Evaluation of thermal gradients and thermosiphon in dual channel cable-in-conduit conductors

In an effort to optimize superconductor cryogenics of large coils, dual channel cable-in-conduit conductors (CICC) have been designed. The qualitative and economic rationale of the conductor central channel is here justified but brings high complexity to the conductor cooling characteristics. Temperature gradients in the cable must be quantified to guarantee conductor temperature margin during coil operation under heat disturbance and set adequate inlet temperature. A simple one-dimensional thermal model, with neither fluid nor strand or jacket conduction, allows to better understand and quantify the steady state behavior of CICC central and annular channels. This thermohydraulic model with homogeneous central and annular temperatures and no jacket conduction is summarized with explicit thermal coupling equations. Local convection coefficients chosen proportional to friction factors lead to a model of global interchannel heat exchange coefficient serving the bithermal model. A first stationary experimental evaluation of the internal heat transfer coefficient using the interchannel heat exchange space constant at various heat loads and mass flow rates is illustrated on two full size samples tested at cryogenic temperatures. Annular heaters experiments with low distributed power achieve pertinent model correlation. Discrepancy between model and experimental data may be linked to the simplistic homogeneous annular temperature hypothesis, to the estimate of CICC mass flow distribution among channels, and to gravitational effects at high heat loads. Perturbation due to the thermosiphon generated between the two channels is considered since neither the experiments nor the expected applications are free of gravity.     

Performance evaluation of the ITER Toroidal Field Model Coil phase I: Part 2: M&M analysis and interpretation

The ITER Toroidal Field Model Coil (TFMC), a large (2.7 m × 3.8 m × 0.8 m) superconducting (Nb₃Sn) DC coil designed and constructed in collaboration between EU industries and laboratories coordinated by EFDA, has been tested during 2001 in the TOSKA cryogenic facility at Forschungszentrum Karlsruhe, Germany, achieving the nominal 80 kA at 7.8 T peak field and 86 MJ stored energy as a standalone coil (Phase I). The results of the current sharing temperature (T_CS) measurements at I=80, 69 and 57 kA, presented in a companion paper (Part 1), are evaluated here using the M&M code. The critical properties best fitting the experimental voltage-inlet temperature characteristic of the P1.2 pancake are deduced from the TFMC data under the assumption of an ideal collective behaviour of the strands. The TFMC results are compared first with the expected conductor performance, showing that at the maximal current the performance was borderline with what was expected, while at the minimal current tested it was better than expected. Second, they are compared with the performance of the single strand as measured in the lab, showing that, in order to reproduce the TFMC data, one has to invoke that some degradation, larger at higher current, occurred when going from the strand to the cable.     

JackPot: A novel model to study the influence of current non-uniformity and cabling patterns in cable-in-conduit conductors

JackPot is a new model that is used to analyse how and to what extend current non-uniformity among strands in a cable-in-conduit conductor (CICC) affects its performance. The joints at the extremities of the CICCs in coils and short samples introduce a non-uniform current distribution among the strands. A detailed and quantitative study down to strand level is required to explain the involved phenomena, to understand their implications on short sample and coil tests and to provide adequate solutions for improvements. The model can be used to evaluate the influence of the joint design and to define its baseline requirements for short-sample qualification testing, and for optimum magnet performance of for example the ITER coils.JackPot is an electrical network model that simulates the interaction between the superconducting strands in the cable (following their precise trajectories), the interstrand contact resistances, the conduit, and the cable’s connection to the joints. The backbone of JackPot is its cable geometry model, from which all relevant properties are derived. All parameters are derived from well defined experimental measurements on conductor sections and joints, except the axial strain for Nb₃Sn strands, which is the only free parameter in the model.The simulations demonstrate that the current non-uniformity is the source for a number of observed phenomena. Another conclusion is that completely filling the bottom joints and upper terminations of a short sample with solder, opposed to only (partly) soldering the cable surface, improves short-sample testing significantly for qualifying the ITER type CICCs. This paper describes the model and gives a few examples of applications for its validation.     

