NCSX M. Cole, P. Fogarty, K. Freudenberg, T. Hargrove, G. Jones, G. Lovett, B. Nelson, D. Williamson April 27, 2005 Modular Coil Type-C Final Design Review – Part I

NCSX 2 Charge Questions Is the C1 cladding ready for fabrication at PPPL? What is procurement plan for C2-C6, A, B? How is fabrication data managed (in-house vs supplier)? What issues remain for Type-C? How to solve? What is status/schedule for SRD, DACs, etc?

NCSX 3 MCWF C1 to be completed by 6/24

NCSX 4 MCWF C1 machining (cont’d)

NCSX 5 MCWF C1 machining (cont’d)

NCSX 6 MCWF mods address coil winding

NCSX 7 Winding form prep Drawing SE establishes layout of studs, hole numbering scheme Based on Lawton model with machining features added Stud length increased to 2-in

NCSX 8 C1 cladding incorporates TRC input Increase part spacing to.125-in, tab gap =.060-in (done) Make min tab width >.2-in (not completely addressed) Increase tab length, trim at assembly (chill plates) Form main body to tee/wp, bend tabs individually Notch parts for identification, alignment (not done) Add sprue cutouts to flat pattern (not done) Number parts according to hole position (not done) Replace cladding with strips in tight bends Reduce number of slits (not completely addressed) Reduce radius of clamp cutout (done) Modify staking tools and procedure

NCSX 9 C1 cladding flat patterns Approx 5 patterns per drawing, 156 drawings total (promoted to fab 4/20) Two layers, cut outline and “etch” layer for part number, bend lines

NCSX 10 Flat patterns done, asm drawings not TRC style, cladding in groups Alternate drawing, organized by clamp no.

NCSX 11 Schedule for remaining cladding/chill plates Fabrication drawings: Type-C cladding flat patterns Apr-20, need parts by Jun-13 (receive C1) Type-C chill plate flat patterns May-18, need by Sep-8 (start of chill plate asm) Type-A cladding and chill plate flat patterns Jul-6, need by Nov-8 (receive A1) Type-B cladding and chill plate flat patterns Aug-31, need by Apr-2006 (receive B1)

NCSX 12 Plans for procurement package Coil C1 cladding and chill plates to be fabricated by PPPL Coils C2-C6, A1-A6, B1-B6 cladding and chill plates to be procured via fixed price subcontract: –Draft C-Spec, SOW Jul-1 –Modified Type-C DXF (based on C1 experience) Jul-30 –List of potential vendors Jul-30 –RFP on street Aug-5 –A, B cladding, chill plate DXF files complete Sep-1

NCSX 13 Organization of dwg packages C1 patterns (DXF) have been transmitted as.ZIP file to PPPL shops TRC models had problems with dropped lines, should try.DWG format All files (in-house, supplier) to be stored on manufacturing FTP site –Drawings / DXF files will be posted on website –Only the current documents on website will be certified for fab. –All files and hardcopies must come from website and must be checked for possible updates prior to fabrication Bob Simmons has included this process in procedures Tom Brown will announce availability/changes as is done for MCWF

NCSX 14 Chill plates, lead blocks, terminal are remaining issues Chill plate drawings - Is there a faster method to produce them? Lead block design - Difficult geometry, need complete set of parts at start Jumper mounting block - Reduce height to maintain clearance TRC as-built lead blocks assembled to MCWF C1

NCSX 15 Lead block asm End View SE142C-020.ASM shows TRC lead blocks assembled to MCWF C1 Working on addition of mounting bosses to back of straight blocks, contour of finger blocks to fit complex winding pack shape Main issue: lead block design is difficult to adapt to twisted, curved coils without major modifications, and will still retain bad features (tight curvature, keystoning) associated with TRC design Plan View

NCSX 16 Lead block modifications Revise lead geometry slightly to: –Increase bend radii more than factor of two –Decrease linear extent of lead region to minimize effects of curvature and twist in winding pack –Reduce field errors by reducing current loop areas Schedule impact minimized by making stereolithography models of all parts for fit check prior to receipt of actual parts May require slight tweak to lead slot openings in winding form

NCSX 17 Plan to complete lead blocks Order long lead G11-CR blank material Develop models, evaluate current filaments for field errors Create STL model of lead block asm to check fitup of actual parts Revise/issue part drawings in order of need for C1 Pre-fit parts with STL assembly before use on coil

NCSX 18 Terminal block height must be reduced Offset height of 1-in gives.25-in clearance with TF coil, but limits space to manipulate insulated cable Options: –Pre-bend cable prior to brazing on termination - need R&D using split chill block with formed shape –Insulate cable after bending –Relieve TF structure to reduce interference Chill block modified for cond pre-bend Asm w/ 2-in offset

NCSX 19 Status of design documentation SRD has been issued for final comments Comments will be incorporated and SRD signed prior to final Type-C FDR in May No substantial changes have occurred since November draft All other documentation has been issued as draft, except for the coil assembly specification (TRC spec not a good example) Analysis updates are needed –Material properties from beam tests, tensile tests, and transverse compression tests –Update of allowable stress values –Re-run non-linear analysis of TRC, compare test results to analysis for benchmark –Re-run non-linear analysis of all coil types with correct properties, compare to allowable stresses

NCSX 20 Conclusion Is the C1 cladding ready for fabrication at PPPL? –DXF files are released, asm drawings in progress –Modifications can be made later for small no. of parts What is procurement plan for C2-C6, A, B? –Type-C, -A flat patterns ready to order in Jul, Type-B in Sep How is fabrication data managed (in-house vs supplier)? –FTP site to manage all packages and revisions What issues remain for Type-C? How to solve? –Quantify min bend, adjust design to coil shapes What is status/schedule for SRD, DACs, etc? –SRD approval is imminent, CSPEC and ICDs lagging, analysis needs update to match config, material test results

NCSX 21 Backup Slides

NCSX 22 Winding Pack Thermal Analysis Temperature dependent heat generation (see next slide) Crimp conductivity set to 100 W/m-K Groundwrap overlap is reduced from 2X to 1.3X. Copper thickness is 0.04 in. Pulse shot is still 2T, high beta, 10,390 Amps/cable. Cool down time is still 15 minutes. K. Freudenberg

NCSX 23 First Cycle Immediately after pulse T = 15 minutes (after cool down)

NCSX 24 Ten Cycles Tee Temp Winding Temp

NCSX 25 Temperatures during the 10 th shot Temperature after the 10 th shot Temperature after the 10 th cool down

NCSX 26 After 10 th cycle (winding and tee isolated)