NSTX Centerstack Fabrication

1. NSTX-U Supported by NSTX Centerstack Fabrication Coll of Wm & Mary Columbia U CompX General Atomics FIU INL Johns Hopkins U LANL LLNL Lodestar MIT Lehigh U Nova Photonics Old Dominion ORNL PPPL Princeton U Purdue U SNL Think Tank, Inc. UC Davis UC Irvine UCLA UCSD U Colorado U Illinois U Maryland U Rochester U Tennessee U Tulsa U Washington U Wisconsin X Science LLC Culham Sci Ctr York U Chubu U Fukui U Hiroshima U Hyogo U Kyoto U Kyushu U Kyushu Tokai U NIFS Niigata U U Tokyo JAEA Inst for Nucl Res, Kiev Ioffe Inst TRINITI Chonbuk Natl U NFRI KAIST POSTECH Seoul Natl U ASIPP CIEMAT FOM Inst DIFFER ENEA, Frascati CEA, Cadarache IPP, Jülich IPP, Garching ASCR, Czech Rep James H. Chrzanowski and the NSTX Upgrade Team Princeton Plasma Physics Laboratory NSTX Upgrade Project Office of Science Review LSB B318 May 2 - 3, 2012

2. Progress Since Last Review • A great deal of work and accomplishments have been achieved since the last review. • TF Conductor Sub-assembly operations are underway • Solder trials for TF conductor have been completed • Centerstack Casing fabrication is underway • Area preparation for Centerstack fabrication has been completed • Tooling fabrication and procurement is underway • OH conductor has been shipped • Outer TF Coils procurement now underway • Final Centerstack Assembly on schedule for October 2013 completion

3. General Arrangement Umbrella Structure TF Flex Bus and Support Structure Centerstack Assembly Major Centerstack Components Outer TF Coils Vacuum Vessel

4. TF Conductor Assembly • Major Tool and Edison Welding Institute have successfully delivered to PPPL four (4) TF conductors. • The balance of the conductors for first Quadrant will be delivered by mid May. • Final development of the Friction Stir Welding (FSW) procedures and the necessary NDT testing has started slowly. However these delays have now ended and production has started.

5. TF Fabrication Sequence Bars inspected at Major Tool & preliminary machining performed Bars shipped to Major Tool Bars shipped to EWI Leads extensions are FSW to conductors Bars shipped back to PPPL Bars are shipped to Major Tool Final machining of TF Assemblies FSW joints are Non Destructively Tested

6. TF Conductor Production Videos

7. TF Solder Trials • Solder Trials: • Trials have been performed with the assistance of Solder Consultant to verify materials and heating processes • Successful heat runs w/actual TF bar • Materials: • Solder paste- 96.5 Sn /3.5 Ag w/ GMS based “R” flux [Glyceryl Mono-stearate, Terigitol (a detergent) and Cyclohexlamine Hydro-bromide] • Solder Temperatures: • Liquidus ~221º C (430º F) • Soludus~ 246º C (475ºF) • TF solder temperature~ 270 degrees C to ensure wetting • Heating Method: • Power supply w/heating plate • Torch heat to complete process • Begin production soldering first week of May

8. Centerstack Casing • The contract for manufacturing the Inconel casing has been awarded to Martinez & Turliz in California. • They have been making good progress in the manufacturing • Raw material has all been received • Main components have been rolled and welded • Flanges have been machined • Inconel forgings for the transition sections will arrive in mid May • PPPL team will revisit in May • Delivery scheduled 9-20-12

9. Area Setup- TF Fabrication VPI Station

10. Safety Involvement • The fabrication & assembly of the Centerstack will be performed by PPPL personnel at the laboratory. • Safetyis an important part of the PPPL culture • Safety is incorporated in all aspects of the development program- carryover to production • Industrial Hygiene(IH) has participated in the planning and setup of the coil area • Job Hazard Analysis (JHA’s)are being developed for each procedure • Procedures: Clearly identify safety precautions for specific operations • Personnel protective equipment(PPE’s) being used • Involvement of all safety groups

11. Tooling Fabrication and Procurement • Inner TF Bundle- tooling • Soldering station- complete√ • Grit blasting station complete√ • Turn insulation station complete √ • Oven commissioned- complete √ • Quadrant mold- Delivery 1st. week of May • Priming station complete √ • VPI station- complete √ • Full TF mold- Requisition in system

12. Tooling Fabrication and Procurement • OH Solenoid- tooling • OH copper conductor has been procured-delivery early May • OH conductor sandblasting & priming will be sub-contracted –October 2012 • Induction braze station has been procured to support OH braze joints- delivery end of May • Braze qualification program scheduled for this summer • Aquapour mold fabrication-complete √ • Trials have been scheduled for later this summer • Tension unit & taping machines are scheduled for fabrication this summer • OH Mold has been designed, but will not be procured until October 2012 • OH Winding station- winder delivered√

13. OH Solenoid Winding Facility

14. Testing of Aquapour for Center Stack Fabrication • Rolled Aluminum Cylinder Represents TF Bundle • Maintains true TF OD and clearance space at top and bottom • Will use actual mold segments and alignment pins • Will test: • 1. Filling of Aquapour • 2. Curing of Aquapour with heating blankets • 3. Washing Out of Aquapour 10.5” Trials will be performed this summer 92” 8.5” 15.788” Center Stack Immediately Before Washing Aquapour “Mock TF Bundle” with 3x Mold Segments

15. Lehman Review Recommendation dispositon log • 201110 - L02 from October 2011 Lehman Review • Item:2.2 Evaluate procuring spare key fabrication tooling ( e.g. induction heater) to reduce schedule risk from failures prior to start of fabrication. • Status: The project has procured induction braze unit- delivery end of May • Spare parts: investigated purchase of spare parts. Parts are readily available so only spare work coil procured. • A total of 24 production induction brazes are needed for OH solenoid

16. Plans Forward for Centerstack Components • Inner TF Bundle • VPI first Quadrant- July 12, 2012 • VPI Full Bundle- January 15, 2013 • OH Solenoid • Begin winding OH solenoid-March 20, 2013 • VPI OH Solenoid- July 1, 2013 • Centerstack Casing • Delivery is scheduled for September 2012 • Outer TF Coils • Requisition has been submitted to procurement • Delivery two (2) OTF coils- December 2012

17. Plans Forward- continued • Inner Poloidal Field Coils • Place purchase order for PF coils- October 2012 • Delivery spring/summer 2013 • TF buss and support components • Place requisitions in procurement- October 2012 • > $946.0 k procurements • Centerstack Assembly- • Assembly will occur between May to October 2013 • Developing Assembly procedures • Deliver completed Centerstack Assembly October 2013 MT Torque-nut™ Flex-Bus (Cu-Cr-Zr)

18. Conclusion • The risks associated with the production of the TF conductors have been addressed and conductors are being delivered • The soldering trials have been completed and the first conductor is ready to be soldered • The TF bundle manufacturing facility has been setup and ready to begin production • Awaiting delivery of molds and completion of procedures • The Inconel casing has been ordered and is on schedule • The OH conductor has been shipped • Tooling for the OH winding has been developed. Some has been delivered the balance will be ordered this summer • The production of the Centerstack Assembly is ready to begin