NCSX TF Conductor NCSX TF Coil Conductor FDR

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

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

Requirements NCSX • 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? NCSX TF Coil Conductor FDR 5/17/05 3

TF Coil Winding Pack NCSX • Winding Pack 3 x 4 • Extruded Conductor Wound “Hard Way” • Center Hole LN 2 Cooled • Each Layer Requires 88’, 100’ to 110’ supplied • 4 Spools Required per Coil NCSX TF Coil Conductor FDR 5/17/05 4

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

Winding Pack Insulation Scheme NCSX • 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 1/8” Groundwrap on inboard wedging leg 3/8” Groundwrap on outboard leg NCSX TF Coil Conductor FDR 5/17/05 6

Conductor Material Properties NCSX • Yield Strength – – • Tensile 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 LN 2 Temperature 225 MPa Min. Ultimate Tensile Strength shall be 36, 000 psi min. (248 MPa) with a minimum extension under load of 25% at room temperature At LN 2 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. NCSX TF Coil Conductor FDR 5/17/05 7

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

Yield and Tensile Requirement Adequate per Analysis NCSX • Primary Membrane + Bending (PM+PB < 1. 5 Sm): σ(PM+ PB) =117 MPa < 225 MPa (1. 5 Sm) • General Primary Membrane (PM < 1. 0 Sm): σ(PM) = FZ/ACu = 30 MPa <150 MPa (1. 0 Sm) NCSX TF Coil Conductor FDR 5/17/05 9

Fatigue Requirements Met NCSX • Fatigue (Cumulative Usage Factor, CUF < 1. 0) Entering the 2 x 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 NCSX TF Coil Conductor FDR 5/17/05 10

Thermal / Hydraulic Analysis Verifies Cross Section and Hole Diameter NCSX • Pre-Pulse Temp 80 K • System pressure adequate to guarantee single phase flow • Pulse repetition rate shall not exceed 15 minutes • • • 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 k. A 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 LN 2 system will be pressurized to a min. pressure of 60 psi allowing a max temp of 95 K for single phase LN 2 flow Peak temperature insensitive to flow rate Full recovery to 80 deg. K after ~720 seconds with a 60 psi differential pressure applied. NCSX TF Coil Conductor FDR 5/17/05 11

Procurement NCSX • 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 = $85 K • Delivery = 60 days (+shipping for Outo. Kumpu) NCSX TF Coil Conductor FDR 5/17/05 12