Quantitative correlation between the void morphology of niobium-tin wires and their irreversible critical current degradation upon mechanical loading

BEATS: BEAmline for synchrotron X-ray microTomography at SESAME

The ID10 beamline of the SESAME (Synchrotron-light for Experimental Science and Applications in the Middle East) synchrotron light source in Jordan was inaugurated in June 2023 and is now open to scientific users. The beamline, which was designed and installed within the European Horizon 2020 project BEAmline for Tomography at SESAME (BEATS), provides full-field X-ray radiography and microtomography imaging with monochromatic or polychromatic X-rays up to photon energies of 100 keV. The photon source generated by a 2.9 T wavelength shifter with variable gap, and a double-multilayer monochromator system allow versatile application for experiments requiring either an X-ray beam with high intensity and flux, and/or a partially spatial coherent beam for phase-contrast applications. Sample manipulation and X-ray detection systems are designed to allow scanning samples with different size, weight and material, providing image voxel sizes from 13 µm down to 0.33 µm. A state-of-the-art computing infrastructure for data collection, three-dimensional (3D) image reconstruction and data analysis allows the visualization and exploration of results online within a few seconds from the completion of a scan. Insights from 3D X-ray imaging are key to the investigation of specimens from archaeology and cultural heritage, biology and health sciences, materials science and engineering, earth, environmental sciences and more. Microtomography scans and preliminary results obtained at the beamline demonstrate that the new beamline ID10-BEATS expands significantly the range of scientific applications that can be targeted at SESAME.

Damage evolution during fracture by correlative microscopy with hyperspectral electron microscopy and laboratory-based microtomography

Damage evolution during fracture of metals is a critical factor in determining the reliability and integrity of the infrastructure that the society relies upon. However, experimental techniques for directly observing these phenomena have remained challenged. We have addressed this gap by developing a correlative microscopy framework combining high-resolution hyperspectral electron microscopy with laboratory x-ray microtomography (XMT) and applied it to study fracture mechanisms in a steel inclusion system. We observed damage nucleation and growth to be inhomogeneous and anisotropic. Fracture resistance was observed to be controlled by inclusion distribution and the size scale of an inclusion-depleted zone. Furthermore, our studies demonstrate that laboratory XMT can characterize damage to the micrometer scale with a large field of view in dense metals like steel, offering a more accessible alternative to synchrotron-based tomography. The framework presented provides a means to broadly adopt correlative microscopy for studies of degradation phenomena and help accelerate discovery of new materials solutions.

Tomography analysis tool: an application for image analysis based on unsupervised machine learning

We developed a graphical user interface (GUI) to analyse tomographic images of superconducting Nb3Sn wires designed for the next generation accelerator magnets. The Tomography Analysis Tool (TAT) relies on the k-means algorithm, an unsupervised machine learning technique which is widely used to partition images into separated clusters. The GUI is compatible with both Linux and Windows operating systems. The software reliability was tested by optical inspecting the tomographic images superimposed on the clustered image obtained by the k-means algorithm. TAT was proven to correctly segment the various components of the Nb3Sn superconducting wires with single pixel precision. Finally, this software can be a useful tool for the scientific community to segment and analyse quickly and reproducibly tomographic images.

Machine learning applied to X-ray tomography as a new tool to analyze the voids in RRP Nb3Sn wires

The electro-mechanical and electro-thermal properties of high-performance Restacked-Rod-Process (RRP) Nb₃Sn wires are key factors in the realization of compact magnets above 15 T for the future particle physics experiments. Combining X-ray micro-tomography with unsupervised machine learning algorithm, we provide a new tool capable to study the internal features of RRP wires and unlock different approaches to enhance their performances. Such tool is ideal to characterize the distribution and morphology of the voids that are generated during the heat treatment necessary to form the Nb₃Sn superconducting phase. Two different types of voids can be detected in this type of wires: one inside the copper matrix and the other inside the Nb₃Sn sub-elements. The former type can be related to Sn leaking from sub-elements to the copper matrix which leads to poor electro-thermal stability of the whole wire. The second type is detrimental for the electro-mechanical performance of the wires as superconducting wires experience large electromagnetic stresses in high field and high current conditions. We analyze these aspects thoroughly and discuss the potential of the X-ray tomography analysis tool to help modeling and predicting electro-mechanical and electro-thermal behavior of RRP wires and optimize their design.

