Nanostructured Aluminum Conductors: Next Generation Electrical Power Transmission Cables
Overview
Within the next 10 years the USA must invest $1.5 trillion to overhaul elements of the aging electrical power grid, including adding 16,000 km of new transmission cable to integrate solar and wind power sources. Presently, 6.9% of the electrical energy transmitted into the U.S. power grid is lost as heat through resistive losses. The overall objective of this project is to develop higher conductivity and higher strength aluminum conductor wire for the new high voltage electrical power transmission system. If the strength of aluminum conductor alloys can be increased sufficiently by nanostructuring, then high conductivity nano-aluminum with conductivity over 58%IACS (%IACS is a measure of conductivity compared to copper, according to the International Annealed Copper Standard) can replace steel reinforcements with 8%IACS conductivity in the widely used Aluminum Conductor Steel Reinforced (ACSR) transmission cables. The net effect of replacing ACSR cables with nano-aluminum would be to nearly double the ampacity of the U.S. power grid, without adding any additional transmission towers or lines.
Project Description
This project builds upon the same approaches we have applied to develop bioabsorbable magnesium alloys: altering grain size and precipitation by High Shear Deformation. In this case, our goal is the increase electrical conductivity by increasing the amounts of alloying elements that migrate from solid solution into very fine precipitates, while also increasing strength through grain size refinement. The central premise of the research is that shear mixing imposed by HSD enhances diffusivity and alters the nucleation and growth kinetics of several families of precipitates. The project has three major phases: 1) development of nanostructuring methods to modify existing aluminum conductor alloys to achieve high strength and electrical conductivity, 2) demonstration of the speed-up of nanostructuring methods, and 3) analysis of the thermal stability of nanostructured aluminum alloys, including simulating the thermomechanical processing history. This project is designed to create high strength/conductivity aluminum alloy wires, hybrid alloy/cable designs, numerical models to guide thermo-mechanical process control, and a pilot scale aluminum wire production line.
Status
The first phase of the research has focused on increasing strength. Towards this goal, we have achieved notable increases in the strength of the commonly used Al-Si-Mg AA6201conductor alloy: by 93% to 578 MPa. This strength increase is associated with an over 100-fold decrease in grain size, achieved through just 2 passes of the ECAP-C process. We have also increased the strength of the more dilute Al-Mg-Si AA6101 alloy by 55%, while also increasing the electrical conductivity from the nominal value of 52%IACS to over 57%IACS.
The second phase has focused on assessing methods to implement high speed manufacturing of nanostructured aluminum wires. Towards this goal, we have designed and constructed a research-scale continuous coil-to-coil manufacturing system. The system allows us to create coils of aluminum conductor rod up to 250 meters in length, as shown in Figure 8.
Figure 8 Coil-to-coil spooling of aluminum conductor rod through ECAP-C tooling.
The third phase focuses on evaluating the long term thermal stability of nanostructured aluminum and developing computational models to guide process design and scale up. Toward this end we have conducted non-isothermal finite element modeling of 93% to 578 MPa. This strength increase is associated with an over 100-fold decrease in grain size, achieved through just 2 passes of the ECAP-C process. We have also increased the strength of the more dilute Al-Mg-Si AA6101 alloy by 55%, while also increasing the electrical conductivity from the nominal value of 52%IACS to over 57%IACS.
The second phase has focused on assessing methods to implement high speed manufacturing of nanostructured aluminum wires. Towards this goal, we have designed and constructed a research-scale continuous coil-to-coil manufacturing system. The system allows us to create coils of aluminum conductor rod up to 250 meters in length, as shown in Figure 8.
With placement outcomes within three months of graduation exceeding 80 percent for the last five years and average starting salaries over $69,000, our graduates continue to be in high demand for industry, government, military and graduate school positions across the country.
