Cryogenic design and test results of 30-m flexible hybrid energy transfer line with liquid hydrogen and superconducting MgB2 cable

In this paper we present the development of a new hybrid energy transfer line with 30 m length. The line is essentially a flexible 30 m hydrogen cryostat that has three sections with different types of thermal insulation in each section: simple vacuum superinsulation, vacuum superinsulation with liquid nitrogen precooling and active evaporating cryostatting (AEC) system. We performed thermo-hydraulic tests of the cryostat to compare three thermo-insulating methods. The tests were made at temperatures from 20 to 26 K, hydrogen flow from 70 to 450 g/s and pressure from 0.25 to 0.5 MPa. It was found that AEC thermal insulation was the most effective in reducing heat transfer from room temperature to liquid hydrogen in ∼10 m section of the cryostat, indicating that it can be used for long superconducting power cables. High voltage current leads were developed as well. The current leads and superconducting MgB₂ cable passed high voltage DC test up to 50 kV DC. Critical current of the cable at ∼21 K was 3500 A. It means that the 30 m hybrid energy system developed is able to deliver ∼50–60 MW of chemical power and ∼50–75 MW of electrical power, i.e. up to ∼135 MW in total.     

Microstructure and properties of the Si3N4/silica aerogel composites fabricated by the sol–gel method via ambient pressure drying

Si₃N₄ particle reinforced silica aerogel composites have been fabricated by the sol–gel method via ambient pressure drying. The microstructure and mechanical, thermal insulation and dielectric properties of the composites were investigated. The effect of the Si₃N₄ content on the microstructure and properties were also clarified. The results indicate that the obtained mesoporous composites exhibit low thermal conductivity (0.024–0.072 Wm^− 1 K^− 1), low dielectric constant (1.55–1.85) and low loss tangent (0.005–0.007). As the Si₃N₄ content increased from 5 to 20 vol.%, the compressive strength and the flexural strength of the composites increased from 3.21 to 12.05 MPa and from 0.36 to 2.45 MPa, respectively. The obtained composites exhibit considerable promise in wave transparency and thermal insulation functional integration applications.     

Performance validation tests on 80 K bubble type of shields for SST-1

The 80 K thermal shields of Steady State Superconducting Tokamak (SST-1) minimize the steady state heat loads on the superconducting magnet system at 4.5 K from ambient. Uniform temperature, vacuum and cryo compatibility is desired for the 80 K shields. In order to meet these requirements, the bubble/embossed type of design concept is adopted. This design ensures lower pressure drop and better temperature uniformity within ±5 K. Special attention has been given for preventing direct radiation on the magnet system. As part of performance validation tests, a group of 80 K thermal shields have undergone rigorous testing protocols and procedures. The temperature distribution, helium leak tightness and insulation resistance tests have been carried out for SST-1 thermal shields before final assembly of the machine. The test design, procedures and results of the 80 K thermal shields will be discussed in this paper.     

Ultralow density carbon aerogels with low thermal conductivity up to 2000 °C

Ultralow density (0.052 g cm^?3) carbon aerogels (CAs) were prepared for ultrahigh temperature thermal insulation, and their thermal conductivities were determined by laser flash method. The CAs have a total thermal conductivity as low as 0.601 W m^?1 K^?1, which is only one third of the value for closed-pore carbon foam (CF) with a density of 0.054 g cm^?3, at 2000 °C under 0.15 MPa argon. The solid, gaseous, and radiative conductivities of the CA are all much lower than those of the CF, because of the special nanoporous and pearl-necklace nanoparticle structures of the CA. The ultralow density CA clearly demonstrates its great potentials as thermal insulations for extreme applications.     

The thermal and mechanical properties of graphite foam/epoxy resin composites

A series of epoxy resin (EP) filled graphite foam (GF) composites were prepared to explore a new material with good heat transfer property. The effects of the mass fraction of EP and the network structure of GFs on the thermal diffusivity and the compression strength of the composites were investigated. The thermal diffusivity of the GF/EP composite with EP mass fraction of 91.45% was raised to 6.541 mm²/s, which was 45.7 times higher than the pure EP. The thermal conductivity reached to 14.67 W/(m K), which was 43.1 times higher than the pure EP. The compression strength of the GF/EP increased 55% above the value of pure EP. In addition, the thermal diffusivity of GF/EP increased with the decrease of the mass fraction of EP. A model was formulated to calculate the pressure needed for a mass fraction of EP.     

