Super Conducting REBCO Cable Wrapper
NIU 2026 Senior Design Showcase
Gillen, Kameron [Northern Illinois U.]↗
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Experimental and Computational Studies of Structure-Property Relationships in Flat-flex Cable Adhesives and UV-cured Thiol-ene Resins
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Chemistry↗
Project Title: Demonstration High Temperature Superconducting NonPlanar Stellarator Magnet with Advanced Manufactured Assemblies
This is the final report for the project “Demonstration High Temperature Superconducting Non- Planar Stellarator Magnet with Advanced Manufactured Assemblies”, funded by DOE, and performed by Type One Energy from September, 2020, to March 2024 involving the Fusion Technology Institute at the University of Wisconsin–Madison, the Plasma Science and Fusion Center (PSFC) at the Massachusetts Institute of Technology (MIT) and Commonwealth Fusion Systems (CFS) to design and fabricate the first non-planar HTS (REBCO) coil for a high-field stellarator based on the SPARC tokamak’s VIPER cable concept. Stellarators at high fields make high-temperature superconducting magnets necessary for a compact fusion device. But the asymmetric and non-planar nature of its components, especially the magnets make it difficult for scalable producibility. To address these challenges, two promising technologies have emerged: advanced manufacturing (AM) for the supporting plates for forming the magnets, and high-temperature superconducting (HTS) cables inside the plates. AM has advanced enough to produce stellarator components with the necessary geometric complexity, size, and the precision, leading to potentially significant reductions in production time, cost, and waste. The cost of HTS tape has decreased dramatically, and progress in HTS planar magnet development has reached a point where it can be proposed for application to complex 3D non-planar magnets. The main objective of this project is to develop, demonstrate and pre-commercialize a novel, non-planar HTS coil shape that remains superconducting to achieve production scalable reductions in time and cost and performance. The proposed technology is based on the novel concept of a precision sub-scale HTS nonplanar coil assembly. This project focuses on the design, fabrication, material optimization of cable design, and validation and demonstration of the high current carrying capability of superconducting magnets and their support in a complex 3D shape needed for application to stellarator magnetic plasma confinement. The specific objectives of this research program include: (1) The successful application of metal AM to build a precision sub-scale HTS nonplanar coil, (2) An HTS cable and cross-section design that can conform to the required nonplanar coil shape (bend radii as tight as 10-cm) and remains superconducting at an engineering current density of 1.35 kA/cm 2 at 77 K and 1 tesla at the conductor (5 kA in the cable). To achieve the above challenging goals, we have formed a multidisciplinary research team consisting of members from Type One Energy and UW-Madison, MIT PSFC and CFS with complementary skills and strong facilities. The team worked collaboratively on fundamental and applied research on the following three major technical areas: (1) Design, fabrication, and optimization of non-planar HTS Cable The ultimate goal of the project is to determine if commercial REBCO tapes and additive manufacturing can be used to fabricate high field (≥ 10T) non-planar coils with tight bending radii (≃ 100mm) and with a degradation of the critical current (Ic) smaller than 20% with respect to the expected performance. We started with shorter length cable to evaluate the scalability of the production process and eventually reached multiple turns for higher magnetic fields. Our findings suggest that a stellarator coil system of a relevant size, characterized by its asymmetric and non-planar components, can be fabricated using a formed cable in plate method. This system can be simulated using a large-scale modeling approach. The use of hybrid modeling 3 techniques will be pivotal in reducing the complexity of the model and in assessing expected performance in designs. (2) Modeling and simulation of the non-planar HTS Cable Multiphysics simulations are performed using the commercial software and are carried out in self-field conditions, involving 2D and 3D models and twisted around one slot of twist-pitched VIPER cable. Multiphysics simulations are mainly focused on the coil for the critical current evaluation, the magnetic field map, self-Lorentz forces and mechanical, and magnetothermal behavior and the quench dynamics. The detailed model and prediction of the superconducting performance of a stellarator-relevant demonstration cable from numerical simulations supports the results from the actual testing backing the results. A detailed description and results are provided in the later sections. (3) Design, fabrication, and optimization of support for the non-planar HTS Cable The team developed an additive manufactured (AM) coil positioning plate that formed into the required non-planar geometry (with bend radii as tight as 10-cm) and to acceptable tolerances required for a stellarator magnet: (+0.25-mm from ideal on dimensions of coil positioning plates and up to +1-mm from ideal for position of wound coil). The plate materials is also included in this selection process from fabrication and 3D printing perspective and commensurate with eventual application to a fusion reactor. From the cost effectiveness point of view, the HTS coil and plate has the potential to cost less than that made in conventional methods with less waste (<75% waste) reducing time (<50%) and cost (<50%), especially as the AM field matures. The application of advanced manufacturing in the construction of the support plates will also lead to cost reduction, as the cables can be easily replaced, thereby making the assembly modular. With such high primary cost and time savings, high current densities and magnetic field, the funded R&D work has validated the designs, proven the feasibility, and characterized the performance of the HTS coil and plate assembly, paving the way for a relevant-size stellarator coil system.