Thermo-hydraulic analysis of the gradual cool-down to 80 K of the ITER toroidal field coil

A time-dependent thermo-hydraulic simulation for an ITER toroidal field (TF) coil gradual cool-down to 80 K has been performed using a new FORTRAN code. The code is based on a 1D helium flow and 1D multi-region solid heat conduction model. The whole TF coil is simulated taking into account thermal conduction between winding pack and case, which are cooled down separately. To limit coil mechanical stresses and coolant pressure drop in the cooling channels, an improved cool-down mode has been developed based on the analysis. Typical and gradual cool-down temperature distributions of TF coil and case are presented. The results indicate that gradual cool-down to 80 K can be achieved in 3 weeks.     

Tension-tension fatigue behavior of GFRP woven laminates at low temperatures

This paper describes an experimental study on the fatigue damage behavior of GFRP woven laminates in terms of stiffness degradation and residual strength under cyclic loading at low temperatures. Uniaxial, load-controlled, tension-tension fatigue tests were conducted at room and low temperatures. The applied stress versus cycles to failure (S-N) relationships and fatigue limits were obtained for the GFRP woven laminates and the microcrack evolution due to fatigue loading was characterized using optical microscopy. Temperatures were also measured using a thermocouple embedded in the center of the specimens.     

Acoustic emission and fracture behavior of GFRP woven laminates at cryogenic temperatures

This paper describes an experimental and analytical study on fracture and damage behavior of GFRP woven laminates at cryogenic temperatures. CT (compact tension) tests were carried out at room temperature, liquid nitrogen temperature (77 K) and liquid helium temperature (4 K) to evaluate the critical values of the fracture mechanics parameters. During the CT tests, AE (acoustic emission) method was implemented. AE signals can identify the critical load at which gross failure occurs. A FEA (finite element analysis) was also applied to calculate the fracture mechanics parameters. The failure criteria (Hoffman criterion and maximum strain criterion) or the damage variable based on the continuum damage mechanics was incorporated into the model to interpret the experimental measurements and to study the damage distributions within the specimen. Several methods of calculating J-integral are discussed.     

Cryogenic fatigue behavior of plain weave glass/epoxy composite laminates under tension-tension cycling

This paper focuses on understanding the tension-tension fatigue behavior of woven glass fiber reinforced polymer laminates at cryogenic temperatures. Tension-tension fatigue tests at frequencies of 4 and 10 Hz with a stress ratio of 0.1 were conducted at room temperature, 77 and 4 K. The fatigue stress versus cycles to failure (S-N) relationships and fatigue limits for 10⁶ cycles were obtained. Fractured specimens tested under fatigue tests were also examined with optical microscope.     

Small punch testing for determining the cryogenic fracture properties of 304 and 316 austenitic stainless steels in a high magnetic field

This paper examines the effect of magnetic field on the fracture properties of austenitic stainless steels at liquid helium temperature (4 K). Small punch tests were performed on cold-rolled 304 and 316 austenitic stainless steels. Previously proposed correlation for small punch and elastic-plastic fracture toughness test methods was applied to predict a small punch test-based fracture toughness from equivalent fracture strain.     

Liquid helium centrifugal pump characteristics from 80 g/s to 1200 g/s

The large amount of data collected from three different centrifugal liquid helium pumps tested, namely with 80, 600 and 1200 g/s nominal mass flow are reviewed. The data include the analysis of the characteristic curves, their total efficiencies, their Net Positive Suction Head (NPSH) and the slip factor. The 1200 g/s pumps tested are of the full emission type, with curved blades, whilst the other pumps have straight blades. The pumps were also tested at different rotary speeds. The pumps were manufactured by Barber & Nichols (Denver, USA).     

Fracture and deformation properties of Ni-Fe superalloy in cryogenic high magnetic field environments

The present paper includes experimental and analytical data on the fracture properties of a nickel-iron superalloy, a ferromagnetic austenite, at 4 K in magnetic fields of 0 and 6 T. The tensile, notch tensile and small punch tests are employed. A finite element analysis is also performed to convert the experimentally measured load-displacement data into useful engineering information. To interpret the results we review the available theory of the influence of magnetic field on the stress intensity factor for a crack in ferromagnetic materials.     

