NCSX R&D Activity Update

1. NCSX R&D Activity Update Jim Chrzanowski June 18, 2003

2. Keystone Tests- Turns vs. Radius • Winding form 2.5 inch diameter • Wind full conductor both hard and easy directions • Measure keystoning of each turn • Single conductor insulation • 1 butt lapped layer glass & 3-butt lapped layers co-wound glass/Kapton

3. Keystone Test Setup

4. 3.511” 2.730” 2.106” 1.424” 1.25 inch radius Keystone Tests in Hard Direction 3.56” Predictions based on average conductor measurements 2.848” 2.136” 1.25 inch radius 1.424” 0.712” 0.606” 0.762” 0.612” 0.673” 0.584” 0.642” 0.608” 0.627” 0.601” 0.625” 0.605” To base plate Turn 1 Turn 2 Turn Turn 4 Turn 5

5. Keystone Tests in Easy Direction 5.355” Predictions based on average conductor measurements 4.76” 4.165” 3.57” 1.25 inch radius 2.975” 2.38” 1.785” 1.19” 0.595” 0.706” (avg.) 5.477” 4.834” 4.257” 3.598” 3.041” 2.414” 1.81” 1.25 inch radius 0.625” 1.224” To base plate Being measured Turn 1 Turn 2 Turn 3 Turn 4 Turn 5 Turn 6 Turn 7 Turn 8 Turn 9

6. Keystone Trials- Easy Direction

7. Test Setup • Insulated conductors were wound on 3 inch diameter pipe

8. 0.761 0.552 D A B B A C 0.708 0.765 0.586 0.600 0.701 0.726 A B 0.666 0.764 D 0.741 0.557 0.656 0.644 0.750 0.635 C 0.737 0.619 0.618 0.763 0.724 C D 0.630 0.688 0.773 Results of Bench Top Tests- Easy Direction Prior to Winding After Winding After Squaring Butt- lapped Half- lapped Butt- lapped Half- lapped Butt- lapped Half- lapped Width A Width A Height C Height D Height D Height C Width B Width B

9. Single Conductor Half Lapped

10. Single Conductor Butt Lapped

11. Twisted Racetrack Casting June 18th. Casting June 11th. Casting

12. Twisted Racetrack Casting June 11th. Casting June 18th. Casting