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
Distributed Acoustic Sensing for Whale Vocalization Monitoring: A Vertical Deployment Field Test
Abstract There is growing interest in floating offshore wind turbine (FOWT) technology, where turbines are installed on floating structures anchored to the seabed, allowing wind energy development in areas unsuitable for traditional fixed-platform turbines. Responsible development requires monitoring the impact of FOWTs on marine wildlife, such as whales, throughout the operational lifecycle of the turbines. Distributed acoustic sensing (DAS)—a technology that transforms fiber-optic cables into vibration sensor arrays—has been demonstrated for acoustic monitoring of whales using seafloor telecommunications cables. However, no studies have yet evaluated DAS performance in dynamic, engineered environments, such as floating platforms or moving vessels with complex, dynamic strain loads, despite their relevance to FOWT settings. This study addresses that gap by deploying DAS aboard a boat in Monterey Bay, California, where a fiber-optic cable was lowered using a weighted and suspended mooring line, enabling vertical deployment. Humpback whale vocalizations were captured and identified in the DAS data, noise sources were identified, and DAS data were compared to audio captured by a standalone hydrophone attached to the mooring line and a nearby hydrophone on a cabled observatory. This study is unique in: (1) deploying DAS in a vertical deployment mode, where noise from turbulence, cable vibrations, and other sources posed additional challenges compared to seafloor DAS applications; (2) demonstrating DAS in a dynamic, nonstationary setup, which is uncommon for DAS interrogators typically used in more stable environments; and (3) leveraging looped sections of the cable to reduce the noise floor and mitigate the effects of excessive cable vibrations and strain. This research demonstrates DAS’s ability to capture whale vocalizations in challenging environments, highlighting its potential to enhance underwater acoustic monitoring, particularly in the context of renewable energy development in offshore environments.
Saw, Jaewon↗
Reference floating wind array designs for three representative regions
This work presents the systematic development of three open-source reference floating wind array designs. The designs are tailored to representative site conditions for three regions of the United States: Humboldt Bay off the coast of California, the Gulf of Maine, and the Gulf of America. We adopted existing reference designs for the individual 15 MW turbines, semisubmersible floating platforms, substations, mooring systems, and power cables – integrating and adapting them as needed for each location. We adapted existing dynamic cable designs to use larger conductor sizes to meet the arrays' power transmission requirements, and we set up redundant mooring systems for each substation. The layout of each array is a uniform-grid design optimized to approximately minimize the levelized cost of energy (LCOE) within a square lease area while satisfying spatial constraints. These constraints ensure adequate clearances between adjacent turbines and between underwater components during the layout optimization to prevent clashing and ensure that all components reside within the lease boundaries. Substations are included to allow accounting for intra-array cable costs. They are placed within the uniform grid to maintain the navigability of the arrays. For each feasible layout considered, annual energy production and cable routing costs are calculated and updated in the LCOE objective function. After the optimization, we refined the cable routing with a mix of algorithmic and manual methods to ensure that the cables avoid mooring system components and approach the substation with adequate clearances. We confirmed the suitability of each reference array's layout by comparing the wake losses at each wind heading angle to the wind rose, observing that the optimized layouts largely avoid wake losses in the predominant wind directions. These reference arrays provide open-source baseline designs to enable future research and innovation of floating wind technology at the array scale.