Lightweight carbon-bonded carbon fiber composites with quasi-layered and network structure

Lightweight carbon-bonded carbon fiber (CBCF) composites were fabricated with chopped carbon fibers and dilute phenolic resin solution by pressure filtration, followed by carbonization at 1000 °C in argon. The as-prepared CBCF composites had a homogenous fiber network distribution in xy direction and quasi-layered structure in z direction. The pyrolytic carbon derived from phenolic resin was mainly accumulated at the intersections and surfaces of chopped carbon fibers. The composites possessed compressive strengths ranged from 0.93–6.63 MPa in xy direction to 0.30–2.01 MPa in z direction with a density of 0.162–0.381 g cm^− 3. The thermal conductivity increased from 0.314–0.505 to 0.139–0.368 Wm^− 1 K^− 1 in xy and z directions, respectively. The experimental results indicate that the CBCF composites prepared by this technique can significantly contribute to improve the thermal insulation and mechanical properties at high temperature.     

Mechanical properties of a diamond–copper composite with high thermal conductivity

Using pressureless infiltration of copper into a bed of coarse (180 μm) diamond particles pre-coated with tungsten, a composite with a thermal conductivity of 720 W/(m K) was prepared. The bending strength and compression strength of the composite were measured as 380 MPa. As measured by sound velocity, the Young's modulus of the composite was 310 GPa. Model calculations of the thermal conductivity, the strength and elastic constants of the copper–diamond composite were carried out, depending on the size and volume fraction of filler particles. The coincidence of the values of bending strength and compressive strength and the relatively high deformation at failure (a few percent) characterize the fabricated diamond–copper composite as ductile. The properties of the composite are compared to the known analogues — metal matrix composites with a high thermal conductivity having a high content of filler particles (~ 60 vol.%). In strength and ductility our composite is superior to diamond–metal composites with a coarse filler; in thermal conductivity it surpasses composites of SiC–Al, W–Cu and WC–Cu, and dispersion-strengthened copper.     

Thermal conductivity and Kapitza resistance of cyanate ester epoxy mix and tri-functional epoxy electrical insulations at superfluid helium temperature

In the framework of the European Union FP7 project EuCARD, two composite insulation systems made of cyanate ester epoxy mix and tri-functional epoxy (TGPAP-DETDA) with S-glass fiber have been thermally tested as possible candidates to be the electrical insulation of 13 T Nb₃Sn high field magnets under development for this program. Since it is expected to be operated in pressurized superfluid helium at 1.9 K and 1 atm, the thermal conductivity and the Kapitza resistance are the most important input parameters for the thermal design of this type of magnet and have been determined in this study. For determining these thermal properties, three sheets of each material with different thicknesses varying from 245 to 598 μm have been tested in steady-state condition in the temperature range of 1.6–2.0 K. The thermal conductivity for the tri-functional epoxy (TGPAP-DETDA) epoxy resin insulation is found to be k = [(34.2 ± 5.5)?T ? (16.4 ± 8.2)] × 10^?3 Wm^?1 K^?1 and for the cyanate ester epoxy k = [(26.8 ± 4.8)?T ? (9.6 ± 5.2)] × 10^?3 Wm^?1 K^?1. For the Kapitza resistance, R_k, the best curve fitting the experimental data is described by R_k = (3057 ± 593) × 10^?6?T (?1.79 ± 0.34) m² KW^?1 for the TGPAP-DETDA insulation and R_k = (4114 ± 971) × 10^?6?T (?1.73 ± 0.41) m² KW^?1 for the cyanate ester epoxy insulation. Our results are compared with other epoxy based composite electrical insulation found in the literature.     