Additional Program Information
Accreditation
Both degrees leading to the Bachelor of Science are accredited by the Engineering Accreditation Commission of the Accreditation Board for Engineering and Technology (ABET), 111 Market Place, Suite 1050, Baltimore, MD 21202-4012, (410) 347-7700. ABET, the recognized accreditor for college and university programs in applied science, computing, engineering, and technology, is a federation of 28 professional and technical societies representing these fields.
The Chemical and Biological Engineering Department at Mines has two undergraduate degree programs: 1) BS Chemical Engineering and 2) BS Chemical and Biochemical Engineering. Both degree programs are ABET-accredited through 2018.
To be accredited, a program must have educational objectives and associated student outcomes that lead to meeting those objectives. Programs must also have a comprehensive assessment methodology in place that provides continuous feedback and demonstrates that the objectives are being met.
For both degree programs. our objectives for our graduates within three to five years of completing their degree are that they will:
- be in graduate school or in the workforce utilizing their education in chemical engineering fundamentals; and
- be applying their knowledge of and skills in engineering fundamentals in conventional areas of chemical engineering and in contemporary and growing fields; and
- have demonstrated both their commitment to continuing to develop personally and professionally, and an appreciation for the ethical and social responsibilities associated with being an engineer and a world citizen.
In addition to the above objectives, our Chemical and Biochemical Engineering graduates three to five years out will:
- be applying their knowledge of and skills in biochemical engineering fundamentals.
Combined Baccalaureate / Master's Degree Program
The Chemical and Biological Engineering Department offers the opportunity to begin work on a master of science (with thesis) degree while completing the requirements of the bachelor’s degree. These combined BS/MS programs are designed to allow undergraduates engaged in research to apply their experience to an advanced degree. An advantage of the combined BS/MS program is that students may apply two classes (6 credit hours) to both their BS and MS degrees. These two classes must be chemical engineering elective courses at the 400-level or higher. The remaining MS curriculum consists of the four core graduate courses (CHEN507, CHEN509, CHEN516 and CHEN518) and 18 thesis credits. It is expected that a student would be able to complete both degrees in five to five and a half years. To take advantage of the combined program, students should be engaged in research and taking graduate coursework during their senior year. For this reason, students are expected to apply to the program by the end of their junior year. Students must have a GPA greater than 3.0 to be considered for the program. Interested students are encouraged to get more information from their advisor or the faculty member in charge of graduate affairs.
Advising Sheet: Chemical Engineering
Freshman Year, Fall Semester
| Course No. | Title | Hours |
| CHGN 121 | Principles of Chemistry | 4 |
| CSM 101 | Freshman Success Seminar | 0.5 |
| EPIC 151 | Design I | 3 |
| CBEN 110 | Fundamentals of Biology I | 4 |
| MATH 111 | Calculus for Scientists and Engineers I | 4 |
