1. NSTX NSTX LidsJuly 6, 2010 1 NSTX Supported by College W&M Colorado Sch Mines Columbia U CompX General Atomics INEL Johns Hopkins U LANL LLNL Lodestar MIT Nova Photonics New York U Old Dominion U ORNL PPPL PSI Princeton U Purdue U SNL Think Tank, Inc. UC Davis UC Irvine UCLA UCSD U Colorado U Illinois U Maryland U Rochester U Washington U Wisconsin NSTX Upgrade Structural upgrade Lids assembly 6 Coils Support Structures Culham Sci Ctr U St. Andrews York U Chubu U Fukui U Hiroshima U Hyogo U Kyoto U Kyushu U Kyushu Tokai U NIFS Niigata U U Tokyo JAEA Hebrew U Ioffe Inst RRC Kurchatov Inst TRINITI KBSI KAIST POSTECH ASIPP ENEA, Frascati CEA, Cadarache IPP, Jülich IPP, Garching ASCR, Czech Rep U Quebec Danny Mangra

2. NSTX NSTX LidsJuly 6, 2010 Outer TF free-body-out of plane loads Applied forces: 23,000 or 28,000 or 41,000 lbs Reactions at aluminum blocks has moments or more equivalent reaction forces Similar free body is need for inner stack to lids interface 9000 lbs per bolt(36 total) is used Actual stress is larger due to in plane loads eg launch

3. NSTX NSTX LidsJuly 6, 2010 Plate.5” thick.5” thick plate ~700 lbs 36000 lbs per teeth Max stress >50,000 psi

4. NSTX NSTX LidsJuly 6, 2010.5” lid Max deflection ~.025”

5. NSTX NSTX LidsJuly 6, 2010 Inner g10 crown/ strength 38,000 psi cross Inner g10 crown 18000 lbs per tooth Max stress> 24000 psi Design limit < 19000 psi.25” Radius

6. NSTX NSTX LidsJuly 6, 2010 G10 inner crown deflection Max deflection ~.026” Actual max flection is much larger 100” copper stem

7. NSTX NSTX LidsJuly 6, 2010 Crown to lid interface-teeth details Crown teeth need shaping Eg of standard teeth involute Current design Stress in g10> 30,000 psi Multiplications from shaping Or crushing of teeth

8. NSTX NSTX LidsJuly 6, 2010 Center stack thermal growth 9 mm.5” thk plate Fixed at outer boundary

9. NSTX NSTX LidsJuly 6, 2010 Thermal growth 9 mm.5” thk Max stress > 45000 psi Add to torsional stress

10. NSTX NSTX LidsJuly 6, 2010 Lower crown/inconel 5/8 ~ 16,000 lbs in shear or 27,000 lbs tension 18,000 lbs in shear per bolt 1000 lbs per bolt launch load Halo current 2000 lbs per bolt in shear 18 x 5/8 bolt ~.3 sq in 18000 lbs in shear Inconel allowable 90,000 psi in tension or ~54,000 psi in shear Bolt ~ 60,000 psi in shear + bending etc G10 bearing pressure

11. NSTX NSTX LidsJuly 6, 2010 Summary/using Pete’s force Current g11 /teeth design need much work in upper crown Lower crown~18 bolts design negative margin Insulation material need a strength ration>60,000 psi.5” thk plate need work at teeth area Torsion stress + thermal stress > 75000 psi with current concept Basically lots of increase scope to design –G10 interface/teeth design to lid –Sst interface –Thermal concept –Crown to pedestal need work, 18 bolts need resizing

12. NSTX NSTX LidsJuly 6, 2010 Design Single crown radius of g10 teeth remove tension between buss/flag Double crown remove margin from flex strap bolt or add more insert removable but no slippage