Ultra-lightweight concrete: Conceptual design and performance evaluation

The present study presents a methodology to design ultra-lightweight concrete that could be potentially applied in monolithic concrete structures, performing as both load bearing element and thermal insulator. A particle grading model is employed to secure a densely packed matrix, composed of a binder and lightweight aggregates produced from recycled glass.The developed ultra-lightweight concrete, with a dry density of about 650–700 kg/m³, shows excellent thermal properties, with a thermal conductivity of about 0.12 W/(m K); and moderate mechanical properties, with a 28-day compressive strength of about 10–12 N/mm². Furthermore, the developed concrete exhibits excellent resistance against water penetration.     

Mechanical and transport properties of low-temperature negative thermal expansion material Mn3CuN co-doped with Ge and Si

Anti-perovskite manganese nitrides Mn₃CuN co-doped with Ge and Si show good negative thermal expansion properties at cryogenic temperatures and thus have great potential for cryogenic applications. In this work, Mn₃(Cu_0.6Si_xGe_0.4?x)N (x = 0.05, 0.1, 0.15) were prepared by reactive sintering under pressure. Their structures, densities, electrical resistivities, thermal conductivities and mechanical properties were studied at room and cryogenic temperatures. The results show that the values of electrical resistivities and thermal conductivities of Mn₃(Cu_0.6Si_xGe_0.4?x)N (x = 0.05, 0.1, 0.15) are in the range of 2.5–4.3 × 10^?6 Ω m and 1.9–3.6 W(m K)^?1, respectively. Compression tests indicate the compressive strength and Young’s modulus are about 700 MPa and 110 GPa, respectively.     

Thermo-mechanical behavior of baritic concrete exposed to high temperature

A number of structures close to the core of the reactor in nuclear power plants or designed to confine X rays in medical facilities are required to have radiation-shielding capabilities. To this aim, dense concretes are used, and – among them – baritic concretes containing barite aggregates, with a mass per unit volume from 25% to 50% higher than that of ordinary concrete.Information on their mechanical and thermal properties at high temperature – however – is scarce and rather outdated, something that should be looked at, as required by the ongoing revamping of several nuclear power plants and by the increasing use of heavy concrete in waste repositories and in medical facilities.A research project on the high-temperature behavior of a rather typical baritic concrete (target strength on cylinders = 30 MPa, mass per unit volume = 3100–3200 kg/m³) has been recently completed in Milan. After the usual curing period, the specimens were kept for three years either in air or in a moist environment. The strength in tension/compression and the elastic modulus after heating and cooling down to room temperature (= residual mechanical properties), as well as the mass loss, the thermal diffusivity and the porosity were investigated up to 750 °C, and damage indices were introduced to quantify the mechanical damage.Compared to ordinary concrete (as indicated in ACI and European documents, and by previous tests performed by the authors), baritic concrete is shown to have better insulation properties, a slightly better residual compressive strength above 500 °C, a similar tensile strength by splitting and a slightly lower stiffness (elastic modulus). In general, however, the high-temperature performance of baritic concrete is similar to that of any good ordinary concrete, thanks to the closeness of the thermal coefficients of baritic aggregate and baritic mortar.     

Information relevant for the design of structure: Ferritic – Heat resistant high chromium steel X10CrAlSi25

In order to determine the behavior of the X10CrAlSi25 steel at room and elevated temperatures, a number of uniaxial tests were performed using a modern computer controlled material testing machine. Based on these tests, two types of their responses were considered. The first type of responses refers to the material properties presented in the form of engineering stress–strain diagrams. From these diagrams it is possible to derive and consequently to determine tensile strength, yield strength and a Modulus of elasticity. The second type of responses refers to creep behavior presented in the form of creep curves. Based on these curves, creep resistance of the considered material can be derived. Besides, the Charpy impact tests were performed with a Charpy impact machine to define Charpy impact energy as the basis for calculating fracture toughness. Considering tensile strength (584 MPa/20 °C) and yield strength (487 MPa/20 °C), it is visible that both of them are decreased when temperature is increased and fairly low strength levels at high temperature (tensile strength: 29 MPa/800 °C; yield strength: 26 MPa/800 °C) are measured. According to performed creep tests it is visible that this material does not belong to the materials resistant to creep.     

