1. NCSX Coil Winding Development Program Application of Epoxy/Fiberglass Modular Coil Molds -Ventilation/Exhaust Issues

2. 2 NCSX Cross-section Modular coils

3. 3 Modular Modular Coil Fabrication  The modular coils will be wound in the TFTR Test Cell Two winding stations “VPI” Vacuum- Pressure Impregnation station using autoclave VPI Exhaust ventilation

4. 4 Fabrication Fabrication Steps- part 2 VPI  Waffle Boards and fill ports (sprues) will be added to the modular coil bundle.  Tedlar insulation (non-stick) will then be over- wrapped.  The mold will then be installed around the turns (R&D program will define the VPI methodology)  Mold shall be epoxy/glass fiber sprayed over Tedlar insulation  The shell is non-conductive and could remain around coil  The modular coil will then be vacuum impregnated with the resin system approved by the NCSX Project based upon the R&D program  Once cured, the coil will be electrically tested and transferred to Field Period Assembly station

5. 5 NCSX Modular Coil Typical Cross-section

6. 6 Two Phases of Work Prototyping Development –Components will be “table-top” sized, ~ 4 foot in length. – Six to eight prototypes samples will be encased. –We plan to do the work in a portable tent enclosure set up in the TFTR Test Cell. –Modest amounts of material use. Modular coil molds. –Much larger enclosure needed. –Each coil has +20 feet of coil. –19 coils to encase.

7. 7 Typical Application

8. 8 Materials- Spray Application Materials being proposed –Hetron 980/35 Resin System (Low Styrene Content Epoxy Vinyl Ester Resin) Promoter-Nuodex DMR Cobalt 6% Naphthenate Co-promoter-N, N-Dimethylaniline Catalysts- Cadox L-50a –Acetone (for cleaning)

9. 9 Safety Concerns Ventilation- good air flow Personnel protective equipment –Respirators –Eye/face protection –Gloves, coveralls, etc. Exhaust- via the elephant trunk system –HP concerns –Environmental –Flammability concerns –Mixed waste