17 WIND ENERGY↗
Return on Investment and Sustainability of HVDC Links: Role of Diagnostics, Condition Monitoring, and Material Innovations
HVDC cable systems are becoming an upscaled technical option, compared to AC, because of various factors, including easier interconnections, lower losses, and longer transmission distances. In addition, renewables providing direct DC energy, electrified transportation, and aerospace where DC can be favored because of higher carried specific power all point in the direction of broad future usage of HV and MV DC links. However, contrary to AC, there is little return from on-field installation as regards long-term cable reliability and aging processes. This gap must be covered by intensive research, and contributing to this research is the purpose of this paper. The focus is on key points for HVDC (and MVDC) cable reliability and sustainability, from design modeling able to account for voltage transients and extrinsic aging (such as that caused by partial discharges) to the impact of aging on insulation conductivity (which rules the electric field distribution, thus aging rate). Also, recyclable and nanostructured materials, as well as health conditions, are considered. It is shown how cable design can account for accelerated aging due to voltage transients, as well as for aging-time dependence of conductivity, and how design can be free of extrinsic aging caused by PDs. Algorithms for health condition evaluations, which have additional value in a relatively new technology such as HVDC polymeric cables, are applied to insulation system aging under partial discharges, showing how they can provide an indication of insulation degradation globally or locally (weak spots) and of possible maintenance times. All of this can effectively contribute to reducing the risk of major cable breakdown and damage under operation, which would significantly affect the return on investment (ROI).
Montanari, Gian Carlo (ORCID:0000000320258693)↗
Study of CORC Conductors With Respect to Individual Tape Properties
CEA has been studying the advantages of a conductor based on an assembly of CORC cables in the high field zone of a hybrid Central Solenoid (CS) magnet for EU-DEMO. To this end, the detailed study of geometrical and electrical parameters of a CORC structure are studied in order to evaluate the cable’s electrical performance as well as to determine a number of important parameters (crossing points, contact surface etc…) as function of the cable structure. The paper first presents these geometrical and performance analyses. It will then try to introduce smeared models in order to reduce the cable’s performance to 1D tape scaling law using effective parameters. That reduction is of importance for use in thermohydraulic models. Finally, the paper will present the case study of a particular CORC conductor that is being procured and is foreseen to be tested in SULTAN in 2025. The paper also will try to give some predictive estimate of the cable performance and identify some of the unknowns related to current redistribution and joint resistance.
CORC↗
The ICARUS light detection system (Fermilab Italian summer student program 2023)
The ICARUS T600 detector is the largest Liquid Argon Time Projection Chamber ever used on a neutrino beam, and it acts as the far detector of the Short Baseline Neutrino program at Fermilab. Its purpose is the study of the possibility of the existence of a fourth sterile neutrino in the O(eV2) mass range that could take part in the neutrino oscillations. The light detection system of the ICARUS detector plays the role of localising in space and time the neutrino interactions taking place inside the detector, collecting the argon scintillation photons generated when an event occurs. This light detection system also has a crucial role in the trigger system and the rejection of the huge amount of background cosmic events, working together with the trigger request signals sent by the beam complex. In August 2023 part of the cables that are used to carry the signals from the photomultipliers to the electronics were replaced with a new model, because a deterioration of the quality of the signal inside the cables had previously been observed. An analysis of the performance of the new cables was carried out, comparing laser run data collected before and after the change of the cable model, and it was proved that the introduction of the new cables lead to a general improvement of the quality of the signals reaching the electronics.
72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
Advanced Diagnosis and Accelerated Testing of Balance of System Components for Utility Scale PV Installations: October 1, 2022-September 30, 2024
A study of the durability of PV Balance of System components was performed. Specifically, wire cable jackets and cable connectors were examined within the direct current (DC) PV Power Transmission Chain (PTC). Degraded and failed samples have been obtained from utility PV installations to provide feedback on the degradation modes and the related damage-enabling considerations in today's PV systems. An industry interface group (including system owners, system inspectors, component manufacturers, and test labs) was used to help identify and obtain field-failed samples, for feedback (including samples and experimental design), and to facilitate the subsequent dissemination of the results of this study. Samples were empirically studied using accelerated stress testing with steady-state conditions (cable jackets) in addition to combined-accelerated stress testing (cable jackets, connectors and uncapped connectors). Steady-state accelerated testing has been performed using at least one applied stressor (e.g. UV light) to aid understanding of jacket durability relative to its application. Component- and material-focused failure analysis was conducted to develop an understanding and advise the PV industry. In-depth characterization will be applied selectively to field- and artificially aged-samples, to gain scientific understanding of the structural, chemical, electrical, mechanical, and thermal properties enabling degradation.
