Wire Cross Section Research Articles

REBCO tapes for applications in ultra-high fields: critical current surface and scaling relations

Abstract REBa2Cu3O7−x (REBCO) tapes produced by leading manufacturers were tested at UNIGE to characterize the dependence of the critical current on temperature, field intensity and orientation. This measurement campaign was carried out in the frame of international collaborations having the common goal of developing technology for ultra-high field magnets in the 30–50 T range. The examined samples differ in many respects, e.g. processing methods, thickness of the superconducting layer, Rare Earth element in REBCO, and type of artificial pinning centers (3D nanoparticles vs extended 1D nanorods). We measured the transport critical current of full-width tapes at 4.2 K and 20 K in magnetic fields up to 19 T and at various orientations of the field with respect to the tape surface. Additionally, magnetic characterization was conducted over a wider temperature range (4.2–77 K). The highly engineered vortex pinning results in outstanding critical current performance for all examined tapes: the non-copper critical current density, i.e. the critical current divided by the wire cross-section area minus the Cu area, ranges between 1500 and 2000 A mm−2 at 4.2 K, 19 T and close to 1000 A mm−2 at 20 K, 19 T in the perpendicular field orientation. We obtained scaling expressions for the critical current surface based on the analysis of the pinning-force curves but the pinning-force shape parameters were found to vary from one manufacturer to another. The results presented in this work may offer valuable information not only to magnet designers but also to manufacturers looking to optimize their tapes and achieve better performance.

Methodology for selecting optimal wire grade and cross-section based on an integrated technical and economic criterion

The aim was to develop a methodology for selecting an optimal wire grade and cross-section for overhead power lines with a voltage of above 1 kV under intensive development of power grid systems. This aim was solved using the authors’ previously developed methods: selection of an optimal wire grade based on hierarchy analysis and selection of an optimal wire cross-section by optimizing the specific discounted costs during the entire period of construction and operation of overhead power lines. In the present study, these methods are integrated into a single methodology. It is proposed to implement wire inspections prior to the stage of technical and economic calculations, since the necessary data has already been taken into account during the selection of a wire grade and its cross-section. The proposed methodology was tested on a typical example of reconstruction of the Zapadnaya– Davydovka 110 kV overhead line, which creates limitations in the power supply of Primorsky Krai due to insufficient wire capacity and its operation beyond the normative period. SENILEK AT3/C 150/24 wire was selected as a solution for the example under consideration. The application of this wire grade allows not only the overhead line capacity to be increased by 151% without replacing the existing supports, but also active and reactive power losses in the electric network to be reduced by 18.9 and 2.5%, respectively. The proposed methodology enables selection of an optimal grade and cross-section of any wire design, taking the dynamically changing operational conditions of power grid systems into account. The solutions found by the proposed methodology may contribute to a more efficient operation of power lines due to increasing their transmission capacity, reducing the number of used supports, replacing the line wire without replacing supports, decreasing ice formation on wires, and reducing power losses.

Tensile capacity degradation of randomly corroded strands based on a refined numerical model

In this study, we develop a sophisticated numerical model to analyze the axial tension behavior of seven-wire steel strands subjected to corrosion by employing the ANSYS finite element software. The axial tensile performance of steel strands subjected to random corrosion is examined, and the model's accuracy is validated by comparing it with experimental results. The corrosion degree in the steel strands is quantified by the mass loss rate χ, which denotes the ratio of the mass lost due to corrosion to the total mass. The reduction factor θ is employed to characterize the diminished axial tensile performance of the steel strands following corrosion. Two corrosion modes under random corrosion in steel strands were proposed, with lower bound formulas for the θ-χ distribution derived for each. In Mode I, the largest corrosion depth is prespecified. Mode II is characterized by destructive cross-sectional corrosion. As the corrosion intensifies, the corrosion pits can expand indefinitely across the wire's cross-section, potentially leading to significant loss or complete corrosion of a section of the steel strand. The finite element analysis indicates that the wire diameter and the corrosion pit depth affect θ-χ. The element size, steel strand length, and lay length have minimal impact.

