Patent Application
20050176586
The present invention concerns methods for the manufacture of superconductor materials. More particularly, the invention concerns methods of increasing the upper critical field value (“BC2”) of crystalline superconductor materials to produce high-field superconductor materials, e.g. for use in superconducting electromagnets, or in power transmission applications.
In relation to superconductor materials, the upper critical field (BC2) is the magnetic field strength (Tesla, T) that delineates the superconducting phase from the non-superconducting (or normal) phase. Clearly a material cannot be used in magnetic fields above BC2 in superconducting applications. The critical current density (JC) is the maximum useful current density a superconductor can carry. JC depends on the magnetic field the superconductor is exposed to. As a ball-park figure, when JC drops below about 4×104 A.cm−2, the size of the magnet starts to increase and costs start to increase rapidly.
High magnetic fields play an important role in modern technological society. There are essentially three areas of activity:
Prior efforts to increase BC2 have concentrated on doping high field superconductors. Many of the improvements are explained using:
BC2(0)=3.1×103γρNTC
The present invention provides a method of increasing the upper critical field of a crystalline superconducting material, comprising the steps of:
It will be appreciated that a “crystalline superconducting material” as referred to here includes material that is only crystalline in part.
Preferably, the method further comprises the step of crystallising the material.
Generally, the step of crystallising the substantially amorphous material comprises nanocrystallisation of the material.
The method may also have the effect of increasing the critical current density (JC) of the material.
The superconductor may be converted to a substantially amorphous state by any means that pumps energy into the material to increase its energy state from a low level (crystalline) to a high level (amorphous). This is most preferably done by mechanical attrition (such as ball-milling), but other equivalent methods may be used.
The substantially amorphous material may be re-compacted and crystallised by means of heat and/or pressure, most preferably by thermomechanical processing (such as hot isostatic pressing (HIP) and/or annealing).
The resultant material has a small grain size with a high defect density, thereby increasing the resistivity and thus BC2 as compared with the original crystalline material. The grains themselves may also have a high defect density. These properties may also have the effect of increasing JC as compared with the original material.
Existing high-field superconductors operating in magnetic fields above 12 T tend to be brittle materials. The application of the present invention to such materials provides materials with increased BC2 and/or JC, enabling new and/or improved applications of such materials. Existing ductile superconductors tend to have relatively low BC2, unsuitable for high-field applications above 12 T. The application of the present invention to such materials may provide ductile materials suitable for higher-field applications.
For example, the invention may be applied to improve BC2 in existing commercial 12-22 T field superconductor materials, such as Nb3Sn. The invention may also be applied to improve BC2 in existing commercial <12 T field superconductor materials such as NbTi (including doped NbTi), extending the use of such materials to higher fields. It may also be applied to elemental superconductors such as Nb and Pb, or alloys of these metals, where TC is sufficiently high for applications but BC2 is far to low. For example body scanners could operate at higher fields with higher resolution; all low field sections of high field (12 T-22 T) large scale systems could use such improved materials.
The invention may also be applied to superconductor materials that are currently only of interest as research materials, such as Chevrel phase materials, potentially improving the properties of such materials to the extent that they become commercially useful.
The invention has been used to increase BC2 in a Chevrel phase compound from 60 T up to 120 T by using ball-milling followed by HIP/annealing.
It will be understood that BC2 is temperature dependent and that, as is conventional in the art, values of BC2 quoted herein are extrapolated values for BC2 at zero Kelvin (“BC2 (0)”).
The invention has also been applied to increase JC in a Chevrel phase compound (PbMo6S8, “PMS”) at zero field by about a factor of 2 and to increase JC in high fields by at least a factor of 3. The invention may also increase JC in other materials by a similar factor.
The resistivity of the superconductor material increases markedly after ball-milling and compaction and then decreases following HIP'ing/annealing. The resistivity is strongly correlated with an increase in BC2 (and kappa—the Ginzburg-Landau constant, κ). See Table 1, below which shows how the resistivity increases from 80 μΩ.cm (BC2˜47 T) without any milling up to 676 μΩ.cm (BC2˜139 T) by ball-milling and back down again 485 μΩ.cm (BC2˜107 T) to 363 μΩ.cm (BC2˜66 T) with differing heat treatments.
Processing condition:
No. 1: PMS, milling time: 0 h, HIP 800° C. × 8 h.
No. 2: PMS, milling time: 200 h, HIP 800° C. × 8.
No. 3: PMS, milling time: 200 h, HIP 800° C. × 8 h, annealing: 800° C. × 40 h.
No. 4: PMS, milling time: 200 h, HIP 600° C. × 8 h, anneal: 600° C. × 40 h, 1000° C. × 40 h
As noted above, the invention uses ball-milling (or an equivalent process) to produce substantially amorphous superconducting material. The material is then recompacted and crystallised to produce very small grain size material which probably has many scattering centres and pinning defects inside the grains. The small grain size and high defect concentration results in high resistivity with high upper critical field, BC2.
