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NSTX CSU Testing

This document outlines the initial material fatigue testing of PMX Industries' Alloy #151, used in NSTX CSU strap conductors. The material specifications include a hardness of H04, with a composition of 99.8% copper and 0.1% zirconium. Testing followed ASTM standards, measuring tensile and yield strengths, electrical and thermal conductivity, and hardness. The study focused on evaluating the specimen's performance under specified loading conditions to determine fatigue life and implications for structural integrity in practical applications. ###

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NSTX CSU Testing

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  1. NSTX CSUTesting Flex Strap Conductor Initial Material Fatigue Testing

  2. Material • Manufacture PMX Industries • Manufacture Alloy # 151 • ASTM Specification B747 • USN/CDA # C15100 • Material Section 4” x 0.077” • Hardness H04

  3. Manufacture’s PublishedMaterial Specifications • Hardness: H04 (Hard) • Chemistry: Copper (99.8%) Zirconium (0.1%) • Density: 0.323 lb/in3 • Modulus of Elasticity: 17 x 106 psi • Electrical Conductivity: 95% I.A.C.S. @68oF • Thermal Conductivity: 208 Btu/ft-hr-oF @ 68oF • Coef. Therm. Expan.: 9.8 x 106 in/in-oF • Tensile Strength: 53-62 Ksi • Yield Strength: 56 Ksi

  4. Test Samples • Specimen Specification ASTM E 8 • Specimen Type Rectangular Tension • Specimen Size 1/4-in Subsize • Material Orientation Longitudinal (six samples) & Transverse (seven samples)

  5. Test Parameters • Test Method Plain-Strain Fracture Toughness • Test Spec. ASTM E 399 • Load Cycle: • Function: Sin • Rate: 1 Hz • Ratio: 10% to 100% (R=0.1)

  6. Test Procedure • Measure and record the dimensions of each sample • Measure and record the hardness of each sample • Mark sample with gauge length points • Configure Test fixture for E399 tension test • Configure testing program and verify operation with extra sample • Install and tension cycle each sample • Record number of cycles to failure or, if no failure, any change in gauge length

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