Controllable phase transition process of polycrystalline diamond surface for low friction via suppressing oxygen involved tribochemical reactions

The diamond inner wall of drawing die is crucial for the precise formation of ultra-fine wires during the drawing process. Unexpectedly, when drawing soft metal wire, a significant wear occurs on hard-phase diamond surface, resulting in increased friction at the drawing interface, which leads to the wire cross-section distortion, uneven wire diameter, surface scratches and burrs. In this study, the interface interaction and friction products between diamond and iron were investigated, focusing on the primary factors influencing diamond phase transitions by adjusting friction atmosphere. Whether in air or nitrogen, the friction coefficient (CoF) decreases with the increase of load, but CoF value is relatively lower in nitrogen environment. The friction curve of diamond against iron stabilized after an initial downward trend, reaching a minimum CoF of 0.08 in nitrogen under a load of 15 N. The friction mechanism is explained through material transfer, friction products, phase transition, tribolayer formation, and interfaces interactions. It is speculated that in nitrogen, even if a small amount of oxide forms on iron surface, iron remains in contact with diamond, generating a large amount of iron carbide and inducing the graphitization of diamond, which would act as a lubricating role. In contrast, in air, oxygen atoms continuously interact with iron, forming a dense oxide film at the friction interface, which prevents carbon from continuous contacting iron atoms and limits the formation of iron carbide. Overall, the discovery provides new insights into the interaction between metals and diamonds, and offers theoretical guidance for the drawing of iron wires.

Unveiling the mechanisms behind texture formation and its impact on the torsional performance of cold-drawn pearlitic steel wires

High carbon pearlitic steel wires are widely used in the industry, such as for producing tyre cords and steel cables due to its excellent mechanical properties. Cold drawing is a crucial step in steel wire production. Due to the loading state during the cold drawing process, pearlitic wires tend to exhibit a <110> fiber texture. The non-uniform texture distribution on the cross-section of steel wires has been observed experimentally. The mechanisms yielding this non-uniformly distributed texture are carefully investigated in this study using a multi-scale computational approach. Firstly, a macroscale finite element model is established to simulate the deformation behaviour of pearlitic steel wires during cold drawing, with the aim of thoroughly investigating the inhomogeneous elastic-plastic deformation behaviours. Secondly, the macro mechanical responses are incorporated into the mesoscale representative volume element model as boundary conditions to comprehensively study the effect of inhomogeneous deformation characteristics on texture formation. The results present a significant advancement by revealing that the non-uniform texture distribution in a steel wire can primarily be attributed to the multiaxial stress state on the cross-section. Notably, at the center of the steel wire, the maximum principal stress aligns with the drawing axis, resulting in a dominant <110> fiber texture. Conversely, at the subsurface, the maximum principal stress progressively shifts towards the circumferential direction, yielding an evolving texture characterized by a {110}<110> circumferential texture. Furthermore, the research uncovers a crucial finding that it is the {110}<110> circumferential texture that significantly weakens the torsion ability of the wires. This is due to the limited activation of slip systems, marking a key advancement in understanding the mechanical properties of steel wires.

Enhancing non-metallic gasket performance with shape memory fibers

This study aims to enhance the sealing performance of non-metallic gaskets by incorporating shape memory fibers. The analytical exploration focuses on analyzing the thermomechanical behavior of Nitinol fibers in their woven state within the gasket. Specifically, the investigation examines the variation of phase transformation zones across the wire cross-section with changes in temperature. Subsequently, a series of SMA fiber-reinforced gasket samples were fabricated, and experimental investigations were conducted to assess the impact of Nitinol fibers on composite gaskets using a helium gas leak test. The results demonstrate that the integration of shape memory alloy wires into the composition of gaskets can significantly improve their sealing performance. Moreover, this study examines a number of pivotal factors such as fiber volume fraction, temperature application, woven fiber arrangement, leakage rates, gasket deformation, contact stress, and structural bending. These comprehensive investigations may provide valuable insights into the efficacy of Nitinol fibers in enhancing gasket sealing performance.

Electrical transport characteristics of atomic contact and nanogap dynamically formed by electromigration

The feature size of circuits was gradually reduced to a few nanometers, which is prone to lead to the failure of the metal circuit even upon a low bias voltage due to the electromigration. Therefore, it is essential to understand the electrical transport characteristics of a narrow metal wire shrunk to atomic scale due to electromigration. To this end, we report that the approach for metal deposition and the underneath substrate play a critical role in determining the electron transport behavior. It is observed that the conductance of the narrow metal wire fabricated on a SiO2 substrate first rises and then decreases during the electromigration process when the cross section of the metal wire is reduced to a few atoms. However, such a phenomenon is not observed for the metal wire fabricated on a polyimide substrate. Assisted by component analysis technology, it is revealed that the metal atoms can penetrate into the underneath substrate during the metal deposition process, and the metal atoms buried in the different substrates result in distinguished conductance behavior.

