Wire Current Density Research Articles

Thermal Mitigation and Optimization Via Multitier Bond Wire Layout for IGBT Modules Considering Multicellular Electro-Thermal Effect

The stitch wire configuration is widely adopted for large-area IGBT chips. However, an inhomogeneous wire current density introduces uneven self-heating and nonuniform chip heating, which exacerbates the chip thermal stress. In this article, a multicellular electro-thermal model considering the stitch-bonding wires is derived to optimize the wire layout parameters. Furthermore, the current density alleviation of wire bonds is investigated to be the most sensitive and effective method to comprehensively mitigate the thermal nonequilibrium and local overheating. Consequently, an improved multitier layout is proposed to further achieve thermal stress suppression without any additional components and advanced materials. Finally, a triple-tier-bonded IGBT module with optimal design parameters is fabricated to validate the thermal mitigation performance. The prototype experimental results demonstrate that the modeling error is less than 3.0%. The multitier layout decreases the current density by 57.6%, hence, the maximum and average chip temperature are reduced by 21.8% and 12.4%, respectively.

Stable, predictable and training-free operation of superconducting Bi-2212 Rutherford cable racetrack coils at the wire current density of 1000\u2009A/mm2

High-temperature superconductors (HTS) could enable high-field magnets stronger than is possible with Nb-Ti and Nb3Sn, but two challenges have so far been the low engineering critical current density JE, especially in high-current cables, and the danger of quenches. Most HTS magnets made so far have been made out of REBCO coated conductor. Here we demonstrate stable, reliable and training-quench-free performance of Bi-2212 racetrack coils wound with a Rutherford cable fabricated from wires made with a new precursor powder. These round multifilamentary wires exhibited a record JE up to 950 A/mm2 at 30 T at 4.2 K. These coils carried up to 8.6 kA while generating 3.5 T at 4.2 K at a JE of 1020 A/mm2. Different from the unpredictable training performance of Nb-Ti and Nb3Sn magnets, these Bi-2212 magnets showed no training quenches and entered the flux flow state in a stable manner before thermal runaway and quench occurred. Also different from Nb-Ti, Nb3Sn, and REBCO magnets for which localized thermal runaways occur at unpredictable locations, the quenches of Bi-2212 magnets consistently occurred in the high field regions over a long conductor length. These characteristics make quench detection simple, enabling safe protection, and suggest a new paradigm of constructing quench-predictable superconducting magnets from Bi-2212.

High-field quench behavior and dependence of hot spot temperature on quench detection voltage threshold in a Bi2Sr2CaCu2Ox coil

Small insert solenoids have been built using a multifilamentary Ag/Bi2Sr2CaCu2Ox round wire insulated with a mullite sleeve (∼100 μm in thickness) and characterized in background fields to explore the quench behaviors and limits of Bi2Sr2CaCu2Ox superconducting magnets, with an emphasis on assessing the impact of slow normal zone propagation on quench detection. Using heaters of various lengths to initiate a small normal zone, a coil was quenched safely more than 70 times without degradation, with the maximum coil temperature reaching 280 K. Coils withstood a resistive voltage of tens of mV for seconds without quenching, showing the high stability of these coils and suggesting that the quench detection voltage should be greater than 50 mV in order not to falsely trigger protection. The hot spot temperature for the resistive voltage of the normal zone to reach 100 mV increased from ∼40–∼80 K while increasing the operating wire current density Jo from 89 A mm−2 to 354 A mm−2, whereas for the voltage to reach 1 V, it increased from ∼60–∼140 K. This shows the increasing negative impact of slow normal zone propagation on quench detection with increasing Jo and the need to limit the quench detection voltage to <1 V. These measurements, coupled with an analytical quench model, were used to assess the impact of the maximum allowable detection voltage and temperature upon quench detection on the quench protection, assuming a limit of the hot spot temperature to <300 K.

