3D simulation of AC loss in a twisted multi-filamentary superconducting wire

In the AC loss simulation, it is a huge challenge to model the twisted wire at the filament level, due to the complex structure as well as long-time computation consumption. In this paper, we use 3D finite-element method based on H-formulation to study the AC loss in a twisted superconducting wire. The wire is treated as a homogenous material with the anisotropic conductivity in the filament region. We quantitatively simulate the AC loss induced by the AC transport current and magnetic field profile, and the effect of the twist pitch on the AC loss. In the case of AC transport current, larger pitch length leads to higher loss, and the pitch length effect is contrary to the case of applied magnetic field. The influences of the magnetic field direction and non-uniform current distribution subjected to the strand bending are also investigated. It is observed that, the transverse magnetic field has a more significant influence on the AC loss than the longitudinal magnetic field. The non-uniform current distribution can result in a higher AC loss, compared to a corresponding uniform current distribution.     

工艺参数对连续挤压铜/铝复合接触线成形的数值模拟研究

针对铜铝无法复合成形和铜铝结合面不紧密等问题,采用Deform-3D有限元软件,模拟了铜铝复合接触线连续挤压包覆成形过程,研究了成形过程不同模芯端部导流角、复合变形区长度、坯料与模具表面状态和挤压轮转速对铜铝复合接触线包覆质量的影响.研究结果表明:模芯端部导流角度取45°~30°,复合变形区长度L取5 mm,铜铝结合紧密度高,包覆效果好;提高铜线与铝线之间的摩擦,降低模具与铜线之间的摩擦,有利于实现铜铝流动的同步性;适当提高挤压轮转速有利于铜铝结合面紧密度的提高.在TLJ340连续挤压机上进行了铜铝复合试验,试验结果与数值模拟结果相吻合,成功生产出质量合格的铜铝复合接触线产品.     

Losses in a multifilamentary superconducting wire caused by a simultaneous sweep of current and magnetic field

A theoretical discussion is presented on the energy loss in a multi-filamentary superconducting wire when an applied transport current and an external transverse magnetic field are varied simultaneously with a repeating pulsive wave form. In the present calculation, the effects of the ‘uniforming time constant’ which has been introduced by the authors as a characteristic time constant for the change in the transport-current distribution inside the wire is taken into account, together with the field dependence of the critical current density of superconducting filaments.Thus the present analytic expression for the energy loss of multi-filamentary wire is available to the whole range of the external magnetic field. It is shown that the contribution of the dynamic resistance loss to the total loss is strongly dependent on the position of the wire inside a coil.     

新型碳纤维复合芯铝合金导线的特性研究

采用拉挤成型工艺制备了碳纤维增强环氧树脂复合材料导线芯,在外部绞合铝绞线制备成导线.并对线芯的密度和拉伸强度以及导线的应力应变曲线和弧垂等性能做了研究.结果表明,碳纤维复合芯的密度仅为1.60g/mm~3,断裂强度高达2874MPa,大大超过普通钢芯;由于在拉伸过程中复合芯只表现出弹性变化,而铝绞线要发生弹塑性变形,使导线的应力应变曲线上存在斜率的突然变化;线芯的热膨胀系数比铝绞线要小的多,使在温度升高到一定值时导线的弧垂基本不再增加,从而允许导线在更高的温度下使用.现场应用情况表明,新型导线完全可以取代传统钢芯导线,改造输电线路.     

Fabrication of 6-filament MgB2 wires enhanced by high strength 91-filament Cu–Nb composite

We chose high strength and high conductive Cu–Nb composite as strengthening core to improve the mechanical properties of 6-filament MgB₂ wires. The Cu–Nb core become partially dispersion strengthened during the fabrications of the MgB₂ wires. It has been found that this Cu–Nb composite offers good promise of increased strength while maintaining the superconducting properties of the MgB₂ wire. The Young’s modulus of the best wire samples increased significantly to about 130 GPa, which is comparable to those of high strength ferromagnetic materials sheathed wires but without negative ferromagnetic effects. Those mechanical properties were enough to satisfy the low field application needs. The critical current I _c also achieves 200 A (engineering critical current density, J _ce above 1.30 × 10⁴ A/cm²) at 20 K 1 T field. The 91-filament Cu–Nb composite core reinforced wires were fabricated by in situ Powder In Tube method.     

