1. J.H. ChrzanowskiMod Coil R&D Update1 Modular Coil R&D Update April 9, 2003 James H. Chrzanowski

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

3. J.H. ChrzanowskiMod Coil R&D Update3 Modular Coil R&D Update- Epoxy Studies A contract has been 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] [S-044353-G] 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 last week Compression samples will be sent to CTD this 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 Electron Beam Photo’s of VPI Sample

7. J.H. ChrzanowskiMod Coil R&D Update7 Electron Beam Photo’s of VPI Sample

8. J.H. ChrzanowskiMod Coil R&D Update8 Impregnated 4- Rope Conductor

9. J.H. ChrzanowskiMod Coil R&D Update9 Keystone Trials- A Peer review was held last week to discuss the type of measurements to be made on the Keystone winding form. Keystone winding will begin sometime next week.

10. J.H. ChrzanowskiMod Coil R&D Update10 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

11. J.H. ChrzanowskiMod Coil R&D Update11 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.

12. J.H. ChrzanowskiMod Coil R&D Update12 Demonstration Coil- J.P. Pattern has completed the casting and machining of the demo coil winding form. The casting was received on Friday April 4 th. Machining for the leads will begin next week at PPPL. Detail coil winding drawings will be completed by ORNL- chill plates, winding clamps and flux loop locations File will be sent to ORNL by Friday

13. J.H. ChrzanowskiMod Coil R&D Update13 Demonstration Coil- The winding and VPI will completed in May. Testing in late May or early June

14. J.H. ChrzanowskiMod Coil R&D Update14 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.