It has been long known that in low magnetic fields the critical current density, JC, increases when the grain size is decreased. The use of ball-milling to produce amorphous material which can then be crystallised into material with very small grain-size also increases JC markedly.
Chevrel phase superconductors and Nb3Sn have both been used as powders to produce wires. High temperature superconductors are also produced routinely using powder metallurgy. Techniques such as ball-milling may be used to thoroughly mix the powders, however, this type of mixing is very different from the present use of ball-milling for producing amorphous material and crystallising.
It will be understood that suitable or optimal parameters for ball-milling, HIP and/or annealing (or equivalents) for the purposes of the present invention may be determined empirically for particular materials. The basic principle for the crystallisation method is to control the crystallisation kinetics of amorphous solids by optimising the heat treatment conditions (for example, annealing temperature, time and heating rate) so that the amorphous phase crystallises into a polycrystalline material with ultrafine crystallites; i.e. to ensure that the nucleation rate is high while the growth rate is small.
As used herein, “substantially amorphous” means amorphous or nanocrystalline or a mixture thereof. Also as used herein, references to crystallising the substantially amorphous material means returning amorphous material to a crystalline state and “re-crystallising” any nanocrystalline components of the “substantially amorphous material”. It will be understood that “re-crystallisation”, when used in its strict technical sense, generally means changing a material with small crystals or strained crystals into a material with larger crystals. “Crystallised” is often used to describe changing an amorphous material into a crystalline material. The method of the present invention predominantly involves “crystallising” amorphous material, but since the material may not be completely amorphous some limited “re-crystallisation” may also take place.
Nanocrystalline (NC) materials are characterized structurally by the ultrafine grains and the numerous grain boundaries. The grain boundaries of NC materials may be different from those of conventional coarse grain, such as equiaxed grain morphology, low-energy grain boundary structure and flat grain boundary configuration. This produces unusual physical, chemical and mechanical properties with respect to the conventional coarse grained materials. Ball-milling is one of the most effective routes to fabricate NC materials of metals and alloys. High-energy impact during ball milling introduces severe plastic deformation of the milled powder and forms nanocrystalline or amorphous powder. Nanocrystallisation of the amorphous powder results in formation of NC materials which usually have dense and clean grain boundaries, low microstrain and nearly perfect crystallite structure.
By way of an example of the present invention, nanocrystalline and amorphous PbMo6S8 (PMS) powder was fabricated using ball-milling. The ball-milled PMS powder was then subsequently hot isostatic pressed (HIP'ed) and (in some cases) annealed to obtain bulk samples.
Sintered PMS powder (5 g) with 6 Syalon balls with a diameter of 20 mm was put into the Syalon pot and ball-milled for 200 h at a rotational velocity of 300 revolutions per minute (rpm). The weight ratio of ball to powder was ˜16:1. Ball milling was carried out in a steel box under Ar gas flow. The milled powder was wrapped with Mo foil and stainless steel and then HIP'ed at a pressure of 2000 bar and temperatures of 600, 800° C. for 8 h. Some of the HIP'ed samples were subsequently annealed at temperatures of 600, 800 and 1000° C. for 40 h. The details of the processing conditions are listed in Table 1 above.
The milled powder has a relatively regular and equiaxed morphology. The particle sizes are in the range of 50-300 nm for the powder milled for 200 h. A preliminary TEM study reveals that the milled particles consist of amorphous and nanocrystalline phase with grain sizes of 10-20 nm.
As a second example, the invention has also been used to increase BC2 at 2 K in Nb from 1.3 T up to 3.9 T by using ball-milling followed by pressing at room temperature.
BC2 is temperature dependent and measurements quoted for Nb are extrapolated values for BC2 at 2 K.
Processing condition:
No. 1: Nb, milling time: 0 h, Uniaxially pressed 20° C. × 10 mins.
No. 2: Nb, milling time: 10 h, Uniaxially pressed 20° C. × 10 mins.
The step of re-compacting the amorphous/nanocrystalline material is achieved by pressing the Nb at room temperature. The produced pressed powder exhibits the physical properties of a significantly increased upper critical field and critical current density. As the process is carried out at room temperature, that is, no special heat treatments are applied, there is no crystallisation involved. However, any form of heat treatment could be additionally applied, which may result in a bulk material being produced that exhibits an even larger increase in BC2 and JC.
Improvements and modifications may be incorporated without departing from the scope of the invention.
| Number | Date | Country | Kind |
|---|---|---|---|
| 0210041.0 | May 2002 | GB | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/GB03/01920 | 5/2/2003 | WO |
