1. NSTX TF Flag Joint Design Review OVERVIEW C Neumeyer 8/7/3

2. Topics Requirements Forces Temperatures and Thermal Effects Contact Resistance Load Paths Description of New Design

3. FIELD AND CURRENT Base GRD requirement: 3kG at R 0 =0.854m with 4.5 sec flat top, once every 300s 35580 Amp with 36 turn coil High field GRD requirement: 6kG at R 0 =0.854m with 0.6 sec flat top, once every 300s 71160 Amp with 36 turn coil

4. CURRENT WAVEFORMS Engineering design accounts for PS response, inc’l L/R decay in case of fault from I max ∫I 2 T = 6.0 x 10 9 A 2 -s for 3kG-4.5s ∫I 2 T = 6.15 x 10 9 A 2 -s for 6kG-0.6s Design basis ∫I 2 T = 6.5 x 10 9 A 2 -s which causes adiabatic  T of 80 o C in Cu 6kG pulse is most critical for joint since forces are maximum and time for heat diffusion is minimum

5. VOLTAGES TF PS is 1kV DC no-load –1012.85 volts DC avg –750*sqrt(2)=1060 volts peak High resistance grounded, V line-ground =500V nominal, 1kV max CHI can elevate hub assembly and OH tension tube to 1kV Max design voltages: –turn-to-turn = 1000/36 ~ 30V for adjacent conductors, 1kV max –turn-to-ground (hub and OH tension tube) = 2kV –base hipot = 2E+1= 5kV –routine hipot ~ 3kV

6. IN-PLANE FORCES ComponentForce (lbf) Moment (in-lbf) Inner Tier Flag/Link923531719 Outer Tier Flag/Link230914343 Total All Turns249325 Note: B t =6kG

7. OUT-OF-PLANE FORCES ComponentForce (lbf) Moment (in-lbf) Inner Tier Flag/Link469855609 Outer Tier Flag/Link303937174 Total All Turns1491981.78e6 Inner Legs below Flags4.90e5 Notes: 1)B t =6kG, OH and all PF at maximum current 2)OH contribution is bi-directional

8. TEMPERATURES Inner Leg - T SOFT = 29 o C - T EOFT = 66 o C - T EOP = 95 o C (worst case) Wet lay-up & collar - negligible  T

9. THERMAL EFFECTS Vertical length of inner leg bundle from bottom to top increases by approximately 0.35” during a pulse Vertical length of inner leg from torque collar to top of bundle increases due to inner leg temperature rise, whereas flag and hub remain relatively cool Radius of inner leg bundle increases bundle increases by approximately 0.006” during a pulse Flag heats modestly during a pulse (  T ~ 5 o C) but can ratchet to  T ≤25 o C at rated duty cycle, corresponding to an increase of 0.005” in length

10. CONTACT PRESSURE & RESISTANCE

11. LOAD PATHS 1)Friction 2)Shear Shoe 3)Torque Collar 4)Hub/Spline/VV

12. KEY DESIGN FEATURES Flag Flag bolt (stud) Shear Shoe Flag Box Box Bolt (stud)Collar Hub Disk Probe Tail

13. TORQUE COLLAR

14. VOLTAGE PROBES IDI 100526 Coax Probe terminated in SMB connector -commercial spring loaded probe used in semiconductor test industry

15. DESIGN HIGHLIGHTS Solid flags insulated with two half-lapped layers of Kapton, glass wrapped and potted in 304SS boxes Boxes bolted to the hub disks using 5/8” hardware Flags attached via 3/8” Inconel bolts (studs) preloaded to 5000lbf Belleville washers provide redundancy to necked-down flag bolts Shear shoe located on outer edge of flags is bolted to ends of inner leg conductor using A286 SS bolts, one vertical and one angled for the moment reaction Three segment torque collar w/two 1/2” dia. bolts and 6000 lbf belleville washers at each joint with 0.180” thick wet lay-up (Hysol E-120HP), 1ksi minimum compression Collar transmits torque to hub structure at 3 anchor points Redundant voltage probes are located on each side of the flag