Failure analysis of strain clamps on a ± 800 kV transmission line

During X-ray testing of a ± 800 kV ultra-high voltage direct current transmission line tension clamp, it was found that the internal steel core had broken. To investigate the cause of the steel core fracture, the failed clamp was dissected and analyzed, including chemical material testing, mechanical performance testing, fracture morphology inspection, and analysis of the compression process of the tension clamp. A preliminary judgment was proposed on the cause of the internal steel core fracture of the tension clamp, And verification experiments and simulation analysis were conducted to preliminarily determine the cause of the steel core fracture, and it was ultimately concluded that the main reason for the steel core fracture was the incorrect compression sequence of the large cross-section wire tension clamp.

ENSURING THE THREAD CAPACITY OF ELECTRICAL TRANSMISSION LINES UNDER THE CONDITIONS OF THEIR RESERVATION

A method of increasing the power transmission capacity in the post-emergency mode is considered, when a redundant line is connected to one of the working power transmission lines (LEP) with a voltage of 10 kV using the point of automatic switching on of the reserve (AVR). The effectiveness of such redundancy in most cases turns out to be low due to the limited capacity of trunk sections of mutually reserved lines with smaller cross-sections of wires at the end sections of these lines, which were built as radial lines. This leads to increased losses of active power and voltage, and, as a result, unacceptable deviation of voltage in remote load nodes of the redundant power transmission line. In order to improve the parameters of the operation mode of power transmission, it is proposed to use devices of longitudinal capacitive compensation and reactive power compensation in the scheme of the AVR point. An assessment of the effectiveness of the proposed measure was made.

Effective Computational Model for Determining the Geometry of the Transition Zone of End Coils of Machined Springs, Enabling Efficient Use of the Spring Material.

This paper presents an analysis of the effect of the geometry of the end-coil transition zone on the material stress state of a machined compression spring with a rectangular wire cross-section. The literature relationships for determining the stresses in rectangular wire compression springs neglect the effects associated with the geometry of this zone. A series of non-linear numerical analyses were carried out for models of machined compression springs with a wide range of variation in geometrical parameters. The results of these analyses were used to develop a computational model to estimate the minimum value of the rounding radius ρmin, which ensures that the stresses in this zone are reduced to the level of the maximum coil stresses. The model is simple to apply, and allows the radius ρmin to be estimated for springs with a spring index between 2.5 and 10, a helix angle between 1° and 15°, and a proportion of the sides of the wire section between 0.4 and 5.

Morphological Evolution of Single-Core Multi-Strand Wires during Ultrasonic Metal Welding

Ultrasonic metal welding (USMW) finds widespread utilization in automotive industries, where it is used for connecting the wire harness of the vehicle, consisting of stranded wires, to the terminals. However, the behavior of the strands during the compaction process is still understudied and often overlooked. Therefore, this work focuses on the investigation of the wire compaction behavior from a morphological point of view. A newly developed method for investigating cross-sections of such joints is introduced, facilitating area quantification of the strands for a microscale examination of compaction variations for every single strand as a function of welding time. It is shown that the deformation in the wire is not homogenous throughout the wire cross-section; instead, the formation of distinct zones is observed. Three distinct regimes dominating the welding process were observed: (i) linear reduction in nugget height with primary compaction of the nugget and sealing of the interstitial spaces between the strands for weld times from 0 s up to 1.3 s; (ii) accelerated loss of nugget height due to strong plastic deformation of the strands for weld times between 1.3 s and 1.7 s; and (iii) comprehensive welding of the individual strands and strong loss of nugget height. Furthermore, it was demonstrated that the deformation of the wire during the USMW process originates in the coupling area of the horn and the wire and not in the interface of the wire and the terminal. Therefore, it can be assumed that the temperature of the interface between the horn and the wire must be significantly higher than that of the interface between the wire and the terminal. The presented approach and new insights into the behavior of ultrasonically welded joints of stranded wires and terminals provide guidance for improving the welding process.

