Newswise — Materials scientists at the U.S. Department of Energy’s Ames National Laboratory are moving into the field-test phase of a new type of high voltage overhead power conductor (cable). The conductor is similar to that of today’s long-distance power transmission lines, but made of aluminum-calcium composite first developed And patented by Ames Lab. The aluminium-calcium conductor is lighter and stronger than conductors currently in use and has at least 10% lower line loss than existing materials. This conductor can improve the country’s grid reliability and performance.
The high voltage overhead conductors used today have been the industry standard for more than half a century. The most common type is made of aluminum with a steel core. Using these two dissimilar metals creates a number of challenges, including their reaction to weather phenomena such as snow, wind and storms. Many of these challenges can be eliminated by using a conductor made of a uniform material, such as a conductor made from strands of an aluminum-calcium composite.
Ivar Anderson, lead researcher on the project, explained that the mixture is made of microscopic calcium filaments that act as a lightweight reinforcement for the aluminum. Aluminum is an excellent conductor, but is too weak to be used alone in conductors between power poles. The calcium in this new mix eliminates the need for heavy steel cores.
“However, most metal alloy experts would not think of using another weaker metal to add strength to aluminum,” Anderson said. “But, when calcium co-deforms with aluminum (like striped toothpaste) they form very thin, long threads of calcium metal that make the aluminum stronger without making it more brittle.”
This mixture is made from fine aluminum powder mixed with a small amount of calcium powder (less than 10% total). Anderson’s team used its expertise in powder processing to overcome the manufacturing challenges associated with converting the highly reactive calcium into the fine powder required for the composite.
Ames Lab partnered with the entire supply chain of seven US companies to build the first prototype sample conductor. After the compacted powder is co-deformed into a bar, the conductors can be processed with the same manufacturing steps typically used for conventional overhead transmission conductors.
Recently, Ames Lab has joined a partnership with Mid-American Energy. A regional power company based in Des Moines, Iowa will field the test conductors. They will string it between existing transmission towers to determine how well it performs in the real world. They will be tested under variable electrical loads and all the heat, cold, wind and severe weather that occurs on the plains of Iowa.
“Although the strength, conductivity and other properties of individual strands of the new composite conductor have been measured in the lab, measurements on the full conductor form in the natural environment are critical to industry acceptance of this new conductor option,” Anderson said.
Using this aluminum-calcium power conductor for overhead transmission lines in place of traditional steel-core conductors can improve power grid flexibility and efficiency. These new transmission lines can play a vital role in supporting the country’s clean energy goals by delivering clean-energy-generated power where it is needed.
This research is supported by the Advanced Materials and Manufacturing Technologies Office (AMMTO), part of the U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy. AMMTO supports a globally competitive U.S. manufacturing sector that accelerates the adoption of innovative materials and manufacturing technologies in support of a clean, decarbonized economy.
AIIMS National Laboratory there is one United States Department of Energy science office National laboratory operated by Iowa State University. Ames Laboratory creates innovative materials, technologies and energy solutions. We use our expertise, unique capabilities and interdisciplinary collaboration to solve global problems.
Ames National Laboratory is supported by the U.S. Department of Energy’s Office of Science. The Office of Science is the largest supporter of basic research in the physical sciences in the United States and is working to address some of the most pressing challenges of our time. For more information, please visit https://energy.gov/science,
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