| PAGN XXX | Physical Education I | 0.5 |
| TOTAL | 16 | |
Freshman Year, Spring Semester
| Course No. | Title | Hours |
| LAIS 100 | Nature and Human Values | 4 |
| CHGN 122 | Principles of Chemistry | 4 |
| MATH 112 | Calculus for Scientists and Engineers II | 4 |
| PAGN XXX | Physical Education II | 0.5 |
| PHGN 100 | Physics I | 4.5 |
| TOTAL | 17 | |
Sophomore Year, Fall Semester
| Course No. | Title | Hours |
| CBEN 210 | Introduction to Thermodynamics | 3 |
| CHGN 221 | Organic Chemistry I | 3 |
| CHGN 223 | Organic Chemistry I Lab (or in spring) | 1 |
| MATH 213 | Calculus for Scientists and Engineers III | 4 |
| PAGN XXX | Physical Education III | .5 |
| PHGN 200 | Physics II | 4.5 |
| TOTAL | 16 | |
Sophomore Year, Spring Semester
| Course No. | Title | Hours |
| CBEN 201 | Mass and Energy Balances | 3 |
| CBEN 202 | Chemical Process Principles Lab | 1 |
| CHGN 222 | Organic Chemistry II | 3 |
| EBGN 201 | Principles of EconomicsI | 3 |
| EPIC 265 | Biochemical Processes Design II | 3 |
| MATH 225 | Differential Equations | 3 |
| PAGN XXX | Physical Education IV | 0.5 |
| TOTAL | 16.5 | |
Junior Year, Fall Semester
| Course No. | Title | Hours |
| CBEN 307 | Fluid Mechanics | 3 |
| CBEN 357 | Chemical Engineering Thermodynamics | 3 |
| CHGN 351 | Physical Chemistry I | 3 |
| LAIS 200 | Human Systems | 3 |
| Free Elective 1 | 3 | |
| TOTAL | 15 | |
Summer Field Session
| CBEN 312/313 | Unit Operations Lab | 6 |
Junior Year, Spring Semester
| Course No. | Title | Hours |
| CBEN 308 | Chemical Engineering Heat Transfer | 3 |
| CBEN 358 | Chemical Engineering Thermodynamics Lab | 1 |
| CBEN 375 | Chemical Engineering Mass Transfer | 3 |
| CBEN or CHGN Elective (at least 300 level) | 3 | |
| LAIS / EBGN Elective 1 | 3 | |
| Free Elective 2 | 3 | |
| TOTAL | 16 | |
Senior Year, Fall Semester
| Course No. | Title | Hours |
| CBEN 418 | Reaction Engineering | 3 |
| CBEN 430 | Transport Phenomena | 3 |
| CBEN* Elective I | 3 | |
| LAIS / EBGN Elective 2 | 3 | |
| Free Elective 3 | 4 | |
| TOTAL | 16 | |
Senior Year, Spring Semester
| Course No. | Title | Hours |
| CBEN 402 | Chemical Engineering Design | 3 |
| CBEN 403 | Process Dynamics and Control | 3 |
| EBGN 321 | Engineering Economics | 3 |
| CBEN* Elective 2 (400 level) | 3 | |
| LAIS / EBGN Elective 3 (400 level) | 3 | |
| TOTAL | 15 | |
*Not all CBEN courses count as CBEN electives.
Advising Sheet: Chemical and Biochemical Engineering
Freshman Year, Fall Semester
| Course No. | Title | Hours |
| CHGN 121 | Principles of Chemistry | 4 |
| CSM 101 | Freshman Success Seminar | 0.5 |
| EPIC 151 | Design I | 3 |
| CBEN 110 | Fundamentals of Biology I | 4 |
| MATH 111 | Calculus for Scientists and Engineers I | 4 |
| PAGN XXX | Physical Education I | 0.5 |
| TOTAL | 16 | |
Freshman Year, Spring Semester
| Course No. | Title | Hours |
| LAIS 100 | Nature and Human Values | 4 |
| CHGN 122 | Principles of Chemistry | 4 |
| MATH 112 | Calculus for Scientists and Engineers II | 4 |
| PAGN XXX | Physical Education II | 0.5 |
| PHGN 100 | Physics I | 4.5 |
| TOTAL | 17 | |
Sophomore Year, Fall Semester
| Course No. | Title | Hours |
| CBEN 210 | Introduction to Thermodynamics | 3 |
| CHGN 221 | Organic Chemistry I | 3 |
| CHGN 223 | Organic Chemistry I Lab (or in spring) | 1 |
| MATH 213 | Calculus for Scientists and Engineers III | 4 |
| PAGN XXX | Physical Education III | .5 |
| PHGN 200 | Physics II | 4.5 |
