Shear Test Assembly update 3-9-07

Design of Pull Fixture history Single shear through bolt approach abandoned due to potential bending effects entering into test. Double shear (two tapped joints) adopted. Design calls for two tapped joints to be assembled into test fixture in a prototypic manner using all washers, bushings and frictional coatings used in the real assembly (140-190-2).

Use 4-post MTS testing Machine in 4508 50 Kip Loadcell (50 kip max load) Linear Alignment coupler (provided by Rick) [1.5-12 threaded internal and external] LVDT Rack (LVDT’s are 0.25 in max range) McMaster Carr tank [18” X 12” x 18”: 18 gauge) [3763K131] 2” Styrofoam enclosure either purchase or assemble panels with RTB. Tank base – 4.5 OD (2” ID) conflats and bellows Linear Alignment coupler Threaded Adaptor to go from grip to linear alignment coupler

This allows a maximum load of 25,000 lbs/joint in double shear. Machine Specs Max loading on machine in current configuration with loadcell, Grips, spherical bearings is 50 Kips. This allows a maximum load of 25,000 lbs/joint in double shear. Machine Maximum loading is 110 Kips.

Testing of Joint Static 1. Compression preload of 68,000 lbs on NCSX Bolts. (25 pulls) 2. Compressed preload of 25,000 lbs on NCSX bolts. (25 pulls) 3. no preload on joint (25 pulls) Cyclic loading on joint will be performed at 0.5 Hz to 100,000 cycles for case 1 and 2. (approx 55 hrs each of testing to get this) Thermal Float switch for LN2 being developed.

Cryo Containment for tank 4.5 OD half nipple 401004 (Clearance)  REF# 250-1 18 gauge SS can insulation MDC Bellows 400005 (clearance) REF# 250-X 2.00” Bellows ID welded Blank CF flange 110018 (through) REF# F450000 1.5”- 12 1.5”-12 Female Adaptor 1.5” pull rod stainless steel All items shown on this page have been received

Fabrication Status of Load-train All parts for tank-cryo system (including tank, insulation, bellows conflats etc) have been ordered and have arrived Pull rods have been ordered should be received by this week. Couplings, adapters, pull rods to be machined within two weeks. LVDT’s (0.25” max range) to be ordered this week. DWG’s of the pull specimen that PPPL will be assembling will be complete by 3-12-07.

Layout of Pull Fixture 1.5 -12 threaded Alignment between bottom and top pull rods must be maintained. 1.375 – 6 Class 3 tapped holes 140-190-2 bolt Assembly (2X) Tapped for ¾”-10 bolts Four ¾”bolts (2 per side) with slightly oversized holes in bottom plate to allow for alignment. Bottom plate can be made at ORNL if needed 1.5 -12 threaded

LVDT locations Pull Fixture iso view

Quick FEA Model Model has bonded interfaces at all connections. No slipping or sliding G10 bushings and middle shim. Model is locked at one end of rod. 50,000 lbs applied to one end of rod

Global Deflection (scaled)

Bolt assembly Deflection (obviously scaled)

Quick Check; How much length to dissipate LN2 in a 1 Quick Check; How much length to dissipate LN2 in a 1.5” rod in room air. LN2 Tb = 77K, x = 0 Kss = 14 W/m-K, L→∞, D = 1.5” Air: T= 25 C h = 15 W/m^2K Infinitely long rod Need 6 inches before hitting the MTS machine