Studies on the Origins and Nature of Critical Current Variations in Rare Earth Barium Copper Oxide Coated Conductors

REBCO (REBa2Cu3O7-δ, RE=rare earth elements) coated conductor (CC) is one of the best candidates for building high-field magnets and it has been improved greatly in recent years. CC overcome the grain boundary problem by using either a rolling assisted biaxially textured substrate (RABiTS) or ion beam assisted deposition (IBAD) of a template for the REBCO. Artificial pinning centers were also introduced to increase critical current density. Despite all these improvements, one significant residual problem is lengthwise critical current (Ic) variations of the CCs. Characterizations of CCs can not only identify the variations, but also provide insight that can help improve the manufacturing process. This study focuses on cross-sectional and vortex pinning variations in CCs. With the reel-to-reel Ic and magnetization measurement system (YateStar), a systematic study has been carried out for CCs made in the last 5-6 years as this technology has rapidly developed. We found that cross-section variations exist for almost all conductors because of width variations. But this contribution to the total Ic variation is small. Vortex pinning variations are found to be the main reason for Ic variations, especially for conductors from different production runs. Even for conductors from the same run, pinning variations are often present. Microscopy studies show that the density and length of BaZrO3 (BZO) nanorods vary between different conductors even though they have nominally the same specifications. Pinning variations in one single tape are mostly attributed to the size variations of BZO nanorods and the configurations of RE2O3 precipitates. Deconstruction of magnet coils and cables were carried out to understand the reasons for in-service degradation. The prototype coil for the 32 T project was safely quenched more than 100 times but it degraded in 3 spontaneous quenches (conducted in an accelerated fatigue testing campaign at ramp rates much larger than service specification). Its pancake coil deconstruction showed three extremely localized burned regions, whose temperature went to over 800oC based on the appearance of a Cu-Ag eutectic above the damaged REBCO layer. Transverse propagation of the damage was almost as effective as longitudinal propagation. Transmission electron microscope images show that thicker BaZrO3 (BZO) nanorods exist near the centers of damaged zones, compared to longer and thinner BZO nanorods from normal, good regions. Because of the lack of detailed Ic(x) characterizations of the length prior to use, the cause the cause of the coil degradation is not clear. It is possible that local degradation of the vortex pinning initiated the final quenches but another possibility is indicated by deconstruction of a no-insulation coil, which reached 45.5 T in a background field of 31 T. In this case no burn marks were observed but some tapes were heavily deformed on one edge, and some joints delaminated after quenches. Transport measurements show that the deformations correlate to Ic degradations, especially for the outer turns of pancakes. Microstructural studies reveal that the deformed (and cracked) edges are always the one that were slit during manufacturing. It appears that small, pre-existing micro-cracks on slit edges propagate after high-field tests. Study of individual strands of conductor on round core (CORC®) cables demonstrated their steady improvements in the last few years. Overall cable current density, Je, has been greatly improved by replacement of 50 m by 30 m thick substrate in CCs and improved winding procedures cause no damage to the tapes. However, some degradation may appear after cables are bent and tested in high-field (20 T). It is found that inner layers are more vulnerable than outer layers. Winding angles and gaps strongly influence where degradations start. To understand the failure mechanisms and establish the limiting winding conditions for CORC® cables/wires, tapes were wound on different formers at different angles: 23o, 30o, 45o and 60o. For a 2 mm former diameter, the highest winding angle gives the least degradation while the other three are comparable. A major defect type introduced during winding is propagation of pre-existing edge (slitting) cracks, but some delamination under winding stress can also be seen. For the former with 2.54 mm in diameter, no propagations of pre-existing cracks or delaminations were observed after winding. Our studies of CCs made and tested in different ways has shown that further improvement of CC and of CORC® cables/wires can be made and also that some inherent features of the manufacture of CCs exert a strong influence on their service performance.