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NCSX- Cable Property Testing. February 25, 2005 Jim Chrzanowski. Scope. Materials used in Specimens Conductor Insulation Epoxy system Tests Being Performed Test Equipment Description of specimens. 0.375 Ref. 0.359 +/- 0.008. 0.318 +/- 0.008. 0.334 Ref. - PowerPoint PPT Presentation
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February 25, 2005 Jim Chrzanowski
NCSX- Cable Property Testing
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Scope
Materials used in SpecimensConductorInsulationEpoxy system
Tests Being PerformedTest EquipmentDescription of specimens
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Conductor Description
Flexible spooled compacted copper cable [12x5/44/34]Nylon serve on outside surface [0.004 in. thick]2640 strands34 gauge [nom. 0.0063 in.]Conductor A: Normal cable mfg. ProcessConductor B: Clean cable mfg. process
0.359 +/- 0.008
0.318 +/- 0.008
0.334 Ref
0.375 Ref
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Insulation
Conductor is pre-insulated (turn to turn) with (1) half-lapped layer of glass tapeInsulation description
S-2 glass (Four harness satin weave) with reactive amino silane finishNominal thickness 0.004 in. thickGlass tape identifier: ECG150-2/2Temperature class 180 degrees C
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Epoxy SystemResin system selected:Resin system selected: CTD-101K
Product of Composite Technology Dev. Inc.3- Part component epoxy systemExcellent performance at cryogenic temperatures with a lng pot life and low viscosityCure Cycle:
5 hours @ 100 degrees C (Cure)16 hours @ 125 degrees C (Post cure)
Pot Life:145 hours @ 25 degrees C …….1300 Cp 60 hours @ 40 degrees C …….400 Cp 20 hours @ 60 degrees C …….100 Cp
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Performance Tests
Type of TestsType of TestsFlexural tests.. [8 inch long single conductor specimens]Compression tests.. [0.75 inch long single conductor specimens]Tensile tests.. [Racetrack coils- 4-turn specimens]Cure shrinkage [Racetrack coils 2 lengths 4-turn specimens]Fatigue (cyclic) testing [TBD] [single conductor and/or 40 turn bundle
Test ParametersTest Parameters2- different processed conductors (clean vs. standard)3- different temperature ranges (77 deg.K, 194 deg.K and room temperature)
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Mechanical Test Equipment
MTS Servo-Hydraulic Tester Capacity 100 KIPS
MTS Servo-Hydraulic Tester Capacity 10 KIPS
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Flexural and Compression Specimens
Flexural Tests
Compression Tests
Cold Bath
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4-turn racetrack coils will be wound without ground wrap and will be used for the tensile testsCoil leads will allow the coil to be electrically tested during or following the tensile tests
Winding Pack dimensions for 4-turn racetrack coilsalternate conductor
serve 0.004 inturn insulation 0.007 in (.004 center, .007 edge)cable size, width 0.318 in with servecable size, height 0.359 in with servenominal shim, radial 0.043nominal shim, lateral 0.045
"radial" buildno. in subtotal total for Cumulative
layer thickness stack thickness group build
turn wrap, glass 0.007 2 0.014 0.014turn wrap, serve 0.004 1 0.004 0.018turn copper 0.351 1 0.351 0.369turn wrap, serve 0.004 1 0.004 0.373turn wrap, glass 0.007 2 0.014 0.387 0.387shim, layers 1-2 0.043 1 0.043 0.043 0.43turn wrap, glass 0.007 2 0.014 0.444turn wrap, serve 0.004 1 0.004 0.448turn copper 0.351 1 0.351 0.799turn wrap, serve 0.004 1 0.004 0.803turn wrap, glass 0.007 2 0.014 0.387 0.817
0.817 0.817
"lateral" build
no. in subtotal total for Cumulativelayer thickness stack thickness group build
turn wrap, glass 0.007 2 0.014 0.014turn wrap, serve 0.004 1 0.004 0.018turn copper 0.31 1 0.31 0.328turn wrap, serve 0.004 1 0.004 0.332turn wrap, glass 0.007 2 0.014 0.346 0.346shim, turn B-C 0.045 1 0.045 0.045 0.391turn wrap, glass 0.007 2 0.014 0.405turn wrap, serve 0.004 1 0.004 0.409turn copper 0.31 1 0.31 0.719turn wrap, serve 0.004 1 0.004 0.723turn wrap, glass 0.007 2 0.014 0.346 0.737
0.737 0.737
Cond width:0.318+/-0.01(with serve)
Cond height:0.359
+/-0.01w/serve
Shim for tolerance buildup:.045 nominal
Winding Pack width: 0.737 in
Turn insulation:2 x .007 glass
Turn serve: .004 nylon
Layer to layer shim: 0.043 nominalWinding Pack height: 0.817 in
height = 0.817 in
Winding Pack Dimensions for 4-turn Racetrack Coils
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40-Turn Bundle
40-turn bundle with ground wrap will be fabricated and can be used for flexural and fatigue tests
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40 turn Bundle Preparation
Mold release tee surfacesCopper cladding [0.040 “] with Kapton insulation on inner surfaceApply Groundwrap
3 layers- 0.010 in. thick S-2 dry glass2 layers - 0.003 in. thick Type H Kapton
Lay insulated conductor turns in place [4 wide x 10 high] Apply Bag moldVacuum-Pressure-Impregnate [VPI]
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Bag Mold
Install final ground wrapInstall (2) Layers silicone rubber tape mold [secure edge in place with casting groove and copper tubing]Paint mold with 2-part RTV 11 (several layers) Install final coil clamps Install epoxy impregnated felt between the clamps Install strong backs between clamps
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SummaryFabrication of test specimens and testing of mechanical properties is underwayBoth clean and regular processed conductor will be testedSpecimens will be tested at 77deg.K, 194 deg.K and RT
Further discussions are neededFurther discussions are needed:Type of tests being performedTypes of specimens being proposedHow the test should be performed