Expansion of the plasma corona from a wire exploded in vacuum

An experiment was performed with the aim to determine the expansion velocity of the corona that is formed around a wire exploded in vacuum. The corona expansion velocity was found for Al and W wires as the wire current density was increased to 1×108–1.4×108 A/cm2. It was estimated by the time at which current started flowing through auxiliary electrodes separated from the wire axis by a certain distance. The measurements were performed with preliminary heated and unheated wires. It has been demonstrated that for unheated wires the expansion velocity of the plasma corona is determined by the expansion velocity of the desorbed gas and approximately equals (7±0.5)×106, (9±0.5)×106, and (1.1±0.6)×107 cm/s at a generator charge voltage of 10, 20, and 30 kV, respectively. For preliminary heated tungsten wires the metal vapor expansion velocity was (4.2±0.5)×106, (7±0.5)×106, and (9±0.6)×106 cm/s at a charge voltage of 10, 20, and 30 kV, respectively.

A Comparison of Two Design Methods for MRI Magnets

Designs of magnetic resonance imaging (MRI) main magnets obtained from both a functional method and a genetic algorithm method have been compared. While most features in the two approaches are similar, there are several important differences. The functional method leads to fewer coil bundles and a reduced total current, i.e., total ampere turns, (e.g., 6-8 MA) that can be as much as 70% of the total current found with the genetic analysis. While the conclusion about stress is that it is a sensitive function of the choice of wire current density, the designs found with the functional method have a larger hoop stress than that of the genetic design, which may require new or refined manufacturing techniques. Furthermore, the functional approach requires much less computing power (i.e., a personal computer is quite sufficient) while the genetic algorithm method in general demands massively parallel computing techniques. However, in order to search for the optimal magnetic resonance design at a given field strength, it is likely that a combination of these two methods will lead to the best results.

Design study of a high‐temperature superconducting transformer

AbstractMany research and development projects on high‐temperature superconducting apparatus such as a transformer, fault current limiter, and cable are being actively pursued in the power field as a result of performance improvement of Bi silver sheath high‐temperature superconducting (HTS) wire. HTS transformers are considered to be among the most promising applications in view of efficiency improvement, the interface with cryogenic cable and normal temperature devices, incombustibility, overload capability, the function as a reactor, and the possibility of use as a fault current limiter. The necessary technical development items of an HTS transformer in order to achieve performance superior to conventional devices are examined. For this purpose, three‐phase 66‐kV 100‐MVA transformers were designed for the comparison of an HTS transformer and a conventional one with oil cooling. The desirable development items are an HTS wire current density of about 40 A/mm2, an allowable winding strain of about 0.5%, a percent impedance of 7.5%, an air gap flux density of about 0.3 T, and AC losses of about 0.3 W/km‐A. © 2002 Wiley Periodicals, Inc. Electr Eng Jpn, 142(1): 25–31, 2003; Published online in Wiley InterScience (www.interscience.wiley.com). DOI 10.1002/eej.10087

Tests of wire chamber ageing with CF/sub 4//isobutane (80.20), argon/ethane (50:50), and argon/ethane/CF/sub 4/ (48:48:4)

In a series of parallel tests the ageing characteristics of CF/sub 4/ isobutane (80:20), argon ethane (50:50), and argon ethane/CF/sub 4/ (48:48:4), have been investigated. Parameters such as flow rate, gas gain, anode wire current density and materials in contact with the gas stream have been varied. Some tests have been extended beyond 8 Coulomb/cm of wire. The Ar/Et chambers have shown a high incidence of pulse height degradation, dark currents, cathode foil etching, and deposits on the electrodes. A strong correlation between anode wire current density and rate of damage (%/C/cm) is indicated for Ar/Et chambers. The CF/sub 4//Iso chambers have shown effectively zero pulse height degradation and few other problems to accumulated charges exceeding 5 C/cm, except for one low-flow chamber with some cathode etching and cathode related pulse height degradation. The addition of 4% CF/sub 4/ to the Ar/Et mixture has dramatically improved the ageing performance of the Ar/Et/CF/sub 4/ cells. >

Optimum designs of circular coil system for generating nonuniform axial magnetic fields

Optimum shapes are derived for coaxial circular coil systems to produce, for a given wire current density, the greatest d(2)B/dx(2) and dB/dx.