Fatigue of Bridge Steel Wire: A Corrosion Pit Evolution Model under the Effects of Wind and Vehicles

To investigate the damage evolution behavior of corroded steel wires under the influence of alternating loads, a damage evolution model for steel wires based on the theory of continuous damage mechanics was established. The damage evolution process at corrosion pits was simulated by using the element birth and death technique in ANSYS 2020R2. Then, a certain cable-stayed bridge was chosen as the research subject, the stress–time data of the sling were computed using a traffic–bridge–wind simulation analysis model, and the influence of corrosion pit distribution on the mechanical properties and fatigue life of wires under an alternating load was discussed. The results show that, in comparison to single-pitted steel wires, double-pits distributed circumferentially across the cross-section of the steel wires lead to more severe stress concentration, accelerating the damage evolution process and significantly reducing the fatigue life of the steel wires. Conversely, the stress concentration caused by double pits distributed along the longitudinal direction of steel wire is similar to that caused by single pits, and it will be even weaker than that caused by single pits with the change in the relative distance of the double pits. Based on the calculation results of the damage evolution model of steel wire, it was found that the corrosion pit crack nucleation life of steel wire under alternating load accounts for nearly 80% of the fatigue life of steel wire, and different corrosion pit distribution modes will significantly affect the fatigue life of steel wire.

New generation B-Field and RAD-tolerant DC/DC power converter for on-detector operation

The increase in the number of readout channels in new detectors, like the Micro Pattern Gas Detectors (MPGD), in the order of several millions, requires a large amount of electrical power to supply the front-end electronics, up to hundreds kW. If this power is generated at long distances from the detector, the voltage drop on the connection cables puts serious constraints to the supply current, to the wire cross-section and to the power distribution. A large amount of voltage drop on the cables, apart an increased power dissipation on wire resistance, determines regulation issues on the load in case of current transients. To mitigate these problems, a new generation DC/DC converter, working in a heavily hostile environment and with a power density greater than 200 W/dm3, was developed. It is modular, with up to four independent modules, eight channels each, collected in a water-cooled crate, and can supply the load with an adjustable 10 to 12 V output up to 170 W per channel. In this contribution, the design constraints of such a converter are analysed, taking as a basis the environmental, electrical and mechanical requirements of the ATLAS New Small Wheel (NSW) project. Thermal considerations require the converter to be water-cooled, and the dimensional constraints impose the adoption of an innovative design to convey the dissipated heat towards the heat exchanger. The control and monitoring system allows for the full remote management of the converter. Main electrical parameters were measured and are reported. The converter was also characterized in a harsh working environment, with radiation tests in the CERN CHARM facility beyond the limits estimated for ten years operation in ATLAS, and with magnetic field tests in various orientations, using different magnets at CERN up to 1.3 T. A better common mode noise filtering design improvement was implemented after the first characterization. Final performance measurements after the modifications are also reported.

Atomistic modeling of electromechanical properties of piezoelectric zinc oxide nanowires

Currently, numerous articles are devoted to examining the influence of geometry and charge distribution on the mechanical properties and structural stability of piezoelectric nanowires (NWs). The varied modeling techniques adopted in earlier molecular dynamics (MD) works dictated the outcome of the different efforts. In this article, comprehensive MD studies are conducted to determine the influence of varied interatomic potentials (partially charged rigid ion model, [PCRIM] ReaxFF, charged optimized many-body [COMB], and Buckingham), geometrical parameters (cross-section geometry, wire diameter, and length), and charge distribution (uniform full charges versus partially charged surface atoms) on the resulting mechanical properties and structural stability of zinc oxide (ZnO) NWs. Our optimized parameters for the Buckingham interatomic potential are in good agreement with the existing experimental results. Furthermore, we found that the incorrect selection of interatomic potentials could lead to excessive overestimate (61%) of the elastic modulus of the NW. While NW length was found to dictate the strain distribution along the wire, impacting its predicted properties, the cross-section shape did not play a major role. Assigning uniform charges for both the core and surface atoms of ZnO NWs leads to a drastic decrease in fracture properties.

Design of Pulse Spiral Inductor Wound by Rectangular Cross-section Wire

Design of Pulse Spiral Inductor Wound by Rectangular Cross-section Wire

Performance evaluation of a novel monofilar helical antenna with tapered cross-section wire fabricated via metal additive manufacturing

This paper presents a novel formulation for a generalized helical antenna that incorporates non-uniform helix diameters, non-uniform helix spacing, and non-uniform wire cross-section, providing additional degrees of freedom for optimization. By carefully defining the transition between the helix and the center feed point, a thicker wire was used at the base to enhance the antenna’s operating bandwidth capability and mechanical strength, eliminating the need for additional support structures. The fabrication process utilized metal additive manufacturing (MAM) with Maraging steel. The results demonstrate that the helical antenna with a tapered cross-section wire (with a thicker base and a thinner tip) exhibits significantly better performance compared to the control models for operation in the X-band. This design amalgamates impedance matching from antennas with uniform thick wires and radiation characteristics from antennas with uniform thin wires. The major contribution of this work is the demonstration that employing tapered wire cross-sections can enhance helical antenna performance, thereby introducing a new design parameter in metal additive manufacturing. Specifically, we present an eight-turn helical antenna that achieved a measured reflection coefficient less than −10 dB and axial ratio less than 1 dB over the X band, with a peak realized gain in RHCP of 10.8 dBic.