A high speed drive coil for a large capacity bubble memory

We calculated an eddy current loss in a wire as a function of an applied ac field. Estimating the field at an actual coil wire and summing the losses in all points of wires we obtained a formula representing a coil loss. Based on the calculated results, we designed coils which drive thirty-two 64 kb chips. The observed loss of the coils was in good accord with the calculated one. This 2 Mb module was operated at 40 Oe rotation field of 500 kHz with the coil loss of 8 W.     

Improvement of magnetic induction-wire sawing process using a magnetic system

Magnetic induction-free abrasive wire sawing is a hybrid process that applies a homogeneous magnetic field to transport more abrasives into the sawing channel. This causes the performance of wire sawing significantly improved. Magnetic field strength is a key factor in determining the magnetic force acting on the magnetic abrasives, then affecting the quantity of abrasives adsorbed on the saw wire surface. However, the background magnetic induction strength produced by two permanent magnets is limited in this process. To further investigate the influence of magnetic field strength on the wire sawing performance, a magnetic system, which is based on the magnetic circuit design principle and the structure of single-wire sawing machine, is designed and fabricated. The magnetic field characteristics of the designed magnetic system are investigated both by numerical simulations and experiments. An experimental setup that installs the fabricated magnetic system on the single-wire sawing machine is built to conduct the magnetic induction-wire sawing experiments. The results show that the optimal magnetic induction strength is about B₀?=?135?mT. In this case, the kerf loss is decreased by 10% compared to the free abrasive wire sawing technology without a magnetic field.     

Magnetic Field Angular Dependence of Magnetization Loss in ReBCO Superconducting Tapes

In the applications of high-temperature superconductors (HTS), the HTS tapes are usually exposed to the external magnetic field with different orientations. The critical current and AC loss are affected by both the field amplitude and field angles due to the anisotropy of HTS tapes. In this work, we first introduce the experimental system to measure the magnetization loss in HTS tapes based on the calibration-free method. Then, we present the magnetization loss results in 4.8-mm-wide AMSC wire, 4-mm-wide SuperPower wire, 4-mm-wide SuNam wire, and 10-mm-wide Fujikura wire in a perpendicular applied field at 77 K. The field amplitude is up to 100 mT, and the frequency varies from 44.2 to 87.1 Hz. We also present the magnetization loss in AMSC wire, SuperPower wire, SuNam wire, and Fujikura wire at different field angles. The field angle varies from 10 to 90 ^° in 10 ^° steps. The loss reduction with the decreasing of the field angle shows the anisotropic property of HTS tapes. We finally plot the measured magnetization loss of the samples as a function of the magnetic field amplitude normalized by the field angle to verify an empirical formula.     

Experimental Investigation of the Thermal Impedance of Interstitial Material at a Junction

Using a quasi-steady-state T-type probe, experimental evidence of the different behavior of the thermal impedance of a junction with different interstitial material (interposer) was presented. In the T-type probe, a short hot wire serves both as a heater and a thermometer, which is subjected to an alternating current, and a thermally infinite long test wire is attached to the midpoint of the hot wire with an interposer. The thermal impedance of the interposer was introduced, which was taken to be the product of the steady-state thermal resistance and a complex ratio function. A complete expression for the thermal impedance of the interposer was derived, and the effects of the radiation heat loss as well as the deviation of the contact junction position were theoretically estimated. A microscale Pt wire with two interposers was measured, including solidified platinum black and Apiezon N vacuum grease. Experimental results showed that the platinum black contact with high thermal effusivity served as a negative thermal impedance, while a positive thermal impedance was observed for the Apiezon N contact. The obtained thermal impedance of the Apiezon N contact could be equivalent to its thermal resistance, which was verified by measuring the thermal conductivity of a Cu wire using the steady-state T-type probe.     

