Material Property R&D – Review of remaining tests

• Single conductor torsion tests• Transverse compression at LN2• 4 turn racetrack fatigue tests

• Multi-turn beam bending and torsion tests, including fatigue

• Mod coil casting material fatigue property tests- 2 welded, 9 non-welded from EIO -

• 2-D glass/epoxy tests (for TF,PF coils only) and need for 3-D

• Compile material property database

Kozub, Chrzanowski

Kozub, Chrzanowski

Nelson, Cole

Heitzenroeder

Kalish

HM Fan

Material Property R&D – Review of remaining tests

• Single conductor torsion tests – 40 hours – 2 wks cal. time• Transverse compression at LN2 – 8 hours – couple days• Dogbone test - 8 hours @RT, can we do LN2? – not easy• 4 turn racetrack fatigue tests – ~ 200 hours left -

– pull long coil to failure, find out max load, resistance vs strain at room temperature – week or two, done by Oct 15

– Increase cyclic load in 1st short coil to 20000 lbs at LN2 and run to appropriate number for 33% load increase, start by Oct 19

– Increase cyclic load in short coil to 25000 lbs at LN2 and run appropriate number of cycles for 67% load increase

– Increase load to 30000 lbs and run to failure, end by Nov 10– Review plan, then run 2nd coil (e.g. max load not to exceed failure

strain at RT, or some other test, must end by Nov 24 or start after Dec 15

Full scale beam bending and torsion test

• 3-point bend / torsion test in 4-column MTS load frame

• RT or LN2 temp

• 5 extensiometers:– Left, right ends, – Left, right midpts – Center

• Tests for:– Load / deflection– Fatigue

• 3 specimens:– Original 18 turn beam– 40 turn beam– 40 turn beam with

crossovers

Full scale beam bending and torsion test - Status

• Complete:– Beams on site and prepped for test (cut to 42 in long)– All fixtures completed (except insulation)– 5 extensiometers on hand– FEA of original beam completed for bending only– Original beam loaded for testing

• To Do:– Write test / safety procedure for LN2 operation (part of

1403-42F, $24k total in plan)– Procure approved insulation system (part of 1403-42F)– Perform deflection and fatigue tests – 2 wks from start

(part of1403-42F)– Perform FEA analysis of new beams, incl leads (in plan

$22k-1403-42G)

Beam FEA model – 18 turn sample #1

• ½ of beam (one side = 9 turns) modeled• E-cable/epoxy = 9.5 e6 psi• E-epoxy/glass insulation = 1.5 e6 psi• Supported at ends and loaded in center• Loads and supports through small pads

Vertical Deflection, 2000 lb load = 0.05 inches

Von Mises stress, 2000 lb load peaks at load point

XX (lateral) Stress, 2000 lb load, ~0 except load pt

YY(vertical) Stress, 2000 lb load, ~ 0 except load pt.

ZZ (axial) Stress, 2000 lb load, ~ 7.5 ksi tension

YZ (Shear) stress, 2000 lb load

Hand calculation – E effective for .05 in. defl=6.3 Msi

Model parameterslength 40 indepth 5.22 inwidth 0.72 inI 8.53E+00 in^4S 3.27E+00 in^3

P 2000 lbsdefl 0.05 in M 20000 in-lbsstress 6.12E+03 psimax strain 9.79E-04E-effective 6.25E+06 psi

Test beam parameterslength 40 indepth 5.5 inwidth 1.44 inI 2.00E+01 in^4S 7.26E+00 in^3

P 4000 lbsdefl TBD in M 40000 in-lbsstress 5.51E+03 psimax strain TBDE-effective TBD psi