Processes, systems and devices for metal filling of high temperature superconductor cables

1. A method comprising:

obtaining a high temperature superconductor (HTS) cable assembly;

bending the HTS cable assembly;

heating the bent HTS cable assembly to a first temperature;

heating the bent HTS cable assembly to a second temperature higher than the first temperature, that allows a molten metal to flow through the bent HTS cable assembly; and

applying pressure to the molten metal to force the molten metal through the bent HTS cable assembly.

2. The method of claim 1 wherein:

obtaining a high temperature superconductor (HTS) cable assembly comprises obtaining a former having at least one channel with an HTS tape disposed in the channel;

the second temperature allows molten metal to flow through the at least one channel of the former; and

applying pressure to molten metal to force the molten metal through the bent HTS cable assembly includes filling the at least one channel of the former with molten metal such that the molten metal substantially fills the at least one channel and is disposed about the HTS tape.

3. The method of claim 2 wherein filling the at least one channel of the former with a molten metal comprises:

obtaining a source of the molten metal;

heating the HTS cable assembly to a temperature which will allow the molten metal to flow through the at least one channel of the former; and

applying pressure to the molten metal to force the molten metal from the source through the at least one channel of the former.

4. The method of claim 1 wherein:

obtaining the HTS cable assembly comprises obtaining a tube having walls which define at least one channel; and

applying pressure to molten metal to force the molten metal through the bent HTS cable assembly comprises at least partially filling the at least one channel of the tube with the molten metal.

5. The method of claim 4 wherein at least partially filling the at least one channel of the tube with the molten metal comprises completely filling the at least one channel of the tube with the molten metal.

6. The method of claim 4 wherein at least partially filling the at least one channel of the tube with a molten metal comprises:

obtaining a source of the molten metal;

and

applying pressure to the molten metal so as to force the molten metal from the source through the at least one channel of the tube.

7. The method of claim 1 wherein:

the first temperature does not degrade HTS tape in the HTS cable assembly.

8. The method of claim 7 wherein heating the HTS cable assembly to the first temperature which does not degrade the HTS tape comprises heating the HTS cable assembly to a temperature below 185° C.

9. The method of claim 8 further comprising:

holding the HTS cable assembly at the first temperature for a period of time until all points on the HTS cable assembly have reached the first temperature.

10. The method of claim 9 further comprising monitoring the temperature of the HTS cable assembly to ensure that no portion of the HTS cable assembly exceeds a temperature of about 200° C.

11. The method of claim 7 further comprising obtaining a source of the molten metal and wherein:

the obtaining a source of the molten metal comprises obtaining a source of molten Sn 60 Pb 40 solder; and

the applying pressure to the molten metal to force the molten metal from the source through the HTS cable assembly comprises applying pressure to molten Sn 60 Pb 40 solder so as to force molten Sn 60 Pb 40 solder from the source through the HTS cable assembly.

12. The method of claim 11 wherein the HTS cable assembly includes a channel and the method further comprises depositing flux into a channel of the HTS cable assembly prior to applying pressure to force the molten Sn 60 Pb 40 solder through the channel of the HTS cable assembly.

13. The method of claim 1 wherein:

obtaining a high temperature superconductor (HTS) cable assembly comprises obtaining a former having at least one channel; and

filling the at least one channel of the former with molten metal comprises completely filling the at least one channel of the former with the molten metal.

14. The method of claim 1 , wherein the HTS cable assembly comprises a first metal and wherein:

the first temperature is below a melting temperature of the first metal; and

the second temperature is equal to or higher than the melting temperature of the first metal.

15. The method of claim 1 , wherein:

the molten metal is a molten solder;

the first temperature is below a liquidus temperature of the solder; and

the second temperature is equal to or higher than the liquidus temperature of the solder.

16. The method of claim 1 , wherein heating the bent HTS cable assembly to a first temperature comprises heating the bent HTS cable assembly until the bent HTS cable assembly is equilibrated at the first temperature.

17. The method of claim 1 , wherein the molten metal comprises a PbSn solder alloy.

18. A method comprising:

bending an HTS cable assembly to provide a bent HTS cable assembly, the bent HTS cable assembly having at least one channel with HTS material disposed in the at least one channel;

heating the bent HTS cable assembly until the bent HTS cable assembly is heated to a first temperature;

heating the bent HTS cable assembly to a second temperature, higher than the first temperature, that allows a molten metal to flow through the bent HTS cable assembly;

at least partially filling the at least one channel of the bent HTS cable assembly with a molten metal by applying pressure to a source of molten metal to force the molten metal into the bent HTS cable assembly; and

depositing flux into the at least one channel prior to at least partially filling the at least one channel with the molten metal.

