NCSX Procurement Update of 7/28/05

1. MCWF procurement

• Machining of the C-1 casting (MCWF#1) continues at Major Tool. They have completed the first week of 5-axis machining. They provided an update of their detailed C-1 completion schedule (attached). They are making steady progress, but at about half the forecast rate, and the forecast ship date (now 8/23) continues to slip as we expected would happen. Plans for on-site support of the final inspection and test activities by DCMA, PPPL, and EIO are reflected in the 3 columns to the right.
  

• The C-2 casting (MCWF#2) is in rough machining and reportedly making outstanding progress.  They are utilizing the machine programs that were debugged on the C-1, and the problems encountered on the C-1 are not recurring.
  

• Processing of the A-1 casting (MCWF#3) continues, with progress in weld mapping and excavations. Based on our analysis of the thin-wall condition, we have determined that it can be accepted as-is. The EIO team is investigating the root cause to be sure they can adequately control the wall thickness of the remaining Type A’s to ensure stellarator symmetry.
  

• The C-3 (MCWF#4) casting is undergoing weld upgrades. It will probably be the next one to ship to MTM. Forecast ship date is 8/5.
  

• The C-4 (MCWF#5) casting is undergoing initial processing steps, such as removal of the risers and heat treatment.
  

• The mold is being prepared for the C-5 (MCWF#6) casting, estimated to pour 8/12.
  

• Fabrication and assembly of the Type B pattern (the third and last) continues. Forecast delivery date is 9/15.
  

2. VVSA procurement

• Finished welding the first 60-degree sector.  Welding of the second 60-degree sector is in progress.
  

• Eight of the ten panels for the third 60-degree sector are complete. Panel production rate is starting to improve.
  

• Some distortion (about 0.25-in.) has occurred on the first 60-degree sector. Cause and corrective measures are being investigated.  Joining of the first two 60-degree sectors is delayed to 8/22.
  

A visit to Major Tool by project staff (Mike Viola and Hutch Neilson) is tentatively planned for August 9.

Hutch Neilson