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NSTX TF Flag Joint Design Review INTRODUCTION C Neumeyer 8/7/3

NSTX TF Flag Joint Design Review INTRODUCTION C Neumeyer 8/7/3. BACKGROUND. TF joint failed on February 14, 2003 due to structural weaknesses At the April 10, 2003 review….. cause of failure was explained new design was presented

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NSTX TF Flag Joint Design Review INTRODUCTION C Neumeyer 8/7/3

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  1. NSTX TF Flag JointDesign ReviewINTRODUCTIONC Neumeyer8/7/3

  2. BACKGROUND • TF joint failed on February 14, 2003 due to structural weaknesses • At the April 10, 2003 review….. • cause of failure was explained • new design was presented • sufficient confidence was gained to proceed with conductor machining • Since April the analysis, testing, and design has been completed • chits generated during the April review have been resolved • Purpose of this review is to examine the final design • identify any shortcomings which may need correction • Additional review in September will assess cost and schedule • today’s review will establish that the technical basis is sound

  3. PURPOSE OF REVIEW • Obtain critique of new design of the TF Flag Joint • Identify any shortcomings needing attention (chits) • Confirm viability of TF Flag Joint Design • Allow release of all fabrication and assembly activities

  4. SCOPE OF REVIEW • TF Flag Joint and Integrated Assembly • Inner Leg / Flag Interface (the joint) • Flag • Flag Fasteners (threaded inserts, studs, washers, nuts, etc.) • Flag Structural Supports (Boxes, Shear Shoes) • Hub Assembly/Torque Collar • Built-in Instrumentation Features Other aspects may be discussed but are out of scope

  5. AGENDA

  6. REVIEW PROCEDURES • Chits to be submitted to Chairman B Nelson • Chits to be dispositioned by Review Board • Chits to be resolved by Cog Engr C Neumeyer C. Neumeyer* P. Peterson, GA P. Titus, MIT P. Anderson, GA L. Dudek J. Irby, MIT B. Nelson,ORNL** • G. Voss, Culham • ** Chair • * Ex-officio • Remote participant

  7. RECOVERY ACTIVITIES

  8. DESIGN 3D modeling complete, including… • integrated TF inner leg bundle • coolant tube routing and bulkhead • outer leg connections Fabrication drawings complete, including… • conductors • flags • flag boxes • shear shoes • hub assembly • torque collar

  9. ANALYSIS Structural FEA complete, including… • both tiers of conductors • out-of-plane load path through spline • collar and wet lay-up representation • in-plane, out-of-plane, thermal loads • SOFT, EOFT, EOP cases • Other analysis complete, including… • force calculations • temperatures, including joint temperature rise • fastener sizing calculations • miscellaneous calculations • Formal documentation and checking • is not complete at this time

  10. TESTING • Component testing (design input data) consists of: • Pull-out tests on threaded inserts • - one time and 50,000 cycle at 100oC • Pull-out tests on bolts threaded in copper • - one time and 50,000 cycle • Friction coefficient and electrical resistance tests • Shear tests on torque collar attachment • Status: Complete • Prototype testing (design verification) consists of: • Mechanical mock-up tested for 50,000 cycles • Electrical mock-up tested at full current and I2T • Status: In Preparation

  11. HIGHLIGHTS SINCE APRIL • Structural FEA completion • greater insight into thermal-induced behavior • Shear Shoe re-design • Torque Collar - Three segment collar - Torsion-only design (de-coupled vertical and radial loads) • Improved epoxy wet lay-up • Voltage probe using commercial spring-loaded probe • Precision measurement of contact resistivity vs. pressure • Component tests completed

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