19. A method for filling an HTS cable comprising an HTS tape with a molten metal, the method comprising:

heating a bent HTS cable assembly until the bent HTS cable assembly is heated to a first temperature;

heating the bent HTS cable assembly to a second temperature, higher than the first temperature, that allows a molten metal to flow through the bent HTS cable assembly;

wherein heating the bent HTS cable assembly to a first temperature and heating the bent HTS cable assembly to a second temperature comprises heating at least portions of the HTS cable using a time-temperature exposure profile that does not degrade HTS tape characteristics by more than 5%; and

applying pressure to a molten metal to direct the molten metal into the bent HTS cable assembly.

20. A method for filling an HTS cable comprising:

bending a cable assembly having an HTS material disposed therein; and

after bending the cable assembly:

heating the bent cable assembly to a first temperature until the bent cable assembly is heated to the first temperature;

heating the bent cable assembly to a second temperature, higher than the first temperature, while forcing the molten metal into the bent cable assembly; and

applying pressure to force the molten metal through the bent cable assembly.

21. The method of claim 20 wherein bending a cable assembly having an HTS material disposed therein comprises bending the cable assembly to form at least one partial loop.

22. The method of claim 21 wherein

applying pressure to the molten metal comprises applying pressure to the molten metal so as to force the molten metal through the at least one partial loop of the cable assembly.

23. The method of claim 20 wherein bending a cable assembly having an HTS material disposed therein comprises bending the cable assembly to form at least one loop.

24. The method of claim 23 wherein the HTS material comprises at least HTS tape and bending the cable assembly comprises twisting the HTS tape and allowing the HTS tape to re-distribute during bending such that the HTS tape is substantially free of stress prior to filling the cable assembly with the molten metal.

25. The method of claim 24 further comprising cooling the molten metal within the cable assembly to secure the HTS tape within the cable assembly.

26. A method comprising:

obtaining a high temperature superconductor (HTS) cable assembly comprising at least one channel, and a stack of HTS tapes arranged within the at least one channel;

bending the HTS cable assembly to provide a bent HTS cable assembly; and

at least partially filling the at least one channel of the bent HTS cable assembly with a molten metal such that the molten metal is disposed around at least one surface of the stack of HTS tapes, wherein at least partially filling the at least one channel of the bent HTS cable assembly with the molten metal comprises:

heating the bent HTS cable assembly to a first temperature until the bent HTS cable assembly is heated to the first temperature;

heating the bent HTS cable assembly to a second temperature, higher than the first temperature, that allows a molten metal to flow through the bent HTS cable assembly while forcing the molten metal into the bent HTS cable assembly.

27. The method of claim 26 wherein obtaining a high temperature superconductor (HTS) cable assembly comprises obtaining a former having at least one channel.

28. The method of claim 26 wherein the at least one channel is arranged at least partially within a former, and wherein at least partially filling the at least one channel of the bent HTS cable assembly comprises completely filling the at least one channel of the former with the molten metal.

29. The method of claim 26 wherein at least partially filling the at least one channel with the molten metal comprises:

obtaining a source of the molten metal;

and

applying pressure to the molten metal so as to force the molten metal from the source through the at least one channel.

30. The method of claim 26 wherein the HTS cable assembly comprises a tube having walls which at least in part define the at least one channel.

31. The method of claim 30 wherein at least partially filling the at least one channel of the bent HTS cable assembly comprises completely filling the at least one channel of the tube with the molten metal.

32. The method of claim 30 wherein at least partially filling the at least one channel of the tube with the molten metal comprises:

obtaining a source of the molten metal;

and

applying pressure to the molten metal so as to force the molten metal from the source through the at least one channel of the tube.

33. A method for filling a high temperature superconductor (HTS) cable assembly, the method comprising:

bending a cable assembly comprising at least one channel, and an HTS material disposed within the at least one channel; and

after bending the cable assembly, at least partially filling the at least one channel of the cable assembly with a molten metal such that the molten metal is disposed around at least one surface of the HTS material, wherein at least partially filling the at least one channel of the cable assembly with the molten metal comprises heating the cable assembly to a first temperature, and heating the cable assembly to a second temperature, higher than the first temperature that allows the molten metal to flow through the at least one channel, while forcing the molten metal into the at least one channel of the cable assembly.

34. The method of claim 33 wherein bending the cable assembly comprises bending the cable assembly to form at least one partial loop.

35. The method of claim 33 wherein forcing the molten metal into the cable assembly comprises applying pressure to the molten metal so as to force the molten metal through the cable assembly.

36. The method of claim 34 wherein bending the cable assembly comprises bending the cable assembly to form at least one loop.

37. The method of claim 36 wherein the HTS material comprises at least HTS tape and bending the cable assembly comprises twisting the HTS tape and allowing the HTS tape to re-distribute during bending such that the HTS tape is substantially free of stress prior to at least partially filling the at least one channel of the cable assembly with the molten metal.

38. The method of claim 37 further comprising cooling the molten metal within the cable assembly to secure the HTS tape within the cable assembly.