Finite element calculations on detailed 3D models for the superferric main magnets of the FAIR SIS100 synchrotron

The synchrotron SIS100 is one of the two basic accelerators of the future Facility for Antiproton and Ion Research (FAIR) at GSI in Darmstadt. This accelerator should provide high intensity U28+ and proton beams with a pulse repetition rate of 1 Hz (i.e. a ramp rate of 4 T/s). The magnetic system of the accelerator uses superferric 2.1 T dipoles of about 3 m length and 32 T/m quadrupoles of about 1 m length. The magnet coils are made of a hollow tube cable wrapped with Cu/NbTi composite wire cooled with two phase helium flow at 4.5 K. The bore dimensions were defined to 130 × 60 mm for the dipole and 135 × 65 mm for the quadrupole. We present the developed ANSYS models for different important aspects: AC loss, magnetic field quality and mechanical stability. Preliminary studies verified the approaches and these models were applied to calculate the effects for the coil, the yoke and the beam pipe structures. We outline further steps to fully describe the SIS100 magnets including mechanical and thermal properties.     

Liquid helium cryostat for SQUID-based MRI receivers

We describe a liquid helium cryostat, developed to cool SQUID-based receivers in low field MRI systems. The cryostat has a 4 L liquid helium capacity, a hold time of over 3 days and accommodates 10 cm diameter receiver coils. New vacuum insulation methods reduce the noise level by at least an order of magnitude compared to existing commercial designs. The minimum detectable field at 425 kHz, with a 5 cm diameter circular coil, was estimated to be 0.018 fT/Hz^1/2 from Q-factor measurements and 0.035 fT/Hz^1/2 by direct measurement with a SQUID amplifier. Further measurements indicated that most of this field noise probably originates with dielectric losses in the cryostat’s fibreglass shells.     

Three-dimensional analysis for liquid hydrogen in a cryogenic storage tank with heat pipe–pump system

This paper presents a study on fluid flow and heat transfer of liquid hydrogen in a zero boil-off cryogenic storage tank in a microgravity environment. The storage tank is equipped with an active cooling system consisting of a heat pipe and a pump–nozzle unit. The pump collects cryogen at its inlet and discharges it through its nozzle onto the evaporator section of the heat pipe in order to prevent the cryogen from boiling off due to the heat leaking through the tank wall from the surroundings. A three-dimensional (3-D) finite element model is employed in a set of numerical simulations to solve for velocity and temperature fields of liquid hydrogen in steady state. Complex structures of 3-D velocity and temperature distributions determined from the model are presented. Simulations with an axisymmetric model were also performed for comparison. Parametric study results from both models predict that as the speed of the cryogenic fluid discharged from the nozzle increases, the mean or bulk cryogenic fluid speed increases linearly and the maximum temperature within the cryogenic fluid decreases.     

Dynamic simulation of the helium refrigerator/liquefier for LHD

A real-time dynamic simulation has been carried out for the 10 kW class helium refrigerator/liquefier of Large Helical Device (LHD) at National Institute for Fusion Science (NIFS). The refrigerator consists of eight screw compressors, seven expansion turbines, fourteen heat exchangers and a 20 m³ liquid helium reservoir. A simulation model was implemented to Cryogenic Process REal-time SimulaTor (C-PREST), developed as a platform for the plant process study and optimization. Validity of the simulation model has been confirmed based on the design values as well as the results of commissioning tests. This paper describes the cooldown process and expansion turbine trips during the operation. Difficulties of dynamic simulation for the large cryoplant are also discussed.     

Thermal conductance at millikelvin temperatures of woven ribbon cable with phosphor-bronze clad superconducting wires

Woven Nomex® ribbon cables made up with superconducting niobium-titanium wire are used at millikelvin temperatures in many large cryogenic instruments. It is important to know how much heat in transmitted down such cables. However, the conductivity of the materials used is not well known. Another problem is that the wires are normally clad with alloys which exhibit some magnetism. This is a potential problem for instruments employing superconducting detectors. A safe non-magnetic alternative to the usual materials is phosphor-bronze clad niobium-titanium wiring. However, there is little experience with such wires. We have therefore measured the conductance of a ribbon cable made up with these wires. The measured values are in good agreement with our predictions, suggesting that the values we have used to model the cable are sufficiently accurate, and could therefore be used to predict the performance of ribbon cables using other cladding materials, so long as the conductivity of the cladding is reasonably well known. As part of our analysis, we consider the likely variation in thermal conductivity values for C51000 phosphor bronze caused by legitimate variations in composition.     

