excellent joints and solderability
• Long piece lengths: routine 100-300 m lengths
8All Rights Reserved. Copyright SuperPower® Inc. 2013 MEM13 March 12-14, 2013 Aix-en-Provence, France
Further progress planned with Continuous Improvement Programs …Higher critical current (Ic)
9All Rights Reserved. Copyright SuperPower® Inc. 2013 MEM13 March 12-14, 2013 Aix-en-Provence, France
Am
pere
s
0
200
400
600
800
1000
1200
2011 2012 2013 2014 2015 2016
Ic (77K, 0T)
In-field Ic (30K, 2T)
*4mm equiv.
Continuous Improvement Programs …Longer piece lengths
10All Rights Reserved. Copyright SuperPower® Inc. 2013 MEM13 March 12-14, 2013 Aix-en-Provence, France
Met
ers
0
200
400
600
800
1000
1200
2011 2012 2013 2014 2015 2016 2017 2018 2019 2020
Average Length (m)
Average Length (m)
Continuous Improvement Programs …Uniformity: Tighter bandwidth
11All Rights Reserved. Copyright SuperPower® Inc. 2013 MEM13 March 12-14, 2013 Aix-en-Provence, France
Continuous Improvement Programs …Mechanical properties: stronger wire
12All Rights Reserved. Copyright SuperPower® Inc. 2013 MEM13 March 12-14, 2013 Aix-en-Provence, France
0
200
400
600
800
0 0.1 0.2 0.3 0.4 0.5
Strain (%)
Stre
ss (M
Pa)
SP 2G HTSHigh Je
High Strength 1G HTS Low Je
Nb3Sn Moderate JeLow Strength
1G HTSModerate Je
Continuous Improvement Programs …Faster delivery time
13All Rights Reserved. Copyright SuperPower® Inc. 2013 MEM13 March 12-14, 2013 Aix-en-Provence, France
• Custom orders: Reducing lead time from months to weeks
• Orders from inventory: 1-2 days after acceptance of order
Engineering new wire innovations to address customer requests and meet application requirements
• Additional wire insulation methods– Today: Kapton®/Polyimide wrapped– Other options under development:
thinner profile, better coverage
• Additional wire architectures under development – Higher current carrying capability
• Multi-layer combinations, i.e. EuCARD• Cable on Round Core (CORC)• Plus others …
– Custom attributes• FCL – normal state resistance feature
14All Rights Reserved. Copyright SuperPower® Inc. 2013 MEM13 March 12-14, 2013 Aix-en-Provence, France
Courtesy: Advanced Conductor Technologies
• Additional Quality Assurance initiatives introduced to ensure product quality and production improvements: – Kaizen, Six Sigma (continuous improvement plans)– Lean manufacturing (5S program)– SOP, TPM, SPC, Documentation/Measurement
• Performance certification at device operating conditions– Expansion of in-field performance testing
• In-house testing systems in place (up to 9T, 4.2K)• Additional system under development to allow
for production qualification (77-30K, 0-2T, angular dependence)
• Working with partners to expand testing in multiple field and temperature ranges
– Long-term reliability, consistency and uniformity of product
Quality drives success: major focus on product quality and performance certification
15All Rights Reserved. Copyright SuperPower® Inc. 2013 MEM13 March 12-14, 2013 Aix-en-Provence, France
Coil programs support customer activities and build expertise
16All Rights Reserved. Copyright SuperPower® Inc. 2012 MEM13 March 12-14, 2013 Aix-en-Provence, France
• New coil winding approaches examined and under implementation– Coil modeling– 2G winding process development– Various coil types: solenoid, racetrack,
pancake, and layer wound – Various coil testing techniques – Alternative insulation investigations
• Investigation of wire performance under stress– Tensile and compression strength testing– C-axis tensile/peel strength testing– Conductor characterization
(Ic vs. stress)
Applications development programs support wire manufacturing activities• SFCL Transformer: new wire architecture, FCL functionality, low ac
loss configuration• ARPA-E SMES: high current density for high field coil … also toward
price improvement• Army SMES for tactical micro-grid: adaptation of coil from utility medium
voltage interface to lower voltage military performance requirement• ARPA-E REACT Wind turbine generator: 4X improvement in current
density under operating conditions … directly leading to price improvement
17All Rights Reserved. Copyright SuperPower® Inc. 2012 MEM13 March 12-14, 2013 Aix-en-Provence, France
Technology development programs focused on next level of product improvements …
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0
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0 1 2 3 4 5 6 7 8 9
Critical current (A
/12 mm)
Magnetic field (T)
State‐of‐the‐art HTS wire
ARPA‐E REACT Improved HTS wire
30 K, B ⊥wire
68% improvement in wire performance at wind generator operating condition of 30 K, 2.5 T
With structured, well-timed process to transfer advancements into production
• Increase base Ic• Increase lift factor• Increase wire strength• Reduce ac losses
• Increase base Ic• Increase lift factor• Increase wire strength• Reduce ac losses
Summary
• SuperPower’s wire production is stable and sufficient to meet today’s market
• Market requirements become more demanding• Manufacturing initiatives directed toward improvements to meet
application requirements and to speed adoption rate• Further wire development efforts are focused on meeting demands of
key applications
• For more information: [email protected]
19All Rights Reserved. Copyright SuperPower® Inc. 2013 MEM13 March 12-14, 2013 Aix-en-Provence, France