Structural characteristics and elevated temperature mechanical properties of AJ62 Mg alloy

Structure and mechanical properties of the novel casting AJ62 (Mg–6Al–2Sr) alloy developed for elevated temperature applications were studied. The AJ62 alloy was compared to commercial casting AZ91 (Mg–9Al–1Zn) and WE43 (Mg–4Y–3RE) alloys. The structure was examined by scanning electron microscopy, x-ray diffraction and energy dispersive spectrometry. Mechanical properties were characterized by Viskers hardness measurements in the as-cast state and after a long-term heat treatment at 250 °C/150 hours. Compressive mechanical tests were also carried out both at room and elevated temperatures. Compressive creep tests were conducted at a temperature of 250 °C and compressive stresses of 60, 100 and 140 MPa. The structure of the AJ62 alloy consisted of primary α-Mg dendrites and interdendritic nework of the Al₄Sr and massive Al₃Mg₁₃Sr phases. By increasing the cooling rate during solidification from 10 and 120 K/s the average dendrite arm thickness decreased from 18 to 5 μm and the total volume fraction of the interdendritic phases from 20% to 30%. Both factors slightly increased hardness and compressive strength. The room temperature compressive strength and hardness of the alloy solidified at 30 K/s were 298 MPa and 50 HV 5, i.e. similar to those of the as-cast WE43 alloy and lower than those of the AZ91 alloy. At 250 °C the compressive strength of the AJ62 alloy decreased by 50 MPa, whereas those of the AZ91 and WE43 alloys by 100 and 20 MPa, respectively. The creep rate of the AJ62 alloy was higher than that of the WE43 alloy, but significantly lower in comparison with the AZ91 alloy. Different thermal stabilities of the alloys were discussed and related to structural changes during elevated temperature expositions.     

Microstructure and mechanical properties of carbon fiber reinforced multilayered (PyC–SiC)n matrix composites

Carbon fiber reinforced multilayered (PyC–SiC)_n matrix (C/(PyC–SiC)_n) composites were prepared by isothermal chemical vapor infiltration. The phase compositions, microstructures and mechanical properties of the composites were investigated. The results show that the multilayered matrix consists of alternate layers of PyC and β-SiC deposited on carbon fibers. The flexural strength and toughness of C/(PyC–SiC)_n composites with a density of 1.43 g/cm³ are 204.4 MPa and 3028 kJ/m³ respectively, which are 63.4% and 133.3% higher than those of carbon/carbon composites with a density of 1.75 g/cm³. The enhanced mechanical properties of C/(PyC–SiC)_n composites are attributed to the presence of multilayered (PyC–SiC)_n matrix. Cracks deflect and propagate at both fiber/matrix and PyC–SiC interfaces resulting in a step-like fracture mode, which is conducive to fracture energy dissipation. These results demonstrate that the C/(PyC–SiC)_n composite is a promising structural material with low density and high flexural strength and toughness.     

Microstructure and mechanical properties of bulk highly faulted fcc/hcp nanostructured cobalt microstructures

Nanostructured cobalt powders with an average particle size of 50 nm were synthesized using a polyol method and subsequently consolidated by spark plasma sintering (SPS). SPS experiments performed at 650 °C with sintering times ranging from 5 to 45 min under a pressure of 100 MPa, yielded to dense bulk nanostructured cobalt (relative density greater than 97%). X-ray diffraction patterns of the as-prepared powders showed only a face centered cubic (fcc) crystalline phase, whereas the consolidated samples exhibited a mixture of both fcc and hexagonal close packed (hcp) phases. Transmission electron microscopy observations revealed a lamellar substructure with a high density of nanotwins and stacking faults in every grain of the sintered samples. Room temperature compression tests, carried out at a strain rate of 10^− 3 s^− 1, yielded to highest strain to fracture values of up to 5% for sample of holding time of 15 min, which exhibited a yield strength of 1440 MPa, an ultimate strength as high as 1740 MPa and a Young's modulus of 205 GPa. The modulus of elasticity obtained from the nanoindentation tests, ranges from 181 to 218 GPa. The lowest modulus value of 181 GPa was obtained for the sample with the highest sintering time (45 min), which could be related to mass density loss as a consequence of trapped gases releasing.     

