1. Presented at: Radiation-Hard Insulation Workshop Fermi National Accelerator Laboratory April 2006 Radiation-Resistant Insulation For High-Field Magnet Applications Presented by: Matthew W. Hooker 2600 Campus Drive, Suite D Lafayette, Colorado 80026 Phone: 303-664-0394 www.CTD-materials.com NOTICE These SBIR data are furnished with SBIR rights under Grant numbers DE-FG02-05ER84351 and DE-FG02-06ER84456. For a period of 4 years after acceptance of all items to be delivered under this grant, the Government agrees to use these data for Government purposes only, and they shall not be disclosed outside the Government (including disclosure for procurement purposes) during such period without permission of the grantee, except that, subject to the foregoing use and disclosure prohibitions, such data may be disclosed for use by support contractors. After the aforesaid 4-year period the Government has a royalty-free license to use, and to authorize others to use on its behalf, these data for Government purposes, but is relieved of all disclosure prohibitions and assumes no liability for unauthorized use of these data by third parties. This Notice shall be affixed to any reproductions of these data in whole or in part.

2. Radiation-Resistant Insulation for High-Field Magnets 2 “Engineered Material Solutions” CTD is a unique company where the development of original materials is fused with incisive engineering to provide innovative solutions for our customers’ technology and system needs. Electrical and Thermal Insulation For CTD, development of new materials is an engineering tool Elastic Memory Composites Composite Pressure Vessels & Tanks

3. Radiation-Resistant Insulation for High-Field Magnets 3 Insulation Development Goals Mission  Improve system-level performance  Reduce cost  Improve reliability  Reduce manufacturing risk Insulation Processes  Vacuum pressure impregnation (VPI)  Wet-winding  Prepreg  High pressure laminates (HPL) Applications  Fusion energy  High-energy physics  Motors, generators, and transformers  MRI, NMR  Cryogenic adhesives Testing & Validation  Insulation characterization Processing characterization Mechanical testing Electrical testing Thermal testing  Fabricate sub-scale test articles  Environmental testing

4. Radiation-Resistant Insulation for High-Field Magnets 4 Insulation Selection for VPI Design for manufacturability  Low viscosity  Long pot life  Thermosetting resins Enhanced performance  High mechanical strength at operating temperatures  High dielectric strengths  Thermal shock resistance  Radiation resistance Insulation systems for VPI processing  CTD-101 & 101K (epoxy)  CTD-528 (RT-cure epoxy)  CTD-403 (cyanate ester)

5. Radiation-Resistant Insulation for High-Field Magnets 5 CTD-101 & 101K Widely used magnet insulation products  Low viscosity  Long pot life  Excellent strength at cryogenic temperatures  Thermal shock resistance Applications  High energy physics  Fusion  Commercial systems NCSX coil, PPPL HD-1 Magnet, LBNL Commercial systems

6. Radiation-Resistant Insulation for High-Field Magnets 6 CTD-403 CTD-403 (Cyanate ester)  Excellent VPI resin  High-strength insulation from cryogenic to elevated temperatures  Radiation resistant  Moisture resistance improved over epoxies Quasi-Poloidal Stellarator  Fusion device  Compact stellarator  20 Modular coils, 5 coil designs  Operate at 40 to >100°C  Water-cooled coils QPS

7. Radiation-Resistant Insulation for High-Field Magnets 7 Insulated Coil Section Wind-and-React Fabrication of Nb 3 Sn Magnets ApplicationToConductor VPI Impregnate with organic resin and cure Pyrolysis 650°C for 30 hours in N 2 GreenState Monolithic Coil CompletedCoil Hybrid Insulation

8. Radiation-Resistant Insulation for High-Field Magnets 8 Braided Ceramic-Fiber Reinforcements Use or disclosure of the data contained on this page is subject to the restriction on the cover page of this document. Minimizing cost  Lower-cost fiber reinforcements for ceramic-based insulation (CTD-CF-200)  CTD-1202 ceramic binder is 70% less than previous inorganic resin system Improving magnet fabrication efficiency  Textiles braided directly onto Rutherford cable (eliminates taping process)  Wind-and-react, ceramic-based insulation system Enhancing magnet performance  Insulation thickness reduced by 50% Closer spacing of conductors enables higher magnetic fields  Robust, reliable insulation Mechanical strength and stiffness High dielectric strength Radiation resistance

9. Radiation-Resistant Insulation for High-Field Magnets 9 Enhanced Strain in Ceramic-Composite Insulation Graceful Failure Brittle Failure Use or disclosure of the data contained on this page is subject to the restriction on the cover page of this document.

