NCSX

D. Williamson, B. Nelson

August 25, 2004

WBS Engr meeting

Can prototype MCWF be used as production C1?

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NCSXCan prototype MCWF be used as production C1?

• Advantages:– schedule: 2-3 months for first part: receive first finished MCWF in Jan / Feb?

receive last casting, B6, one month earlier?

– cost: up to ~$150k = casting cost of first C1 article less mods to prototype casting

• Disadvantages:– May not be “stellarator symmetric” for eddy currents, structural deformations, etc.– More machining stock on prototype– Complicates procurement?

• Issues:– What are differences between prototype casting and production casting?– What would needed modifications cost?

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NCSXPrototype MCWF vs production C1

Feature Prototype Production C1

Casting shape Based on Nov., 2003 data Same basis

(but hard tool will have different stocking allowances, drafts,etc.)

Poloidal break

- Thickness- Gap width- Bolt holes

Total of 6 inches

2.25 inches (already cut)

7 @ 1.625 in (already bored)

Same location

Same

Same

Same

VV port hole cutouts Based on Nov., 2003 design, but no holes are cut

Based on VV FDR

TF interfaces Based on Nov., 2003 data

Rough machining done

Top, inboard modified so web is toward machine center

VV support locations

No support points on type C same

Lead details Based on Nov., 2003 data

No machining done

Same location, machining details different, may have to

add 0.5 inch thick boss.

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SE141-541EIO stocked model (11/03)with shrink = 0.9746209

Overlay of stocked modeland production MCWFSE141-116

Stocked prototype model vs production MCWFShrink parameter ref T Brown email, 11/19/03

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SE141-541EIO stocked model (11/03)with shrink = 0.9746209

SE141-116 Production MCWF

Midplane cross-section

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SE141-541EIO stocked model (11/03)with shrink = 0.9746209

SE141-116 Production MCWF

Vertical plane cross-section

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Cross-Sections thru Axis at R=50-in

SE141-116NFR1.STPProduction MCWFwithout features

SE141-541EIO stocked model (11/03)with shrink = 0.9746209

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A

B

A

B

Coincidentsurfaces

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A

B

B

A

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B

B

A

MCWF outsideof casting

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SECTION VIEW

MCWF outside of casting

15-deg

Poloidal Break

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Lead block outsideof casting

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Review of stocked reference part se141-116p

T. Brown 11/19/03

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NCSXStocked part shrunk by .9746209 (metal shrinkage factor)

Ref se141-116p Part

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Shrunk stocked part superimposed within the

reference se141-116p part.

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Profile of stocked model

Cross section drawing of superimposed parts

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NCSXWhat next?

• Casting is going to Metaltek

• Get existing measurement data from Lawton?

• Measure casting for as-built dimensions (Lawton under present contract?)

• Compare prototype to production C1 CAD model from Lawton and confirm that there are not insurmountable stellarator “unsymmetries”

• Discuss options with EIO team

• Decision by ???