| TOTAL | 16 | |
Sophomore Year, Spring Semester
| Course No. | Title | Hours |
| CBEN 201 | Mass and Energy Balances | 3 |
| CBEN 202 | Chemical Process Principles Lab | 1 |
| CHGN 222 | Organic Chemistry II | 3 |
| EBGN 201 | Principles of EconomicsI | 3 |
| EPIC 265 | Biochemical Processes Design II | 3 |
| MATH 225 | Differential Equations | 3 |
| PAGN XXX | Physical Education IV | 0.5 |
| TOTAL | 16.5 | |
Junior Year, Fall Semester
| Course No. | Title | Hours |
| CBEN 307 | Fluid Mechanics | 3 |
| CBEN 357 | Chemical Engineering Thermodynamics | 3 |
| CHGN 428 | Intro to Biochemistry | 3 |
| LAIS 200 | Human Systems | 3 |
| Free Elective 1 | 3 | |
| TOTAL | 15 | |
Summer Field Session
| CBEN 312/313 | Unit Operations Lab | 6 |
Junior Year, Spring Semester
| Course No. | Title | Hours |
| CBEN 308 | Chemical Engineering Heat Transfer | 3 |
| CBEN 358 | Chemical Engineering Thermodynamics Lab | 1 |
| CBEN 375 | Chemical Engineering Mass Transfer | 3 |
| CHGN 351 | Physical Chemistry I | 4 |
| CHGN 462 | Microbiology | 3 |
| LAIS / EBGN Elective 1 | 3 | |
| TOTAL | 17 | |
Senior Year, Fall Semester
| Course No. | Title | Hours |
| CBEN 418 | Reaction Engineering | 3 |
| CBEN 430 | Transport Phenomena | 3 |
| CBEN 460 | Bioprocess Engineering | 3 |
| CBEN 461 | Bioprocess Engineering Laboratory | 1 |
| LAIS / EBGN Elective 2 | 3 | |
| Free Elective 2 | 3 | |
| TOTAL | 16 | |
Senior Year, Spring Semester
| Course No. | Title | Hours |
| CBEN 402 | Chemical Engineering Design | 3 |
| CBEN 403 | Process Dynamics and Control | 3 |
| EBGN 321 | Engineering Economics | 3 |
| LAIS / EBGN Elective 3 (400 level) | 3 | |
| Free Elective 3 | 3 | |
| TOTAL | 15 | |
Chemical and Biological Engineering Electives
NOTE: Any CHGN or CBEN 3XX course counts as the CHGN or CBEN 3XX elective listed in the spring semester of the junior year. However, only CBEN courses with engineering content count as the CBEN electives listed in the senior year. Those courses include the following:
| Course No. | Title | Credit Hours |
| CBEN 200 | Computational Methods in Chemical Engineering | 3 |
| CBEN 250 | Introduction to Chemical Engineering Analysis and Design | 3 |
| CBEN 310 | Introduction to Biomedical Engineering | 3 |
| CBEN 315 | Introduction to Electrochemical Engineering | 3 |
| CBEN 340 | Cooperative Education | 1-3 |
| CBEN 35X, 45X, X98, X99 | Honors UG Research, Special Topics, Independent Study* | 1-6 |
| CBEN 368 | Introduction to Undergraduate Research | 1 |
| CBEN 401 | Introduction to Chemical Process Design | 3 |
| CBEN 408 | Natural Gas Processing | 3 |
| CBEN 409 | Petroleum Processes | 3 |
| CBEN 415 | Polymer Science and Technology | 3 |
| CBEN 416 | Polymer Engineering and Technology | 3 |
| CBEN 420 | Mathematical Methods in Chemical Engineering | 3 |
| CBEN 432 | Transport Phenomena in Biological Systems | 3 |
| CBEN 435 | Interdisciplinary Microelectronics | 3 |
| CBEN 440 | Molecular Perspectives in Chemical Engineering | 3 |
| CBEN 460 | Biochemical Process Engineering | 3 |
| CBEN 461 | Biochemical Process Engineering | 1 |
| CBEN 469 | Fuel Cell Science and Technology | 3 |
| CBEN 470 | Introduction to Microfluidics | 3 |
| CBEN 472 | Introduction to Energy Technologies | 3 |
| CBEN 480 | Natural Gas Hydrates | 3 |
*If content has sufficient engineering basis, as determined by the department head given the project description, these courses can count as a CBEN elective.