24 POWER TRANSMISSION AND DISTRIBUTION↗
Earthquake detection in a simulated lunar regolith using distributed acoustic sensing
Current models of inner lunar geology have largely been inferred from the seismic experiments and observations performed during the Apollo missions that comprised a relatively small number of seismic instruments. Refining constraints on fundamental lunar relationships such as crust-mantle and mantle-core boundaries in the future will require seismic arrays spanning larger epicentral distances. A promising technology for installing dense seismic arrays with minimal human effort is distributed acoustic sensing (DAS), an approach that allows a single length of fiber optic cable to act as hundreds or thousands of sensors when coupled with a DAS interrogator. While terrestrial uses of DAS technology for seismic monitoring rely on burying the cable to maximize fidelity of seismic signal transmission to the fiber, digging meters of trench to bury optical fiber on lunar or planetary surfaces is logistically infeasible. To evaluate DAS signal attenuation due to surface deployment of cable in lunar regolith, we completed earthquake detection analyses that evaluated the sensitivity of an optic-fiber DAS system to seismic signals at different burial depths. We deployed a single-mode fiber in a 10-m open-bottom wooden box filled with a lunar regolith simulant (LRS) with fiber buried at different depths within the LRS and recorded signals for four regional and local earthquakes. The results were used to identify and evaluate signal attenuation in surface-deployed fiber compared to buried fiber in the LRS. Burial depth responses to active-source signals were also evaluated similar to previous studies characterizing DAS sensitivity of surface-deployed fiber. Atmospheric noise was minimal as the cable was deployed in an indoor environment; however, where observed, atmospheric and anthropogenic noise was filtered out using the same bandpass filtering used to identify earthquake events. We found that signal attenuation of the surface-deployed fiber compared to buried fiber was relatively high in active-source experiments but was not consistently observed in earthquake signals. That burial depth is not highly correlated to attenuation of the observed earthquake signals indicates that in a noise-limited environment, placing DAS-interrogated fiber directly at the regolith surface may be a promising deployment strategy to consider for sensing remote seismic signals during lunar exploration.
58 GEOSCIENCES↗
Effects of Rolling Reduction on Critical Current Density and Microstructure of Bi-2212 Wires
Bi-2212 Rutherford cables have been fabricated into flat racetrack coils and canted-cosine-theta dipole magnets. The performance gap between the magnets made with Rutherford cables and the “short-sample-limit” is about 30%. To better understand the influence of Rutherford cable processing on the strand performance, we studied three Bi-2212 wires with filament architectures of 37 × 18 and 55 × 18 and diameters of 0.8 and 1.0 mm. To simulate the deformation caused by cabling process, the three wires were rolled with thickness reductions ranging from 10% to 30%. The aspect ratios of rolled strands are between 1.29 and 2.05. The low aspect-ratio wire is also an interesting form for fabricating solenoid coils with higher packing density. The round and rolled strands were heat-treated under 50 bar and with maximum heat treatment temperatures of 885.5 °C and 890.5 °C. The rolling deformation reduced filament size uniformity, resulting in filament merging in fully heat-treated wires. It was found that rolling reduction reduced wire critical current density (JE) by 16 to 18%, but the JE decrease saturated at 15 to 20% of the thickness reduction. It is believed that the reduced JE results from the filament merging caused by rolling and non-uniform shrinking during overpressure heat treatment.
