1. J.H. ChrzanowskiMod Coil R&D Update1 Modular Coil R&D Update April 2, 2003 James H. Chrzanowski

2. J.H. ChrzanowskiMod Coil R&D Update2 Modular Coil R&D Activities- Epoxy Analysis work Keystone Trials Demo Coil Schedule

3. J.H. ChrzanowskiMod Coil R&D Update3 Modular Coil R&D Update- Epoxy Studies A contract will be placed with Composite Technology Inc. to perform tests to determine the mechanical & thermal properties of the epoxy/insulation system using CTD101k –[NCSX-SOW-142-02] The NCSX project will receive a credit of approximately $56.0 k worth of testing in conjunction with a SBIR that CTD has with DOE The cost to the project will be between $10-20 k

4. J.H. ChrzanowskiMod Coil R&D Update4 Modular Coil R&D Update- Epoxy Studies Tests will include: Tensile, compressive and flexural on single conductor samples Shear and flexural on 4-conductor bundle VPI Shrinkage evaluation Thermal expansion

5. J.H. ChrzanowskiMod Coil R&D Update5 Modular Coil R&D Update- Epoxy Studies Test samples will be fabricated at PPPL –Impregnation of compression samples was performed this morning Compression samples will be sent to CTD next week CTD will begin on the VPI shrinkage and compression tests immediately Tooling design & fabrication [test fixtures] will also start immediately

6. J.H. ChrzanowskiMod Coil R&D Update6 Keystone Trials- A Peer review was held yesterday to discuss the type of measurements to be made on the Keystone winding form. Keystone winding will begin sometime next week.

7. J.H. ChrzanowskiMod Coil R&D Update7 Keystone Trials- A combination of global and local measurement systems will be used to obtain conductor position measurements Global measurements with “FARO arm. Local measurements with specially designed instruments Position data from Pro-E model is also available

8. J.H. ChrzanowskiMod Coil R&D Update8 Keystone Trials- Various versions of the local measuring tooling. This tooling is quickly and inexpensively fabricated. We can and will customize versions for the various geometries that we encounter. A simple version of this tooling is envisioned for use as the “go, no-go” gauge for winding the actual coils in the future. With dial indicator for direct reading With dial indicator and roller wheel for +/- reading With a spring loaded rod. Used like a tire tread depth gauge.

9. J.H. ChrzanowskiMod Coil R&D Update9 Demonstration Coil- J.P. Pattern has completed the casting and machining of the demo coil winding form. QA has issued release papers today. Delivery is expected Friday or Monday. Some additional machining for the leads will be performed at PPPL. Detail coil winding drawings still need to be completed prior to starting any winding operations. No designers are available at PPPL.

10. J.H. ChrzanowskiMod Coil R&D Update10 Demonstration Coil- The winding and VPI will completed in May. Testing in early June

11. J.H. ChrzanowskiMod Coil R&D Update11 Schedule Since the epoxy test samples will be made in-house, the decision has been made to delay the VPI of the highly shaped (twisted) tee until the demo coil has been fabricated Keystone tests- Complete by April 30 th. Test sample fabrication-thru mid May [overtime will be required] Demo coil fabrication complete May 30 th.