同轴电缆结构复合丝巨磁阻抗效应的研究

采用脉冲电沉积工艺在直径为200μm的铜丝表面沉积铁镍合金镀层,形成具有同轴电缆结构的巨磁阻抗复合丝材料。分别改变复合丝磁性外壳厚度与铜丝直径,研究复合丝结构对巨磁阻抗效应的影响。发现巨磁阻抗比值随磁性外壳厚度的增大及铜丝直径的增大而增大,特征频率则向低频端移动。本文还发现在外加直流磁场低于5．57kA／m时,驱动交流电幅值增大,巨磁阻抗效应增大;高于5．57kA／m时,驱动交流电幅值的大小几乎不再影响复合丝的巨磁阻抗效应。在驱动电流上叠加20mA以下的直流偏置对巨磁阻抗效应没有影响。     

AC Loss Evaluation of MgB2 Superconducting Windings Located in a Stator Core Slot with a Finite-Element Method

AC losses in stator windings of fully superconducting motors with an MgB₂ wire are numerically evaluated by means of a finite-element method using edge elements for a self-magnetic field. The physical properties of the MgB₂ wire for numerical calculations are obtained from the corresponding experiments with an existing wire. It is assumed that the voltage?Ccurrent characteristics of the MgB₂ wire are given by Bean??s critical-state model, in which the critical current density is independent of the local magnetic field. The influences of core slot size and turn number of windings on the AC losses are discussed quantitatively toward the optimum design of the stator winding with the MgB₂ wire.     

Magnetic field dependence of ac losses in multi-filamentary superconducting wires

The magnetic field dependence of ac losses due to nonlinear flux penetration into superconducting filaments, ie, nonlinearity between an applied magnetic field and a penetrated flux, has been studied experimentally for multi-filamentary superconducting wires with Nb-Tl filaments and Cu matrix. In order to observe this effect, ac loss measurements were extensively carried out for the cases of applied transverse ac magnetic fields ranging from 0.06 to 50 Hz in frequency and from 10^?3 to 0.2 T in amplitude. Shifting of the frequency corresponding to the peak of the eddy current loss with the amplitude of applied magnetic fields was revealed experimentally. The results obtained were explained by taking into account the magnetic field dependence of the effective permeability of the wire originated from nonlinear flux penetration into superconducting filaments. The associated frequency dependence of the hysteresis loss is also discussed.     

Stress/strain characteristics of Cu-alloy sheath MgB2 superconducting wires

The mechanical properties of Cu and Cu-alloy (Cu-Zr, Cu-Be and Cu-Cr) sheath in situ PIT-processed MgB₂ superconducting wires were studied at room temperature (RT) and 4.2 K. The effects of stress/strain on the critical current (I_c) of the wires have also been studied at 4.2 K and in magnetic fields up to 5 T. Alloying the Cu sheath significantly increased the yield stress of the wires. The 0.5% flow stresses of the Cu-alloy sheath wires were 147-237 MPa, whereas that of Cu was 55 MPa. At RT, the serration in the stress-strain curves corresponding to the multiple cracking was observed around a strain of 0.4% and the curve almost saturated beyond that point. The strain dependence of I_c prior to the critical strain (ε_irr) was different depending on the magnetic field; being almost constant at 2 T and increased with strain at 5 T. The I_c decreased beyond ε_irr, which was much larger for Cu-alloy sheath wires as compared with Cu sheath wire. The magnitude of ε_irr is due to the difference in the thermal compressive strain in the MgB₂ core, which was relaxed by yielding in the sheath materials. The transverse compression tests revealed that the I_c of the Cu-alloy sheath wire did not degrade up to about 95 MPa, which is also higher than that of Cu sheath wire.     

Failure Analysis of a Drilling Wire Rope

The failure of a multistrand wire rope used in drilling rig hook is investigated in this case study. The wire rope failed during the raising of the rig and caused some serious damage to the rig structure. Throughout its short time of service, the wire had been used a few times for rig up and rig down. The failure investigation is performed by metallurgical examinations and computational analyses utilizing the finite element method. The wire rope was made of AISI 1095 steel. Its chemical composition, ferrite?Cpearlite structure, and high hardness indicate that the wire is a type of extra extra improved plow steel (EEIPS) grade. The morphologies of fractured surfaces indicate tensile overloading of wires. Finite element analysis confirms the overload in core and strands, and compressive contact stresses between wires, and between wires and sheave surface. The results show that high tensile stresses due to the overload and small ratio of sheave-to-rope diameter were responsible for the failure.     

