NCSX Major Procurement Status July 20, 2005

Steady Progress on C1 and C2 The C1 was transferred to the 5 axis machine last Saturday; finish machining is now underway. –Three relatively minor design changes are being processed to resolve recently uncovered issues (lead block attachment; poloidal break insulator; O-ring groove extent). –All machining is expected to be completed in early August and it is expected to ship in the latter half of August. Machining of the C2 continues in accordance with their predictions. –MTM projects completion in the originally projected 12 weeks.

The A1 “Thin Wall” Issue Received Much Attention This Week thin areas In light blue Machined Casting FEA model – thin areas are tan. Note That Much Of the ThinArea is Machined Away,Lessening its Effect

SCANCO data well quantifies the actual wall thicknesses Specified thickness is 1.375” / Thinnest actual section is 1.18”. “Guesstimate” is the thin area is 15% of the wall area. For analysis purposes, the thin area was all modeled as being 1.05” thick to bound the problem

Even with a t=1.05” (which is less than the measured t=1.18”), and ALL Type A coils modeled this way, Stress is NOT an Issue; Deflections Increase ~20%. Max. Stress Is NOT in this region. Model Condition Max. displ. mm Max. Equiv. stress MPa Original Model; E=193 MPa (shell) (coil) 168 (shell) 239 (coil) Simulating ALL Type A castings with a thin sect. similar to A1 with t=1.05”; E adjusted to 145 to reflect spec value (shell) +19.2%; (coil) +21.7% 161 (shell) -4.2% 248 (coil) +4.7% These increases are mostly due to updating the modulus of the alloy from the 193 MPa used in the original analysis to the 145 MPa spec value rather than localized the thinning of the wall.

The Shell Has Good Factors of Safety on the Allowable Stress The allowable is the lesser of ½ ultimate or 2/3 yield. Using the spec minimum, this would be (the lesser of or 322.5) For the thin area of the shell, the factor of safety (FS) on allowable is 327.6/161= 2.03.

Path Forward for the Type A Castings MTK was authorized to proceed with upgrades of A1 last Friday. EIO is taking steps to assure that the walls of the remaining Type A castings will be no thinner than A1 – i.e., 1.18”. We will process the non-conformance report (NCR) and an Engineering Change Proposal for this. –Analysis supports accepting A1 “as is”. –We will likely request that the remaining Type A castings be made similar to A1 but with the wall thicknesses being no thinner than 1.18”. EIO is evaluating schedule impact yet.

Progress on the C3, C4 Castings and the Type B Pattern Is Good C3 was returned from radiography, and processing of defect indications is underway. –Projected to ship to MTM by 8/5. C4 was poured last week, and was broken out of the of the mold. –Initial indications are good. The Type B pattern is on track for shipment to MTK on 9/15.

The Pace is Picking Up on the Vacuum Vessel MTM followed up on discussions held with Mike Viola last week on ways to improve schedule. –Now have a second press in operation and more personnel assigned. –The first 60 degree half field period vessel segment was welded together. –The 5 panels for the upper ¼ period has been welded, and the 5 panels have been for the remaining ¼ period have been formed.