Peculiarities of Electron Transport through the Contact Regions between Semiconductor Quantum Wires with Different Cross Sections

In present work peculiarities of electron transport with transition from quantum wires with smaller cross sections to quantum wires with larger cross sections are studied. Electron transition probabilities through corresponding contact regions of such quantum wires are calculated as functions of charge carrier kinetic energy and quantum wire cross sections ratio. Peculiarities of electron pass through the defects in quantum wires in the form of rectangular grooves and steps are also studied. Electron transition probabilities through the defect regions are calculated as functions of electron kinetic energy and geometry and size of the defects. Probability density distributions of electron detection in different regions of simulated structures have been calculated.

A Safety Device Based on a High Temperature Shape Memory Alloy

A device has been developed based on alloys with a high-temperature shape memory effect. It aims to be used in mechanical engineering products, in particular, nuclear technology, in order to prevent emergency situations of man-made and natural nature. The device works by breaking the electrical circuit in the event of an emergency increase in the ambient temperature above the permissible temperature by cutting the electrical cable. The shape restoration properties of thermosensitive working elements made of the Ni49.5Ti48.0Hf2.5 alloy with high temperature shape memory have been studied. The results of the experiments allow us to conclude that it is possible to use the device in electrical systems for cutting heat-resistant electrical cables with an outer diameter of dout = 3.4–5.0 mm and a copper wire cross-section of 0.2–1.5 mm2 with a knife in an emergency situation, when the ambient temperature exceeds 100°С and the maximum heating reaches 200°С.

Magnetoimpedance effect in NiFeP thin films deposited on Cu microwire through electrodeposition

Thin coatings of the Nickel–Iron–Phosphorous (NiFeP) alloy is electrodeposited onto copper microwire while varying phosphorus ion concentration in the bath. With increasing phosphorus ion concentration in the deposition bath up to 1 mM, reduced surface roughness, crystallite size and coercivity is witnessed which reflects in enhanced magnetoimpedance (MI) ratio of the plated wires. Maximum MI ratio of 378% and sensitivity of 25 %/Oe is observed at 100 kHz driving frequency for film deposited using 1 mM of P ion in the electrodeposition bath. This enhancement is associated with the reduction of crystallite size and magnetocrystalline anisotropy due to leading formation of amorphous deposits with the optimized incorporation of P atoms coupled with reduction of surface roughness. Additionally, the experimental results of MI measurements are compared with a analytical model and the model parameters related to the circumferential permeability of the NiFeP magnetic film is extracted from it. These parameters are further used to calculate the circumferential permeability of the samples, which is then mapped to a color-coded visualization of current density variation across the wire cross-section, providing a detailed insight into the impedance change.

Fabrication of a gradient AZ91-bioactive glass composite with good biodegradability

This study used friction stir-back extrusion to fabricate the AZ91 + 3 wt% bioactive glass gradient composite wire. The microstructure, mechanical properties, and corrosion resistance of a material in a simulated body fluid were investigated. Three 2-mm diameter holes with varying hole patterns were drilled in the cross-section of the AZ91 rod to apply 3 wt % bioactive glass to the AZ91 matrix. The results demonstrated that the hole pattern strongly influenced the material's flow in the extruded wire's cross-section. By increasing the distance between the center of the initial rod and the center of the holes, a higher temperature and more uniform distribution of plastic strain are formed during friction stir back extrusion, resulting in uniform distribution of bioactive glass particles and α + β eutectic structure near the surface of composite wires. Introducing bioactive glass particles into the zone near the surface of the AZ91 rod results in the formation of a uniform distribution of bioactive glass particles near the surface and their absence in the central zone of the composite wire. A higher amount of discontinuous β-Mg17Al12 phase and α + β eutectic formed at the grain boundaries by increasing the temperature and plastic strain during friction stir-back extrusion. The crystallographic texture of the AZ91 rod changed from prismatic to basal and pyramidal due to the friction stir-back extrusion method. A gradient AZ91-bioactive glass composite wire with ultimate tensile strength, yield strength, elongation, and corrosion resistance 58, 64, 62, and 34%, respectively, greater than AZ91 as-cat rod can be produced by inserting bioactive glass powder using a hole drilling method and applying a friction stir back extrusion process.