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February 25, 2005 Jim Chrzanowski

NCSX- Cable Property Testing

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Scope

Materials used in SpecimensConductorInsulationEpoxy system

Tests Being PerformedTest EquipmentDescription of specimens

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Conductor Description

Flexible spooled compacted copper cable [12x5/44/34]Nylon serve on outside surface [0.004 in. thick]2640 strands34 gauge [nom. 0.0063 in.]Conductor A: Normal cable mfg. ProcessConductor B: Clean cable mfg. process

0.359 +/- 0.008

0.318 +/- 0.008

0.334 Ref

0.375 Ref

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Insulation

Conductor is pre-insulated (turn to turn) with (1) half-lapped layer of glass tapeInsulation description

S-2 glass (Four harness satin weave) with reactive amino silane finishNominal thickness 0.004 in. thickGlass tape identifier: ECG150-2/2Temperature class 180 degrees C

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Epoxy SystemResin system selected:Resin system selected: CTD-101K

Product of Composite Technology Dev. Inc.3- Part component epoxy systemExcellent performance at cryogenic temperatures with a lng pot life and low viscosityCure Cycle:

5 hours @ 100 degrees C (Cure)16 hours @ 125 degrees C (Post cure)

Pot Life:145 hours @ 25 degrees C …….1300 Cp 60 hours @ 40 degrees C …….400 Cp 20 hours @ 60 degrees C …….100 Cp

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Performance Tests

Type of TestsType of TestsFlexural tests.. [8 inch long single conductor specimens]Compression tests.. [0.75 inch long single conductor specimens]Tensile tests.. [Racetrack coils- 4-turn specimens]Cure shrinkage [Racetrack coils 2 lengths 4-turn specimens]Fatigue (cyclic) testing [TBD] [single conductor and/or 40 turn bundle

Test ParametersTest Parameters2- different processed conductors (clean vs. standard)3- different temperature ranges (77 deg.K, 194 deg.K and room temperature)

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Mechanical Test Equipment

MTS Servo-Hydraulic Tester Capacity 100 KIPS

MTS Servo-Hydraulic Tester Capacity 10 KIPS

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Flexural and Compression Specimens

Flexural Tests

Compression Tests

Cold Bath

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4-turn racetrack coils will be wound without ground wrap and will be used for the tensile testsCoil leads will allow the coil to be electrically tested during or following the tensile tests

Winding Pack dimensions for 4-turn racetrack coilsalternate conductor

serve 0.004 inturn insulation 0.007 in (.004 center, .007 edge)cable size, width 0.318 in with servecable size, height 0.359 in with servenominal shim, radial 0.043nominal shim, lateral 0.045

"radial" buildno. in subtotal total for Cumulative

layer thickness stack thickness group build

turn wrap, glass 0.007 2 0.014 0.014turn wrap, serve 0.004 1 0.004 0.018turn copper 0.351 1 0.351 0.369turn wrap, serve 0.004 1 0.004 0.373turn wrap, glass 0.007 2 0.014 0.387 0.387shim, layers 1-2 0.043 1 0.043 0.043 0.43turn wrap, glass 0.007 2 0.014 0.444turn wrap, serve 0.004 1 0.004 0.448turn copper 0.351 1 0.351 0.799turn wrap, serve 0.004 1 0.004 0.803turn wrap, glass 0.007 2 0.014 0.387 0.817

0.817 0.817

"lateral" build

no. in subtotal total for Cumulativelayer thickness stack thickness group build

turn wrap, glass 0.007 2 0.014 0.014turn wrap, serve 0.004 1 0.004 0.018turn copper 0.31 1 0.31 0.328turn wrap, serve 0.004 1 0.004 0.332turn wrap, glass 0.007 2 0.014 0.346 0.346shim, turn B-C 0.045 1 0.045 0.045 0.391turn wrap, glass 0.007 2 0.014 0.405turn wrap, serve 0.004 1 0.004 0.409turn copper 0.31 1 0.31 0.719turn wrap, serve 0.004 1 0.004 0.723turn wrap, glass 0.007 2 0.014 0.346 0.737

0.737 0.737

Cond width:0.318+/-0.01(with serve)

Cond height:0.359

+/-0.01w/serve

Shim for tolerance buildup:.045 nominal

Winding Pack width: 0.737 in

Turn insulation:2 x .007 glass

Turn serve: .004 nylon

Layer to layer shim: 0.043 nominalWinding Pack height: 0.817 in

height = 0.817 in

Winding Pack Dimensions for 4-turn Racetrack Coils

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40-Turn Bundle

40-turn bundle with ground wrap will be fabricated and can be used for flexural and fatigue tests

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40 turn Bundle Preparation

Mold release tee surfacesCopper cladding [0.040 “] with Kapton insulation on inner surfaceApply Groundwrap

3 layers- 0.010 in. thick S-2 dry glass2 layers - 0.003 in. thick Type H Kapton

Lay insulated conductor turns in place [4 wide x 10 high] Apply Bag moldVacuum-Pressure-Impregnate [VPI]

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Bag Mold

Install final ground wrapInstall (2) Layers silicone rubber tape mold [secure edge in place with casting groove and copper tubing]Paint mold with 2-part RTV 11 (several layers) Install final coil clamps Install epoxy impregnated felt between the clamps Install strong backs between clamps

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SummaryFabrication of test specimens and testing of mechanical properties is underwayBoth clean and regular processed conductor will be testedSpecimens will be tested at 77deg.K, 194 deg.K and RT

Further discussions are neededFurther discussions are needed:Type of tests being performedTypes of specimens being proposedHow the test should be performed