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NCSX Mod Coil R&D/Tooling Activity Update

NCSX. NCSX Mod Coil R&D/Tooling Activity Update. Jim Chrzanowski & NCSX Team January 21, 2004. Modular Coil Winding Activities. NCSX. New conductor “Inch-worm casting Twisted Racetrack coil Keystone tests Epoxy impregnated conductor- mechanical & thermal tests

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NCSX Mod Coil R&D/Tooling Activity Update

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  1. NCSX NCSX Mod Coil R&D/Tooling Activity Update Jim Chrzanowski & NCSX Team January 21, 2004

  2. Modular Coil Winding Activities NCSX • New conductor • “Inch-worm casting • Twisted Racetrack coil • Keystone tests • Epoxy impregnated conductor- mechanical & thermal tests • Modular coil production tooling

  3. Copper Conductor NCSX • 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

  4. NCSX 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

  5. NCSX “Inch-Worm” Coil Winding Activities • Inch-worm casting has been mounted to a tilt turn table located in the D-site basement for trials • Trials will begin next week • Inch-worm will be used to: -Develop tooling & measurement devices; train personnel and develop a better understanding in conductor handling and tolerance control

  6. NCSX 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

  7. Keystone Tests NCSX • 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.

  8. Mechanical/Thermal Properties Tests NCSX • 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 Matrix/spec is required to outline testing program

  9. Straight Tee-Specimen NCSX • 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

  10. NCSX 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

  11. NCSX Modular Coil Fabrication -Autoclave Fabrication Upper dome flange is being machined on “Sellers” horizontal mill

  12. NCSX Modular Coil Fabrication -Autoclave Fabrication- continued Electrical panels being manufactured and assembled Salvaged vacuum pumps from PBX being used to provide vacuum

  13. NCSX Modular Coil Fabrication -Autoclave Fabrication- continued Ports being added to lower dome and chamber

  14. NCSX 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)

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