Experimental study of two-phase cryogenic cooling of aluminum stator conductors using a single slot test configuration

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An important goal to enable widespread adoption of electric aircraft propulsion is to develop higher power density motors and generators which are at the same time highly efficient. One way to do this is to use conductors that can carry higher currents and/or generate lower losses. One approach to this is the use of superconducting windings. However, here we focus on very low resistance normal state conductors operating at cryogenic temperatures. The resistivity of both aluminum and copper drops quickly with decreasing temperature, such that the resistivity of Cu drops by about a factor of 7, and that of aluminum by 10, by the time we reach 77 K (LN2). OSU and Hyper Tech have teamed to develop a motor with liquid cryogen cooled aluminum windings (LN2 or LNG cooled). It includes a multi-slot stator with direct cryogen cooling. Here we present the results of a simple “single slot” test which explores the temperature rise of a pair of conductors in a slot directly cooled by LN2. These two aluminum bars are made of 1100 commercial purity Al alloy were placed in parallel with a 1.6 mm gap, which behaved as 120 mm long cryogenic flow channel. Current densities up to 75 A/mm2 were explored, with LN2 flow rates ranging from 1.9 g/s to 6.4 g/s. Thermocouples and voltage taps were used to capture temperature and voltage data during the experiment. As a result, we found stable cooling and operation at these flow rates and current densities, and we characterized the temperature gradient which developed along the conductor bars.