Bi-2212 wire↗
A Low Loss, Fast Ramp HTS Solenoid Prototype for Compact Spherical Tokamaks
To explore AC loss characteristics of commercial Bi-2212 conductors made in the USA, a small ohmic heating (OH) prototype coil is being developed for compact tokamaks using high performance Bi-2212 wires newly manufactured by Bruker EST. Here, the goal is to build and test Bi-2212 prototype coils for fast ramp central solenoid (CS) operation of spherical tokamaks (ST). For a ST pilot plant, one of the key challenges is the tight space available for CS in a center column where in-board legs of the toroidal field (TF) and OH coils are assembled into a cryostat with a few millimeters clearance. A high current density Rutherford cable consisting of 17 legacy Bi-2212 wires, a contribution of the US Magnet Development Program (MDP), was fabricated at the Lawrence Berkeley National Laboratory (LBNL) for the development of fast ramp CS magnets in the ST Advanced Reactor (STAR) designed by PPPL. Characterization of the new and legacy HTS wires is presented, along with the coil design wound directly with new wire, and a Rutherford cable-wound solenoid using the legacy wire. A comparison of AC losses is made based on expected performance for a fast ramp ST operation. The HTS cable and cabled coil fabrication issues such as the heat treatment, coil mandrel design, assembly and 2212 quench characteristics are discussed, along with a test plan for CS design validation.
Zhai, Yuhu [Princeton Plasma Physics Laboratory (P↗
Assessing the Expansion of Ground-Motion Sensing Capability in Smart Cities via Internet Fiber-Optic Infrastructure
Monitoring ground motion in smart cities can improve the public safety by providing critical insights on natural and anthropogenic hazards, for example, earthquakes, landslides, explosions, infrastructure failures, and so forth. Although seismic activity is typically measured using dedicated point sensors (e.g., geophones and accelerometers), techniques such as distributed acoustic sensing have demonstrated the utility of using fiber-optic cable to detect seismic activity over comparable distances. In this article, we present the results of a study that quantifies the expansion in an area monitored for low-amplitude ground-motion events by augmenting existing point sensors with the internet fiber-optic cable infrastructure. Here we begin by describing our methodology, which utilizes geospatial data on point sensors and internet optical fiber deployed in metropolitan statistical areas (MSAs) in the United States. We extend these data to identify the area that can be monitored by (1) considering the observed seismic noise data in target locations, (2) applying the model from Wilson et al. (2021) to understand the potential coverage area gains using optical fiber sensing, and (3) optimizing the selection of fiber segments to maximize coverage and minimize deployment costs. We implement our methodology in ArcGIS to assess the additional area that can be monitored for low-amplitude ground-motion events (i.e., magnitude >0.5) by utilizing internet fiber-optic cables in the 100 most populous MSAs in the United States. We find that the addition of internet fiber-based sensors in MSAs would increase the area monitored on average by over an order of magnitude from 1% to 12%, if the subset of fiber cable segments that maximize coverage and minimize deployment costs is chosen even if only 20% of all fibers are used.
58 GEOSCIENCES↗
Magnetic self-mating fiber optic connector and fiber optic switch sensor
A system or method for a magnetic self-aligning coupling device for a fiber optic cable. The device includes a first end coupling comprising a first magnet and a second magnet. Both magnets include a mating surface and an annular ring defining an axial aperture. The aperture receives a distal end of a segment of fiber optic cable in a tight fit. The fiber optic cable has an exterior sleeve and a fiber core. The fiber core of the first segment and the second segment of the fiber optic cable are axially aligned by magnetic force in the first and second apertures to create a continuous fiber optic path. A method for detecting a security breach of a door using the self-aligning couplings is also described.
Neidigk, Stephen↗
Competing conduction mechanisms in high performance carbon nanotube fibers
The performance of carbon nanotube (CNT) cables, a contender for copper-wire replacement, is tied to its metallic and semi-conducting-like conductivity responses with temperature; the origin of the semi-conducting-like response however is an underappreciated incongruity in literature. With controlled aspect-ratio and doping-degree, over 61 unique cryogenic experiments including anisotropy and Hall measurements, CNT cable performance is explored at extreme temperatures (65 mK) and magnetic-fields (60 T). A semi-conducting-like conductivity response with temperature becomes temperature-independent approaching absolute-zero, uniquely demonstrating for the first time the necessity of heterogeneous fluctuation induced tunneling; complete de-doping leads to localized hopping, contrasting graphite's pure metallic-like response. High-field magneto-resistance (including novel +22 % longitudinal magneto-resistance near room-temperature) is analyzed with hopping and classical two-band models, both yielding a similar parameter useful for conductor development. Varying field-orientation angle uncovers significant two- and four-fold symmetries that are shown to be from Aharonov-Bohm-like corrections to the curvature-induced bandgap, a first for macroscale CNT fibers. Tight-binding calculations using Green's Function formalism model the largest, coherent transport to-date in commensurate CNT bundles in magnetic-field, revealing non-uniform transmission across bundle cross-sections with doping restoring uniformity; independent of doping, transport in bundle-junction-bundle systems are predominantly from CNTs adjacent to the other bundle—demonstrating that smaller bundles are more efficient for electronic transport. The final impact is predicting the ultimate conductivity of heterogeneous CNT cables using temperature and field-dependent transport, surpassing conductivity of traditional metals.
