Processes for producing both the YSZ template film by IBAD and the YBCO superconducting film by PLD at 1 m lengths have achieved I c values of 122 A and J c values of 1 MA/cm 2 . Improvements have been made in all stages of the process. Variations of I c along the length of the 1-m samples stimulated development of a new in-field I c measurement capability. The use of MgO as an IBAD template film has made great progress and can potentially decrease the time to produce the template film by more than an order of magnitude. A combination of electrical and microstructural investigations are being made to understand and improve the properties of the YBCO coated conductors.

Ion-beam assisted deposition was used to fabricate biaxially aligned cubic zirconia on flexible metal substrates. These films were used as templates for heteroepitaxially deposited YBa2Cu3O7-δ (YBCO) films. The quality of the crystalline texture of the template films has a direct influence on the superconducting properties of the final YBCO films. We describe our efforts to fabricate high-quality cubic zirconia templates on short-length substrates processed in stationary mode and meter-long substrates processed in continuous mode. Our best phi scan FWHM values for the films on the meter-long tapes were 12.6 degrees for the template and 6.1 degrees for the overcoated YBCO. This meter-long tape had a self-field, 75 K, superconducting critical current of 122 amps.

The performance and reliability of magnets made from second generation (2G), exfoliated, YBCO conductors are highly improved by use of narrow, stacked, multifilamentary cable instead of a single wide tape. This paper reports on tests of five mini-coils wound from 2.4 mm wide ExoCable™, which is comprised of eight, stacked, exfoliated, YBCO filaments. The filaments are coupled electrically through a re-flow process, which results in enhanced electrical connectivity between the adjacent layers. The coils were tested at 77 K (up to 500 A) in liquid nitrogen and at 22 K (up to 700 A) in a conduction-cooled mode. The cable carries 500 A critical current at 77 K. A six-layer coil wound from 10.5 m of the cable, the largest coil created in the study, demonstrates a critical current of 280 A at 77 K at 0.4 T magnetic field on the winding. The coils were fully impregnated with Stycast 1266 and Henkel W19 low-viscosity epoxies. Repeated thermal cycling, to 77 and 22 K, does not degrade the coil’s performance. The cable AC loss and the coil winding magnetization are compared with the traditional 2G wide tape pancake geometry at 77 K. We observe a five times reduction of the winding magnetization when the 12 mm tape is replaced by a 2.4 mm cable, which is explained by the smaller magnetic moment of the cable winding. The field hysteresis profiles recorded at 22 and 77 K are presented to demonstrate the effect of the operation temperature on the winding magnetization. A finite element analysis of the winding magnetization shows a good agreement between the experimentally measured trapped field value, and the critical state model prediction. Finally, we discuss the stability of an ExoCable™ coil in a conduction-cooled operation.