Production and characterization of lightweight vermiculite/geopolymer-based panels

The production and the properties of lightweight composite panels, with expanded vermiculite as lightweight aggregate and geopolymer as binder, were investigated. Different compositions of the geopolymer binders (metakaolin or alumina-based) and two sizes of expanded vermiculite were tested. The produced composites were subjected to microstructural analyses, as well as to thermal and mechanical tests. Densities ranged between 700 and 900 kg/m³, while the average strength and thermal conductivity were about 2 MPa and 0.2 W/mK, respectively. Results show that lightweight composites can be produced with satisfactory density and mechanical and thermal properties compared with other materials used in building sector, such as plasterboard or cellular concrete.     

Aramid fibers reinforced silica aerogel composites with low thermal conductivity and improved mechanical performance

Aramid fibers reinforced silica aerogel composites (AF/aerogels) for thermal insulation were prepared successfully under ambient pressure drying. The microstructure showed that the aramid fibers were inlaid in the aerogel matrix, acting as the supporting skeletons, to strengthen the aerogel matrix. FTIR revealed AF/aerogels was physical combination between aramid fibers and aerogel matrix without chemical bonds. The as prepared AF/aerogels possessed extremely low thermal conductivity of 0.0227 ± 0.0007 W m⁻¹ K⁻¹ with the fiber content ranging from 1.5% to 6.6%. Due to the softness, low density and remarkable mechanical strength of aramid fibers and the layered structure of the fiber distribution, the AF/aerogels presented nice elasticity and flexibility. TG–DSC indicated the thermal stability reaching approximately 290 °C, can meet the general usage conditions, which was mainly depended on the pure silica aerogels. From mentioned above, AF/aerogels present huge application prospects in heat preservation field, especially in piping insulation.     

The effect of zirconium addition on the microstructure and properties of chopped carbon fiber/carbon composites

Carbon/carbon composites containing zirconium were prepared using chopped carbon fiber, mesophase pitch and Zr powder by the traditional process including molding, carbonization, densification and graphitization. The influence of Zr on the microstructure and properties of the composites were investigated. Results show that Zr can improve the interface bonding, promote more perfect and larger crystallites and enhance the conductive/mechanical properties of the composites. The high in-plane thermal conductivity of 464 W/(m K) and excellent bending strength of 83.6 MPa was obtained for a Zr content of 13.9 wt% at heat treatment temperature(HTT) of 2500 °C. However the conductive/mechanical properties of the composites decrease dramatically for an higher HTT of 3000 °C. SEM micrograph of the fracture surface for the composites shows that lower disorder crystallite arrangement of fiber and carbon matrix come into being in the composites during HTT of 3000 °C, which should be responsible for the low properties. Correlation between the content of Zr and the microstructure and properties are discussed.     

Synergistic effect of boron nitride flakes and tetrapod-shaped ZnO whiskers on the thermal conductivity of electrically insulating phenol formaldehyde composites

Tetrapod-shaped zinc oxide (T-ZnO) whiskers and boron nitride (BN) flakes were employed to improve the thermal conductivity of phenolic formaldehyde resin (PF). A striking synergistic effect on thermal conductivity of PF was achieved. The in-plane thermal conductivity of the PF composite is as high as 1.96 W m⁻¹ K⁻¹ with 30 wt.% BN and 30 wt.% T-ZnO, which is 6.8 times higher than that of neat PF, while its electrical insulation is maintained. With 30 wt.% BN and 30 wt.% T-ZnO, the flexural strength of the composite is 312.9% higher than that of neat PF, and 56.2% higher that of the PF composite with 60 wt.% BN. The elongation at break is also improved by 51.8% in comparison with that of the composite with 60 wt.% BN. Such a synergistic effect results from the bridging of T-ZnO whiskers between BN flakes facilitating the formation of effective thermal conductance network within PF matrix.