1. 9/28/20051 Mike Viola 1, T. Brown 1, P. Heitzenroeder 1, F. Malinowski 1, W. Reiersen 1, L. Sutton 1, P. Goranson 2, B. Nelson 2, M. Cole 2, M. Manuel 3, D. McCorkle 3 1 Princeton Plasma Physics Laboratory, PO Box 451, Princeton NJ 08543 USA 2 Oak Ridge National Laboratory, Oak Ridge, TN 37831-6169 USA 3 Major Tool and Machine, Inc., Indianapolis, IN 46218, USA 21st IEEE/NPSS Symposium on Fusion Engineering (SOFE 2005) MFE Engineering, NCSX and EAST Oral III.e – Sequoyah 3 4:00 PM NCSX Vacuum Vessel Fabrication

2. 9/28/20052 The National Compact Stellarator Experiment (NCSX) is being constructed at the Princeton Plasma Physics Laboratory (PPPL) in conjunction with the Oak Ridge National Laboratory (ORNL). A key element of this device is its highly shaped 3/8” thick Inconel- 625 vacuum vessel. The vessel is being fabricated by Major Tool and Machine, Inc. (MTM) in three identical 120º vessel segments, corresponding to the three NCSX field periods, in order to accommodate assembly of the device at PPPL. The vessel must have a total leak rate less than 5  10 -6 t-l/s, magnetic permeability less than 1.02μ, and its contours must be within 0.188” (4.76 mm). The VVSA’s are scheduled for completion in January 2006. Introduction NCSX Vacuum Vessel Fabrication

3. 9/28/20053 NCSX Vacuum Vessel Fabrication Six identical 60° segments form the NCSX vacuum vessel. 120º vessel segments are formed by welding two 60º segments together. Each 60º segment is fabricated by welding ten press-formed panels together over a collapsible welding fixture which is needed to precisely position the panels. Stellarator Symmetry

4. 9/28/20054 NCSX Vacuum Vessel Fabrication Ten Kirksite die sets (20 total – upper and lower) cast and machined Ten Panels formed per 60° segment –Press – anneal – press – local rework Upper and Lower 5 panel sets joined on a fixture to form 60° ½ segments Each 60º upper and lower ½ segments welded together over a collapsible welding fixture. Two 60º segments welded together on a fixture to form 120º segments. Port holes bored and ports installed Leak checked and thermal cycled Ports cut off and shipped. Reassembled at PPPL after Modular Coils installed. Process Summary

5. 9/28/20055 Prototype vacuum vessel –Solicit interest –develop techniques Statement of Work defined –manufacturing development activities for the 120º Vacuum Vessel Sub-Assembly (VVSA) and –production of a full-scale 20º prototype vacuum vessel segment (PVVS). These activities were also meant to give the fabricator the experience needed to develop and submit a firm fixed price and schedule proposal for producing the three VVSA units. Prototype Vacuum Vessel (PVVS) NCSX Vacuum Vessel Fabrication

6. 9/28/20056 NCSX Vacuum Vessel Fabrication Two companies were chosen that submitted competitive solutions with the most promising technique. Both companies produced prototype vacuum vessels and Major Tool and Machine, Inc. was chosen for the production of the VVSA based on performance. Prototype Vacuum Vessel (PVVS)

7. 9/28/20057 NCSX Vacuum Vessel Fabrication Ten panel segmentation scheme was chosen for each 60° segment for optimization of complexity of forming vs. weld distortion. 60 panels (6 sets of 10) are required for the entire NCSX vacuum vessel. Panel Segmentation

8. 9/28/20058 NCSX Vacuum Vessel Fabrication A set of ten kirksite dies were cast and machined Press – anneal – press – local rework Gauges facilitate rework Rubber and wood carefully placed to make minor corrections Each panel is a work of art Panel Forming

9. 9/28/20059 NCSX Vacuum Vessel Fabrication Allows for the mounting of the ten panels in two 5-panel sections upper and lower. Keyed and segmented to allow for easy disassembly after the 60° segment is welded. Provides stiffness necessary to hold shape and control distortion of the segments during welding. Bolted together as one assembly or as two individual upper and lower assemblies. Cutouts allow a person to stand and weld within the fixture as well as allow for seams to be made which cross the fixture plates. 60° fixture The 60° fixture is ingeniously designed with many features

10. 9/28/200510 NCSX Vacuum Vessel Fabrication Panels are tacked together in a three panel and a two panel configuration on the upper or lower fixture. Partial assemblies are then joined into one complete upper or lower five panel segment. Upper assembly Lower assembly 60° Fixture

11. 9/28/200511 NCSX Vacuum Vessel Fabrication Metrology measurements taken with a Laser Tracker CMM

12. 9/28/200512 NCSX Vacuum Vessel Fabrication Upper and lower segments are mounted back onto the complete 60° fixture and welded into their final configuration. This completes the formation of a 60° segment. Completed 60° segments 60° Segments

13. 9/28/200513 NCSX Vacuum Vessel Fabrication The 120° fixture also has some unique features serving multiple needs. Positions and joins two 60° degree vessel segments together: –datum reference monuments, –strategically placed adjusting rods, –personnel access for completing weld. It is designed to uniformly support the highly shaped vessel surfaces (minimizing gravity induced distortion) –a separate center support structure provide support and rigidity for machining the port holes provide support during the installation of the port extensions and vacuum testing operations. 120° fixture 120° Fixture

14. 9/28/200514 NCSX Vacuum Vessel Fabrication The 120° fixture allows two 60° segments to be aligned and a best fit analysis is performed using Verisurf© software. Alignment and distortion control are critical. The final weld joins two 60° segments to form one completed 120° shell. The port holes are bored on a 5-axis mill. Completed 120° Segment Boring Port Holes 120° Fixture

15. 9/28/200515 NCSX Vacuum Vessel Fabrication The port extensions are welded on, leak checked, cut off within 1” of the vessel surface (provides stiffness as well as a weld stub) at MTM and then reattached at PPPL, to accommodate assembly of the close-fitting modular coils that surround the vessel. The vessel is joined at assembly by welding custom machined 8” (20.3 cm) wide spacer “spool pieces.” Port 2 Port 6 Port 15 Port 7 Port 11 Port 5 Port NBI Port 16 Port 10 Port 4 Port 8 Port 9 Port 18 Port 17Port 12 Port 3 NBI- Port 2 Port 6 Port 15 Port 7 Port 11 Port 5 Port NBI Port 16 Port 10 Port 4 Port 8 Port 9 Port 18 Port 17Port 12 Port 3 Final Steps

16. 9/28/200516 NCSX Vacuum Vessel Fabrication Thank You Sketches and photographs provided by Major Tool and Machine Inc. This research is supported by the U.S. DOE under contract DE-AC02-76CH03073 with Princeton University and contract DE-AC05-00OR22725 with UT-Battelle, LLC. Acknowledgment