ARIES -ST Study L. Waganer 4 December 1998 Page 1 Revised TF Coil Costing Cost Assessment Changes Revised Weights Adjusted to 11/98 Strawman CAD Baseline –0.5 m Thick on Mid-Plane, Can Estimate 0.7-m Case When Available Increased Material Wastage to 5% on Both Cu and Al Obtained Raw Material Quotes - Increment above LME Prices –Suitable Alloys Available with Low Percentages of Adverse Elements –On-Site Recycle of Copper Does Not Seem Practical - Sell to Recyclers Included Fabrication Hardware Cost in Estimate –Al : Furnaces, Transfer Pumps, Heated Piping, Atomizing Heads –Cu: Powder Storage, Transport System, Positioning System, Melting Heads Estimated Energy Cost to Heat and Melt Metals Reduced Number of Alum. Spray Casting Heads to Slow Rate –Reduced Capital Costs More Than Offsets Longer Fabrication Time (6 Mo.) Added Costs for Contingency (20%) and Fee (12%)

ARIES -ST Study L. Waganer 4 December 1998 Page 2 Revised TF Coil Costing Baseline TF Coil Configuration Centerpost Is Now Inverted with Large End Down –Weighs 0.85 x Mkg, 85% Cu –20% Higher Weight Outer Shell Has Three Parts –For 0.5 m Midplane Thick Shell Upper:1.558 Mkg, 85% Al Middle: Mkg, 85% Al Lower:0.548 Mkg, 85% Al Total Weight (2.69 Mkg) is 6% lower –Lower Shell Components May Be Fabricated Upside Down and Inverted For Installation –Large Component Weights Complicate Handling and Installation

ARIES -ST Study L. Waganer 4 December 1998 Page 3 Revised TF Coil Costing Laser or Plasma Arc Forming A laser or plasma-arc deposits a layer of metal (from powder) on a blank to begin the material buildup The laser head is directed to lay down the material in accordance with a CAD part specification AeroMet has produced a variety of titanium parts as seen in attached photo. Some are in as-built condition and others machined to final shape. Also see Penn State for additional information.

ARIES -ST Study L. Waganer 4 December 1998 Page 4 Revised TF Coil Costing Good Material Properties Can Be Obtained Fatigue testing performed on laser formed Ti-6Al-4V, showing performance at the low end of wrought material. Plotted against standard axial fatigue zones of cast and wrought Ti-6Al-4V, Ref Aeromet and DARPA.

ARIES -ST Study L. Waganer 4 December 1998 Page 5 Revised TF Coil Costing Laser Forming Can Easily Fabricate Simple Passive Cooling Systems Cool Water Descends to Bottom of Centerpost in Central Passage, Moves Radially Outward to the Risers in Which the Water Is Heated and Rises to Passive Heat Sink

ARIES -ST Study L. Waganer 4 December 1998 Page 6 Revised TF Coil Costing Forming Centerpost with Laser or Plasma Arc Offers Design Flexibility Holes with Graded Spacing 15% Water Content Slots with Graded Widths and Lengths For Background Information, See Centerpost Cooling Options

ARIES -ST Study L. Waganer 4 December 1998 Page 7 Revised TF Coil Costing Summary of Centerpost Costs Mass of centerpost with holes 851,000 kg Including wastage of 5%894,000 kg Deposition rate with multiple heads200 kg/h Build labor, 24-h operation, 1 operator assistant6702 h Inspection and rework1676 h Total labor hours8628 h Labor $150/h (including overtime and site premium) $1,294,000 Material cost, $2.86/kg (copper)$2,556,000 Energy cost (20% efficiency) for elapsed time + 30% rework$93,000 Material handling and storage $75,000 Postitioning systems$435,000 Melting and forming heads and power supplies$600,000 Inert atmosphere system$44,000 Process computer system$25,000 Subtotal cost of centerpost$5,122,000 Contingency (20%)$1,024,000 Prime Contractor Fee (12%)$738,000 Total centerpost cost$6,884,000 Unit cost (finished mass = 704,000 kg) $8.09/kg (~ 6 mo) Note: New items are green, increased values are red

