1. NCSX NCSX TF Coil Conductor FDR 5/17/05 1 Michael Kalish NCSX TF Conductor

2. NCSX NCSX TF Coil Conductor FDR 5/17/05 2 Outline Requirements Design Calculations Specification, SOW Procurement

3. NCSX NCSX TF Coil Conductor FDR 5/17/05 3 Requirements Is the material specified correctly? Are the yield and ultimate specified for the conductor appropriate? Is the hole big enough? Is the copper cross-section big enough?

4. NCSX NCSX TF Coil Conductor FDR 5/17/05 4 TF Coil Winding Pack Winding Pack 3x4 Extruded Conductor Wound “Hard Way” Center Hole LN2 Cooled Each Layer Requires 88’, 100’ to 110’ supplied 4 Spools Required per Coil

5. NCSX NCSX TF Coil Conductor FDR 5/17/05 5 Drawing / Tolerances Discussions with Vendor Indicate Tolerances Reasonable Edge Radius results from R&D

6. NCSX NCSX TF Coil Conductor FDR 5/17/05 6 Winding Pack Insulation Scheme 3/8” Groundwrap on outboard leg 1/8” Groundwrap on inboard wedging leg Inner TF leg ground wrap thickness is 1/8” Outer leg of TF coil allows for the use of tough 3/8” ground wrap Insulation thickness can accommodate potential.020 inch tolerance build up easily

7. NCSX NCSX TF Coil Conductor FDR 5/17/05 7 Conductor Material Properties Yield Strength –Yield Strength shall be 26,000 psi min. (180 MPa) to 30,000 psi max. (0.5% extension under load) at room temperature –At LN2 Temperature 225 MPa Min. Tensile Strength –Ultimate Tensile Strength shall be 36,000 psi min. (248 MPa) with a minimum extension under load of 25% at room temperature –At LN2 Temperature 340 MPa Min. Hardness –The conductor shall have a Rockwell Hardness F between 60 and 70 at room temperature. If there is a discrepancy between the Hardness requirement and the Yield Strength requirement the Yield Strength measurement shall be the governing requirement.

8. NCSX NCSX TF Coil Conductor FDR 5/17/05 8 Maximum Conductor Stress Requirement + Assumptions showing Highest Conductor Stress Half Tesla TF Only Analysis Un-bonded assumption Maximum Stress = 117 MPa

9. NCSX NCSX TF Coil Conductor FDR 5/17/05 9 Yield and Tensile Requirement Adequate per Analysis Primary Membrane + Bending (PM+PB < 1.5Sm): σ(PM+ PB) =117 MPa < 225 MPa (1.5Sm) General Primary Membrane (PM < 1.0Sm): σ(PM) = FZ/ACu = 30 MPa <150 MPa (1.0Sm)

10. NCSX NCSX TF Coil Conductor FDR 5/17/05 10 Fatigue Requirements Met Fatigue (Cumulative Usage Factor, CUF < 1.0) Entering the 2x stress design-basis fatigue curve with an alternating stress of 74 MPa yields an allowable number of cycles ~ 100,000 cycles > 13,000 cycles required σeq(alt) = σalt /{1 - σmean/σut} = 62/{1-55/340} = 74 MPa

11. NCSX NCSX TF Coil Conductor FDR 5/17/05 11 Thermal / Hydraulic Analysis Verifies Cross Section and Hole Diameter With given cross section and hole size: Peak temperature and recovery time calculated for maximum required pulse (0.5 Tesla TF field) for 16.2 kA peak current with a 1.64 second equivalent square wave (ESW). Peak temperature rise of the coil is ~3.5 deg.K (~6 deg.R) per pulse LN2 system will be pressurized to a min. pressure of 60psi allowing a max temp of 95K for single phase LN2 flow Peak temperature insensitive to flow rate Full recovery to 80 deg.K after ~720 seconds with a 60 psi differential pressure applied. Pre-Pulse Temp 80K System pressure adequate to guarantee single phase flow Pulse repetition rate shall not exceed 15 minutes

12. NCSX NCSX TF Coil Conductor FDR 5/17/05 12 Procurement Cost and Delivery based on preliminary quotes Cost per Spool 247 lbs per spool x $4.47/lb = $1104 Conductor order for 19 coils + one spool for R&D Total = $1104 x 77 spools = $85K Delivery = 60 days (+shipping for OutoKumpu)