NCSX Procurement Update of 7/06/05

1. MCWF procurement

• Machining of the C-1 casting (MCWF#1) continues at Major Tool. They report being 90% complete on the roughing and semifinal machining, which corresponds to the 3-axis operations which were forecast to be completed by July 8 in the detailed schedule submitted on 6/17. The have not flipped the part to the second side yet because they found they could do more on the initial setup than had been anticipated. As of July 1, they reported being 2-3 days behind the 6/17 schedule.
  

• The 5-axis experimentation using the prototype continues to be beneficial. Through trial and error they have found the best setup for fixturing the casting in the mounting plate during 5-axis machining, increasing the clearance for the 5-axis head. They estimate that this effort avoided 2 days of schedule growth  in the  5-axis machining of the C-1. They also proved out a method for machining the groove.
  

• The C-2 casting (MCWF#2) was setup in the machining fixture at Major Tool and machining operations began on July 1.
  

• Radiographic inspection of the  A-1 (MCWF#3) casting indicated very good casting quality with no regions of “shrink,” or inadequate metal supply.  The subcontractor who performed the laser scanning dimensional check is scheduled to return to MetalTek this week to repeat the measurements in areas that did not scan properly.
  

• The C-3 (MCWF#4) casting was shipped to Milwaukee for radiographic testing this week.
  

• Mold setup for the C-4 (MCWF#5) casting is at least 40% complete and due to pour by the end of this week.
  

• Fabrication and assembly of the Type B pattern (the third and last) continues.
  

2. VVSA procurement

• The first 60-degree shell sector (consisting of 10 panels) is being fabricated by first welding panels together in subgroups of 2 or 3, then welding the subgroups together.  Two 3-panel subgroups and one 2-panel subgroup have been welded. Another 2-panel subgroup will be welded over the weekend.
  

• The first 120-degree fixture (of 3) is complete. The remaining two are being welded.
  

• Of the production panels, 16 have been through first forming, of which 6 have been through final forming.
  

Hutch Neilson