36 MATERIALS SCIENCE↗
Neural Network‐Based Methods for Ocean Surface Wave Measurement Using Submarine Distributed Acoustic Sensing (DAS)
Two new data-driven models for estimating ocean surface waves from distributed acoustic sensing (DAS) submarine cable strain rate are developed using supervised machine learning on a 10-day data set collected offshore of Oliktok Point, Alaska. The new models were trained on target data from seafloor pressure moorings at three sites spaced evenly along 27.1 km of cable and were benchmarked against an empirical transfer function method previously used to estimate waves from DAS. A model which uses convolutional neural networks to transform 2-km frequency-wavenumber strain spectra to seafloor pressure spectra outperforms the benchmark in wave height prediction (RMSE of 0.15 vs. 0.41 m) and period prediction (0.29 vs. 0.37 s) when evaluated on a held-out test data set. When applied to a DAS data set collected on the same cable 2 years prior, the CNN-based model maintained similar significant wave height performance (RMSE = 0.23 m) relative to available satellite altimetry data. A two-hidden-layer, fully connected neural network which transforms 1-D strain spectra to seafloor pressure spectra also outperforms the benchmark in wave height prediction (RMSE of 0.19 vs. 0.41 m), but does not generalize as well to the prior data. Regression-based machine learning is useful for estimating waves from DAS data when the pressure-strain relationship varies temporally and spatially across different wave conditions. Models can be applied to DAS data to measure waves with higher spatial resolution and longer temporal coverage than traditional methods, which often measure waves only at a single point.
Davis, Jacob R. [Univ. of Washington, Seattle, WA ↗
An SF 6 gas-insulated −500 kV DC conical insulator vacuum feedthrough
A test electrode was biased to −500 kV direct current (DC) by means of a novel SF 6 gas-insulated conical alumina insulator feedthrough. The design enables the extreme high vacuum conditions required by spin-polarized electron sources by reducing the photogun vacuum chamber volume compared to coaxial cylindrical insulators. In contrast to conventional inverted-insulator photogun designs that rely on solid dielectric interfaces for high-voltage terminations, the present design employs a pressurized SF 6 intervening volume between a conical alumina insulator and a modified commercial epoxy high-voltage cable receptacle. Here, this approach enables the use of commercially available cable hardware while extending the demonstrated operating voltage of solid feedthroughs. A maximum voltage of −500 kV was applied to a test electrode attached to the narrow end of the feedthrough inside a chamber filled with SF 6 at 170.3 kPa (10 psig) and later under vacuum to −259 kV, limited by field emission. The results demonstrate that a commercial high-voltage cable combined with a custom-designed SF 6 gas-insulated vacuum feedthrough can be used to bias photogun electrodes to −500 kV DC.
Palacios-Serrano, Gabriel [Thomas Jefferson Nation↗
Proposal for superconducting quantum networks using multioctave transduction to lower frequencies
We propose networking superconducting quantum circuits by transducing their excitations (typically 4–8 GHz) to 200–500 MHz photons for transmission via superconducting cryogenic coaxial cables. This frequency down-conversion reduces transmission losses and, counterintuitively, reduces noise. We introduce a multioctave asymmetrically threaded superconducting quantum interference device circuit capable of the required efficient, high-rate transduction. For a 100-meter cable with 𝑄 𝑖 = 10 5 at 10 mK, we theoretically show that our approach achieves single-photon fidelities of 0.962 at 200 MHz versus 0.772 at 8 GHz, and triples the lower bound on quantum channel capacity. In conclusion, this method enables highly efficient networking of superconducting qubits while maintaining high fidelities, combining improved performance with the practical advantages of flexible, compact coaxial cables.
75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