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Co-Cured Facings

Co-Cured Facings. Carl Haber Jan 17, 2013. Facings for the Full Length Stave. Cables first shipment had defect Second shipment received in Nov/Dec was fine. We surveyed some of these to measure any built in distortion, then can compare stretch after co-cure

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Co-Cured Facings

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  1. Co-Cured Facings Carl Haber Jan 17, 2013

  2. Facings for the Full Length Stave • Cables first shipment had defect • Second shipment received in Nov/Dec was fine. • We surveyed some of these to measure any built in distortion, then can compare stretch after co-cure • In the past, free cables were typically short of the design ~ 1 mm / 1 m • We always observed 50-100 microns/100 mm of stretch after co-cure • Can this be determined as a fixed correction?

  3. Measuring Scheme • Using Smartscope and circle finding tool measure all the 98 mm nominal separations 98 mm 98 mm

  4. Sample Result on Free Cable Average is 97.923 here - ~80 microns short / 98 mm Over full length = 12 x 80 = 960 microns which exceeds the spacing between modules Red is a re-measurement to check the result

  5. Result for 8 Free Cables 3BH was used on 1st test co-cure, 3AH and 4AH will be used for actual stave

  6. Test Co-Cure result • We co-cured one B grade cable as a test – 3BH • We co-cured with 45 gsm material on the inside of the curved (pipe) form as established in the earlier prototyping • Concerned that uncovered CF (where the power bus will be placed) would exhibit stress deformations due to this. It came out flat!

  7. Before/After Co-cure (Left) Red is free cable and blue is after co-cure. Average stretch is 150 microns Pattern seems to reproduce but the stretch scale varies along the cable This still remains a concern. Could be too long! Note that the B grade free cable was shorter (97.81 mm average) than the 4 A grade cables. If the A grades stretch by the same amount the spacing will be as much as 100-150 microns over the 98 mm target on the longest free cables.

  8. Predicted Stretch on 3AH Average is 98.077, over by 77 microns x 12 = ~0.9 mm

  9. Cable Layout • Cable design was wider than needed for stave. Not sure why. • Determined needed final dimensions and prepared a fixture to accurately trim it.

  10. Conclusions • It is troubling that there is already considerable variation in the measurements of the free cables. • We really need to see if the stretch is consistent on each co-cure • More data soon… • Plan to re-measure all the free cables as well. • Expect to have co-cured facings in ~ 1 week.

  11. Result for 4 Free Cables averages

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