January 21, 2004 1

NCSX Mod Coil R&D/Tooling Activity Update

Jim Chrzanowski & NCSX Team

January 21, 2004

NCSX

January 21, 2004 2

• New conductor• “Inch-worm casting• Twisted Racetrack coil• Keystone tests• Epoxy impregnated conductor- mechanical &

thermal tests• Modular coil production tooling

Modular Coil Winding ActivitiesNCSX

January 21, 2004 3

Copper Conductor

• New copper conductor has been received from New England Electric Wire Corp. for testing– (10) 200+ foot spools of regular processed w/lubricant compacted

copper conductor

– (8) 200+ foot spools of clean process conductor

• Conductor size 0.350 in. x 0.391 in. +/- 0.010 inch with 0.004 in. nylon serve

• Conductor was received with (2) half-lapped layers of 0.004 inch think S-2 glass insulation applied

NCSX

January 21, 2004 4

RGA Results

-Both conductor types were baked out and RGA pressure monitored

-The peaks seen are oxygen, nitrogen, water and argon, typical of cleaned parts exposed to room air

No significant difference is noted

NCSX

January 21, 2004 5

“Inch-Worm” Coil Winding Activities

• Inch-worm casting has been mounted to a tilt turn table located in the D-site basement for trials

• Inch-worm will be used to: -Develop tooling & measurement devices; train personnel and develop a better understanding in conductor handling and tolerance control

• Trials will begin next week

NCSX

January 21, 2004 6

Twisted Racetrack Coil Winding Activities• Casting contract was awarded to EIO with an expected delivery of March 31, 2004

• Winding will begin in April 2004 in the D-site Test Cell using the turning fixture and autoclave equipment

• Need details of copper cladding as well as clamps to initiate component fabrication

Casting pattern

NCSX

January 21, 2004 7

• Keystone tests will begin next week. Tests will be similar to those performed on earlier conductors

• New insulated conductor will be wound in both directions

• Preliminary results should be available by the end of next week.

Keystone TestsNCSX

January 21, 2004 8

• Preparations are under way to begin fabrication of additional specimens for testing the new impregnated conductor

• New straight single specimen mold will be ready this week for 1st. VPI next week. (compression and flexural tests)

• Undetermined number of 4-turn coils will be fabricated and used for testing tensile and fatigue properties-

• Dimensions of winding forms required to proceed

• All testing will be completed in-house at PPPL

Mechanical/Thermal Properties Tests

Matrix/spec is required to outline testing program

NCSX

January 21, 2004 9

Straight Tee-Specimen

• Modifications have been made to the original straight tee section for reuse with the new conductor and insulation scheme

• “Bag mold” grooves as well as additional clamp mounting holes have been added

• Specimen will be produced following completion of the first VPI of specimens sometime next week.“Bag mold” grooves

NCSX

January 21, 2004 10

Modular Coil Fabrication- Turning Fixtures

•All steel has been received for (4) frames and (3) support rings- additional (3) rings are being rolled at vendor

•Majority of frame parts have been fabricated

•First turning fixture will be operational by the end of February

NCSX

January 21, 2004 11

Modular Coil Fabrication -Autoclave Fabrication

Upper dome flange is being machined on “Sellers” horizontal mill

NCSX

January 21, 2004 12

Modular Coil Fabrication -Autoclave Fabrication- continued

Electrical panels being manufactured and assembled

Salvaged vacuum pumps from PBX being used to provide vacuum

NCSX

January 21, 2004 13

Ports being added to lower dome and chamber

Modular Coil Fabrication -Autoclave Fabrication- continued

NCSX

January 21, 2004 14

Additional Tasks

• Completing layout of coil winding facility- with (2) winding stations

• Begin generating a “MIT” plan for manufacturing Modular Coils

• Complete Procurement plan for modular coil production

• Begun identification by name of coil manufacturing team (17 technicians will be required at peak coil production mode)

NCSX