10. Radiation-Resistant Insulation for High-Field Magnets 10 LARP Insulation Requirements Design ParameterDesign Value CTD-1202/CTD-CF-200 Performance Compression Strength*200 MPa650 MPa (77 K) Shear Strength40-60 MPa110 MPa (77 K) Dielectric Strength1 kV14 kV (77 K) Mechanical Cycles10,000 Planned testing to 20,000+ cycles Relative Cost**1.000.20-0.30 *200 MPa is yield strength of Nb 3 Sn **Relative cost as compared to CTD-1012PX Use or disclosure of the data contained on this page is subject to the restriction on the cover page of this document.

11. Radiation-Resistant Insulation for High-Field Magnets 11 CTD Irradiation Timelines 1988 CTD Founded Proposed Ceramic/Polymer Hybrids SBS & Gas Evolution at 4 K 2005-2007 DOE SBIR MIT-NRL Resins & Ceramic/Polymer Hybrids SBS, Compression Adhesive Strength Gas Evolution 1992-1998 ITER Garching/ATI 2000-2003 DOE SBIR ATI Epoxy-Based Insulations SBS, Compression Shear/Compression at 4 K Epoxies & Cyanate Esters SBS, Compression Gas Evolution Epoxy-Based Insulations SBS E-beam Irradiated at 4 K 2008-2009 DOE SBIR NIST 1992-93 SSC GA Fusion HEP

12. Radiation-Resistant Insulation for High-Field Magnets 12 MIT Irradiation Facility MIT Reactor (MITR)  5 MW experimental fission reactor  Radiation exposures at various locations  Irradiations to 100 MGy Insulation test specimens  Short-beam-shear Fiber-reinforced composites Copper/insulation adhesion  Compression  Gas evolution Irradiation test considerations  Specimen size & type  Facility  Cost

13. Radiation-Resistant Insulation for High-Field Magnets 13 Insulation Irradiations Fiber-reinforced VPI systems  CTD-101K (epoxy)  CTD-403 (cyanate ester)  CTD-422 (CE/epoxy blend) Insulation performance  Shear strength most affected by irradiation  Compression strength largely un-affected by irradiation Ongoing irradiations  Ceramic/polymer hybrids  CTD-403  20, 50, & 100 MGy doses  Expect to complete by 8/07

14. Radiation-Resistant Insulation for High-Field Magnets 14 Radiation-Induced Gas Evolution Gas evolution in polymeric materials  Attributed to breaking of C-H bonds, releasing H 2 gas  Gas causes swelling of insulation Gas evolution measurements  Composite specimens sealed in evacuated quartz capsules  After irradiation, capsule fractured in evacuated chamber  Gas evolution correlated to pressure rise in chamber  Dimensional change measured Use or disclosure of the data contained on this page is subject to the restriction on the cover page of this document.

15. Radiation-Resistant Insulation for High-Field Magnets 15 Proposed 4 K Irradiation Low-temperature irradiations  Linear accelerator facility  CTD Dewar design Insulation characterization  Short-beam shear  Gas evolution  Dimensional change Insulations to be tested  Ceramic/polymer hybrids  Polymer composites  Ceramic insulations Use or disclosure of the data contained on this page is subject to the restriction on the cover page of this document.

16. Radiation-Resistant Insulation for High-Field Magnets 16 Continuing Insulation Development & Application Insulation Expertise  Material selection  Processing procedures and specifications  Numerous successes Magnet Insulation Needs  Materials  Testing  Processing  Application Cooperative Research  Industry worldwide  US national laboratories  US government “Enabling Technology for the Superconductor Industry”