横磁处理对1K107纳米晶铁芯磁性能的影响及高频损耗分析

对Fe73.5Cu1Nb3Si13.5B9纳米晶铁芯分别进行普通热处理与横磁处理,并检测铁芯经两种热处理后的各项磁性能。获得了各频率下损耗与幅值磁密的关系。结果表明,横磁处理降低损耗效果较明显,该方法在高频电力电子变压器铁芯领域具有潜在应用前景。损耗分离结果表明,横磁处理后,磁滞损耗、涡流损耗、剩余损耗在总损耗中所占比例分别为不变、升高、降低。横磁处理后,磁畴结构改变,以磁矩旋转磁化为主要磁化方式,降低畴壁共振造成的异常损耗是除降低磁滞损耗外,降低总损耗的另一原因。     

Magnetization Loss of MgB2 Superconducting Wire at Various Temperatures

The magnetization loss of MgB₂ wire was investigated using numerical calculations based on the finite element method. Various superconducting properties of MgB₂ wire such as nonlinearity and the field dependence of the critical current were considered in the numerical formulation. An analysis of magnetization loss was carried out as a function of the external magnetic field for a wide range of operating temperatures. The numerical results were compared with conventional theories and were found to be in relatively good agreement. An alternate approach based on a normalization method using critical current data was also employed as a simple method for predicting magnetization loss. The effectiveness of the simple equation for predicting loss was verified by comparisons of both values for various temperatures.     

Hybridization of filler wire in multi-pass gas metal arc welding of SA516 Gr70 carbon steel

In the present investigation, multi-pass gas metal arc welding (GMAW) of SA516 Gr70 carbon steel was carried out by different filler wires such as solid, metal cored and flux cored, wherein, other process parameters were kept constant. The hybrid approach of multi-pass filler wires was applied to obtain three different welds. The root pass was filled by a solid wire for all three cases while the subsequent filler pass was applied through solid, flux-cored and metal cored filler wires, respectively. Metallographic, mechanical and metallurgical analyses such as macrograph study, optical microscopy, tensile testing and hardness variations were performed to address the quality of weld. The results revealed that defect-free sound welds were produced by the hybrid approach of different filler wires in multi-pass GMAW. Overall cost and time reduction can be achieved through hybrid filler welds, without affecting their mechanical strength. Angular distortion was reported minimum at hybrid weld of solid and metal cored filler wire. Maximum reinforcement with higher penetration was observed at weld of solid and metal cored filler wire. Impact toughness was reported higher in case of hybrid weld of solid and flux cored filler wire. Higher macro hardness was reported at weld of solid and flux cored filler wire.     

On a new principle of a smart multisensor based on magnetic effects

In this paper, a new principle of a smart sensor is proposed, based on three different magnetic effects or operational modes, using the same sensor topology, which consists of a magnetic wire as sensing core, two coils as excitation or search means, and two electric contacts at the ends of the magnetic wire. The magnetic effects currently involved are magnetostriction, magneto-impedance and re-entrant flux reversal. Operating the sensor in these three different modes separately and sequentially, one can obtain the response of the sensor related to three different physical quantities, such as stress, temperature, and field. This paper refers to the first experimental results based on this principle, thus initiating the research work in this field. It has been experimentally observed that the total output of the sensor in each one of the three different modes is equal to the product of each corresponding physical quantity function concerned, provided that a given threshold of the ambient field and preloaded stress is used to bias the sensing element. Therefore, the three unknown parameters of stress, temperature, and field can be determined from a 3/spl times/3 matrix equation. Other magnetic effects may also be involved. Furthermore, other physical quantities may also be determined, such as position, pressure, load, etc.     

Cylindrical vector beam generation in multiple elliptical core fiber with gold wire

A new method to generate cylindrical vector beam carrying helical phase is proposed based on a multiple elliptical core fiber integrated with gold wire. Both the light field distributions in near- and far-field are considered. The simulation results show that the multiple core fiber filled with gold wire in the center can only support low-loss transmission for the analogous azimuthally polarized (AP) light field with discrete rotational symmetric profile in a broadband range, because the resonant coupling between the surface plasmon modes and the fiber core-guided supermodes. The far-field patterns for different number core are demonstrated to represent an effective AP beam. It also acts as an effective broadband transmission filter for azimuthal modes.     

Electric field sensing with a hybrid polymer/glass fiber

We demonstrate the operation of an in-fiber electric field sensor. The sensor is fabricated with selective chemical etching of the core of a D-shaped optical fiber followed by the deposition of an electro-optic polymer (PMMA/DR1), which forms a hybrid core. The device demonstrates electromagnetic field sensitivity less than 100 V/m at a frequency of 2.9 GHz. Epi is estimated to be 60 MV/m with an insertion loss of 14.4 dB.