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

2. BACKGROUND TF joint failed on February 14, 2003 due to structural weaknesses At the April 10, 2003 review….. –cause of failure was explained –new design was presented –sufficient confidence was gained to proceed with conductor machining Since April the analysis, testing, and design has been completed – chits generated during the April review have been resolved Purpose of this review is to examine the final design –identify any shortcomings which may need correction Additional review in September will assess cost and schedule –today’s review will establish that the technical basis is sound

3. PURPOSE OF REVIEW Obtain critique of new design of the TF Flag Joint –Identify any shortcomings needing further attention (chits) Confirm viability of Flag Joint Design for 6kG operation

4. SCOPE OF REVIEW TF Flag Joint and Integrated Assembly –Inner Leg / Flag Interface (the joint) –Flag –Flag Fasteners (threaded inserts, studs, washers, nuts, etc.) –Flag Structural Supports (Boxes, Shear Shoes) –Hub Assembly/Torque Collar –Built-in Instrumentation Features Other aspects may be discussed but are out of scope

5. AGENDA

6. REVIEW PROCEDURES Chits to be submitted to Chairman B Nelson Chits to be dispositioned by Review Board Chits to be resolved by Cog Engr C Neumeyer P. Anderson, GA L. Dudek J. Irby, MIT B. Nelson,ORNL** ** Chair * Ex-officio  Remote participant C. Neumeyer* P. Peterson, GA P. Titus, MIT  G. Voss, Culham

7. RECOVERY ACTIVITIES

8. DESIGN 3D modeling complete, including… integrated TF inner leg bundle coolant tube routing and bulkhead outer leg connections Fabrication drawings complete, including… conductors flags flag boxes shear shoes hub assembly torque collar

9. ANALYSIS Structural FEA complete, including… both tiers of conductors out-of-plane load path through spline collar and wet lay-up representation in-plane, out-of-plane, thermal loads SOFT, EOFT, EOP cases Other analysis complete, including… force calculations temperatures, including joint temperature rise fastener sizing calculations miscellaneous calculations Formal documentation and checking is presently underway

10. TESTING Component testing (design input data) consists of: Pull-out tests on threaded inserts - one time and 50,000 cycle at 100 o C Pull-out tests on bolts threaded in copper - one time and 50,000 cycle Friction coefficient and electrical resistance tests Shear tests on torque collar attachment Status: Complete Prototype testing (design verification) consists of: Mechanical mock-up tested for 50,000 cycles Electrical mock-up tested at full current and I 2 T Status: In Preparation

11. HIGHLIGHTS SINCE APRIL Structural FEA completion -greater insight into thermal-induced behavior Shear Shoe (a.k.a. Shear Key) re-design Torque Collar - Three segment collar - Torsion-only design (de-coupled vertical and radial loads) - Improved epoxy wet lay-up Voltage probe using commercial spring-loaded probe Precision measurement of contact resistivity vs. pressure Component tests completed