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NCSX. NCSX Mod Coil R&D/Tooling Activity Update. Jim Chrzanowski & NCSX Team January 21, 2004. Modular Coil Winding Activities. NCSX. New conductor “Inch-worm casting Twisted Racetrack coil Keystone tests Epoxy impregnated conductor- mechanical & thermal tests

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ncsx mod coil r d tooling activity update


NCSX Mod Coil R&D/Tooling Activity Update

Jim Chrzanowski & NCSX Team

January 21, 2004

modular coil winding activities
Modular Coil Winding Activities


  • New conductor
  • “Inch-worm casting
  • Twisted Racetrack coil
  • Keystone tests
  • Epoxy impregnated conductor- mechanical & thermal tests
  • Modular coil production tooling
copper conductor
Copper Conductor


  • New copper conductor has been received from New England Electric Wire Corp. for testing
    • (10) 200+ foot spools of regular processed w/lubricant compacted copper conductor
    • (8) 200+ foot spools of clean process conductor
  • Conductor size 0.350 in. x 0.391 in. +/- 0.010 inch with 0.004 in. nylon serve
  • Conductor was received with (2) half-lapped layers of 0.004 inch think S-2 glass insulation applied
rga results


RGA Results

-Both conductor types were baked out and RGA pressure monitored

-The peaks seen are oxygen, nitrogen, water and argon, typical of cleaned parts exposed to room air

No significant difference is noted

inch worm coil winding activities


“Inch-Worm” Coil Winding Activities
  • Inch-worm casting has been mounted to a tilt turn table located in the D-site basement for trials
  • Trials will begin next week
  • Inch-worm will be used to: -Develop tooling & measurement devices; train personnel and develop a better understanding in conductor handling and tolerance control
twisted racetrack coil winding activities


Twisted Racetrack Coil Winding Activities
  • Casting contract was awarded to EIO with an expected delivery of March 31, 2004
  • Winding will begin in April 2004 in the D-site Test Cell using the turning fixture and autoclave equipment
  • Need details of copper cladding as well as clamps to initiate component fabrication

Casting pattern

keystone tests
Keystone Tests


  • Keystone tests will begin next week. Tests will be similar to those performed on earlier conductors
  • New insulated conductor will be wound in both directions
  • Preliminary results should be available by the end of next week.
mechanical thermal properties tests
Mechanical/Thermal Properties Tests


  • Preparations are under way to begin fabrication of additional specimens for testing the new impregnated conductor
  • New straight single specimen mold will be ready this week for 1st. VPI next week. (compression and flexural tests)
  • Undetermined number of 4-turn coils will be fabricated and used for testing tensile and fatigue properties-
  • Dimensions of winding forms required to proceed
  • All testing will be completed in-house at PPPL

Matrix/spec is required to outline testing program

straight tee specimen
Straight Tee-Specimen


  • Modifications have been made to the original straight tee section for reuse with the new conductor and insulation scheme
  • “Bag mold” grooves as well as additional clamp mounting holes have been added
  • Specimen will be produced following completion of the first VPI of specimens sometime next week.

“Bag mold” grooves

modular coil fabrication turning fixtures


Modular Coil Fabrication- Turning Fixtures
  • All steel has been received for (4) frames and (3) support rings- additional (3) rings are being rolled at vendor
  • Majority of frame parts have been fabricated
  • First turning fixture will be operational by the end of February
modular coil fabrication autoclave fabrication


Modular Coil Fabrication -Autoclave Fabrication

Upper dome flange is being machined on “Sellers” horizontal mill

modular coil fabrication autoclave fabrication continued


Modular Coil Fabrication -Autoclave Fabrication- continued

Electrical panels being manufactured and assembled

Salvaged vacuum pumps from PBX being used to provide vacuum



Modular Coil Fabrication -Autoclave Fabrication- continued

Ports being added to lower dome and chamber

additional tasks


Additional Tasks
  • Completing layout of coil winding facility- with (2) winding stations
  • Begin generating a “MIT” plan for manufacturing Modular Coils
  • Complete Procurement plan for modular coil production
  • Begun identification by name of coil manufacturing team (17 technicians will be required at peak coil production mode)