On the mechanisms governing the critical current reduction in Nb3Sn Rutherford cables under transverse stress

Within the framework of the HiLumi-LHC project, CERN is currently manufacturing 11 T dipole and quadrupole accelerator magnets using state-of-the-art Nb3Sn Rutherford cables. Even higher magnetic fields are considered by the Hadron Future Circular Collider (FCC-hh) design study, which plans to develop 16 T Nb3Sn bending dipoles. In such high-field magnets, the design pre-stress can reach considerable values (150-200 MPa) and, since Nb3Sn is a brittle compound, this can constitute a technological difficult challenge. Due to the significant impact that a transverse load can have on the performances of a Nb3Sn magnet, CERN has launched a campaign of critical current measurements of reacted and impregnated Nb3Sn cables subjected to transverse pressure up to about 210 MPa. In this paper, results obtained on 18-strand 10-mm-wide cable sample based on a 1-mm-diameter powder-in-tube (PIT) wire are presented. The tests were carried out on a 2-m-long sample by using the FReSCa test station, at T = 4.3 K and background magnetic fields up to 9.6 T. For applied pressures below ≈ 130 MPa, only reversible reductions of the critical current, Ic, are observed. At higher pressures, a permanent Ic reduction occurs; such irreversible behaviour is due to the residual stresses generated by the plastic deformations of the copper stabilizer. This type of current reduction, whether reversible or not, is fully governed by the strain-induced variations of the upper critical field, Bc2. At higher pressures, estimated between 180 and 210 MPa, it is indeed plausible to believe that cracking of filaments occurs, with detrimental consequences for the Nb3Sn cable's electrical performances. The complete set of critical current data here presented, collected at different pressures and as a function of the applied magnetic field, allows for the first time to investigate the evolution of superconducting parameters such as the upper critical field Bc2 in the irreversibility region, where both the effects of Cu matrix plasticization and/or cracking of filaments may occur. The experimental approach and data interpretation have a general value and can be applied to any typology of Rutherford cable.

Implications of the strain irreversibility cliff on the fabrication of particle-accelerator magnets made of restacked-rod-process Nb3Sn wires

The strain irreversibility cliff (SIC), marking the abrupt change of the intrinsic irreversible strain limit ε_irr,0 as a function of heat-treatment (HT) temperature θ in Nb₃Sn superconducting wires made by the restacked-rod process (RRP^®), is confirmed in various wire designs. It adds to the complexity of reconciling conflicting requirements on conductors for fabricating magnets. Those intended for the high-luminosity upgrade of the Large Hardon Collider (LHC) at the European Organization for Nuclear Research (CERN) facility require maintaining the residual resistivity ratio RRR of conductors above 150 to ensure stability of magnets against quenching. This benchmark may compromise the conductors’ mechanical integrity if their ε_irr,0 is within or at the bottom of SIC. In this coupled investigation of strain and RRR properties to fully assess the implications of SIC, we introduce an electro-mechanical stability criterion that takes into account both aspects. For standard-Sn billets, this requires a strikingly narrow HT temperature window that is impractical. On the other hand, reduced-Sn billets offer a significantly wider choice of θ, not only for ensuring that ε_irr,0 is located at the SIC plateau while RRR ≥ 150, but also for containing the strain-induced irreversible degradation of the conductor’s critical-current beyond ε_irr,0. This study suggests that HT of LHC magnets, made of reduced-Sn wires having a Nb/Sn ratio of 3.6 and 108/127 restacking architecture, be operated at θ in the range of 680 to 695 °C (when the dwell time is 48 hours).