The following CBEN bio-related courses DO NOT have sufficient engineering content and therefore DO NOT count as CBEN electives.
| Course No. | Title | Credit Hours |
| CBEN 110 (BIOL 110) | Fundamentals of Biology I | 4 |
| CBEN 303/323/120 | Fundamentals of Biology II | 4 |
| CBEN 304/305 | Anatomy and Physiology | 3 |
| CBEN 306/309 | Anatomy and Physiology: Bone, Muscle and Brain | 3 |
| CBEN 311 | Introduction to Neuroscience | 3 |
| CBEN 320 | Cell Biology and Physiology | 3 |
| CBEN 321 | Introduction to Genetics | 4 |
| CBEN 411 | Neuroscience, Memory and Learning | 3 |
| CBEN 412 | Introduction to Pharmacology | 3 |
| CBEN 431 | Immunology | 3 |
| CBEN 454 | Applied Bioinformatics | 3 |
Biomedical Engineering Minor
To obtain a Biomedical Engineering minor, students must take at least 18 credits related to Biomedical Engineering. Two courses (8 credits) of biology are required. Two restricted requirements include Intro to Biomedical Engineering (required) and at least 3 credits of engineering electives related to BME. Two more courses (or at least 4 credits) may be chosen from the engineering and/or additional electives. The lists of electives will be modified as new related courses that fall into these categories become available.
Required Courses (11 credits)
| CBEN 110 | Fundamentals of Biology I | 4 |
| CBEN 120 | Studio Biology II | 4 |
| CBEN 310 | Intro to Biomedical Engineering | 3 |
Engineering Elective Courses Related to BME
(at least 3 credits)
| CBEN 432 | Transport Phenomena in Biological Systems | 3 |
| CBEN 470 | Introduction to Microfluidics | 3 |
| CBEN 35x, 45x, x98, x99 | Honors Undergraduate Research, Special Topics | 1 – 3 |
| MEGN 330 | Introduction to Biomechanical Engineering | 3 |
| MEGN 430 | Musculoskeletal Biomechanics | 3 |
| MEGN 435/535 | Modeling and Simulation of Human Movement | 3 |
| MEGN 436/536 | Computational Biomechanics | 3 |
| MEGN 530 | Biomedical Instrumentations | 3 |
| MEGN 531 | Prosthetic and Implant Engineering | 3 |
| MEGN 532 | Experimental Methods in Biomech | 3 |
| MEGN 537 | Probabilistic Biomechanics | 3 |
| MTGN 570 | Intro to Biocompatibility | 3 |
Additional Elective Courses Related to BME
(two courses or at least 4 credits from the list above or below)
| CBEN 311 | Introduction to Neuroscience | 3 |
| CBEN 322 | Biology of Behavior | 3 |
| CBEN 398 | Anatomy | 3 |
| CBEN 398 | Anatomy Lab | 1 |
| CBEN 398 | Physiology | 3 |
| CBEN 320 (410) | Cell Biology and Physiology | 3 |
| CBEN 321 | Intro to Genetics (+ Lab) | 4 |
| CBEN 411 | Neuroscience, Memory, and Learning | 3 |
| CBEN 431/531 | Immunology for Engineers and Scientists | 3 |
| CBEN 454/554 | Applied Bioinformatics | 3 |
| CBEN 35x, 45x, x98, x99 | Honors Undergraduate Research, Special Topics | 1-3 |
| CHGN428 | Introductory Biochemistry | 3 |
| CHGN429 | Intro to Biochemistry II | 3 |
| CHGN 462 | Microbiology | 3 |
| MATH 331 | Mathematical Biology | 3 |
| MTGN 472/572 | Biomaterials I | 3 |
| PHGN 433 | Introduction to Biophysics | 3 |