Forced flow boiling heat transfer of liquid hydrogen for superconductor cooling

Heat transfer from inner side of a heated vertical pipe to liquid hydrogen flowing upward was first measured at the pressure of 0.7 MPa for wide ranges of flow rates and liquid temperatures. The heat transfer coefficients in non-boiling regime for each flow velocity were well in agreement with the Dittus–Boelter equation. The heat fluxes at the inception of boiling and the departure from nucleate boiling (DNB) heat fluxes are higher for higher flow velocity and subcooling. It was found that the trend of dependence of the DNB heat flux on flow velocity was expressed by the correlation derived by Hata et al. based on their data for subcooled flow boiling of water, although it has different propensity to subcooling.     

Analytical and finite element investigations of shear/compression test fixtures

Insulation systems are critical components of the international thermonuclear experimental reactor (ITER). They must meet the super conducting magnets design requirements, including mechanical strength under combined shear and compressive stresses at cryogenic temperatures. Past cryogenic magnet systems often relied on woven glass/epoxy materials for insulation. An important point is to find a reliable shear/compression test method for these materials. The present work investigates a commonly used shear/compression setup and aims at measuring the reliability of the obtained test results. Therefore, the stress and failure analysis is performed analytically and numerically using the finite element method. The model is based on woven glass fiber reinforced materials which are subjected to combined shear and compressive stresses as well as to thermal loading, that results from cooling from 293 K to the test temperature of 77 K. A short analytical section shows the problems of common failure criteria which are used to describe the interaction of the shear and compression stresses. The numerical—finite element—section is based on three-dimensional linear elastic finite element models under thermo-mechanical loading. The locations of high stress gradients are investigated using an average stress criterion. Three different model geometries (15°, 45°, and 70°) are analyzed and finally compared with respect to their reliability.     

Numerical optimization of conduction cooled current leads for low current applications

The basic design principles of current leads for superconducting magnets are well established but HTS materials and conduction cooled systems call for new numerical methods. In this paper the design of current leads was formulated as an optimization problem. Both time integration and finite differencing were examined as possible ways to compute the temperature distribution inside the leads. Three examples about optimization of conduction cooled as well as gas cooled systems are presented. First, the design of tubular normal conducting gas cooled current leads was studied. Second, normal conducting leads cooled with a two-stage cryocooler were examined. Third, the optimization was applied to current leads consisting of HTS tapes at the low temperature end of a normal conducting bar. The study took into account the magnetic field and temperature dependent voltage-current characteristics of the anisotropic Bi-2223 material. The results are compared with traditional analytical ones and the numerical optimization is shown to be an efficient design tool for both normal conducting and HTS current leads.     

Development of superconducting and cryogenic technology in the Institute for Technical Physics (ITP) of the Research Center Karlsruhe

Since the early 1970s the Institute for Technical Physics of the Research Center Karlsruhe has been involved in the development of superconductivity for research and industrial applications. A broad program with a focus on the superconducting magnet technology was established to include large magnets for nuclear fusion, high-field magnets for nuclear magnetic resonance spectrometers, ore separation and energy storage magnets. Research and development work was performed in collaborative projects with other national as well as international institutions and industry. The success of these projects has been supported by a broad foundation of engineering science in superconductor development, electrical and cryogenic engineering. Several well known test facilities like TOSKA, STAR, HOMER, MTA along with well equipped laboratories for conductor development, materials at cryogenic temperatures, cryogenic high-voltage engineering have made substantial contributions to in-house, national and international projects. A strong cryogenic infrastructure with two refrigerators and sophisticated cooling circuits from about 4.5 K down to 1.8 K assure the reliable operation of these large facilities. Last but not least, cryogenic research, including vacuum pumps for International Thermonuclear Experimental Reactor, improvements in thermal insulation, cryogenic instrumentation and small on board refrigerators has supported progress in this field. High-temperature superconductivity projects for low AC loss conductors, a 70 kA current lead and a fault current limiter are currently in progress.