ARIES -ST Study L. Waganer 4 December 1998 Page 8 Revised TF Coil Costing Aluminum TF Return Shell TF shell has three parts Spray Cast preform will be vacuum vessel Vacuum vessel will be 0.5” aluminum plate, 5052 or 5002 for low resistance and ease of welding Remainder of VV shell thickness (0.5 to 2.5 m) will be spray cast to final shape and thickness Stainless steel coolant tubes will be embedded in spray cast material Flanges and other features can be spray cast (not costed yet)

ARIES -ST Study L. Waganer 4 December 1998 Page 9 Revised TF Coil Costing Aluminum TF VV Cost Analysis Contingency and Fee Added Mass of 1/2”-thick plates, incl. wastage41,765 kg Material cost: $5/kg$208,825 Bump forming: 90 panels x 60 h/panel 5400 h On-site weld setup: 6 mo x 6 people x 160/mo5760 h Weld prep: 90 panels x 2 h/m + setup(10 h/panel)4776 h Segment welding: 900 m x 0.13 h/m ÷ 25% efficiency472 h Weld inspection: 900 m x 1 h/m900 h He leak check: 900 m x 0.5 h/m450 h Final cleaning for vacuum service 1500 h Total labor hours19,258 h Labor $120/h (including site premium)$2,310,960 Subtotal$2,519,785 Contingency (20%)$503,957 Prime contractor fee (12%)$362,849 Total cost of vacuum vessel$3,386,591 Unit cost (finished mass = 39,776 kg) $85.15/kg 2-3 yrs elasped time

ARIES -ST Study L. Waganer 4 December 1998 Page 10 Revised TF Coil Costing Schematic of Spray Casting Process Molten Metal Furnace, Courtesy of SECO/WARWICK, Inc

ARIES -ST Study L. Waganer 4 December 1998 Page 11 Revised TF Coil Costing TF Return Shell Cost Development Spray cast aluminum is cooled with room temperature water, flowing through embedded SS coolant tubes Part is assumed to be 85% aluminum, 15% coolant Flanges and fittings not included, but additional cost would be minimal Part will be fabricated on site Cost is 10th of a kind, 1998$, fabrication hardware cost included Upper shell built in place Middle and lower shells built upside down, inverted, and moved to Power Core area

ARIES -ST Study L. Waganer 4 December 1998 Page 12 Revised TF Coil Costing Spray Cast Shell Cost Analysis Mass of three shell components2,690,000 kg Including wastage of 5 % 2,820,000 kg Deposition rate per head (4 heads used)0.5 kg/s Build labor, 1 operator+ 1 assistant/inspector, 50% efficiency 1569 h Inspection and rework400 h Total labor hours2089 h Labor $150/h incl. site premium$313,375 Material cost, $1.87/kg (aluminum) + tubes$5,281,815 Energy cost, natural gas + pump electrical$37,398 or $37,398 Melting and handling furnaces incl installation$2,650,000 $985,000 Other fabrication hardware $1,379,000 $1,379,000 Subtotal$9,715,588$8,046,588 Contingency (20%)$1,942,318$1,609,318 Prime Contractor Fee (12%)$1,398,469$1,158,709 Total cost of spray cast shell $13,052,375$10,814,615 Unit cost (finished mass = 2,020,000 kg) $4.85/kg$4.02/kg Note: New items are green, changed values are red Seco/Warwick Schaefer

ARIES -ST Study L. Waganer 4 December 1998 Page 13 Revised TF Coil Costing TF Coil Cost Summary ComponentFinished MassTotal CostUnit Cost Cu Centerpost0.851 Mkg $6.88 M $8.09 TF Vacuum Vessel0.040 Mkg $3.39 M $85.15 Al Spray Cast Shell Mkg $11.93 M (average) $4.44 TF Coil System3.581 Mkg $22.20 M (average) $6.20 (minimum) $5.89 (maximum) $6.51 Recommend using low-cost, automated fabrication technique for Centerpost and TF Return Shell with supporting costs.