NCSX Procurement Update of 6/29/05

A project delegation visited Major Tool and Machine at their Indianapolis facility on June 27-28, along with representatives from EIO, MetalTek, and DCMA.  We developed plans to support the upcoming inspection and release of the MCWF#1, observed the MCWF and VVSA fabrication in progress, and discussed schedule issues.

1. MCWF procurement

• Machining of the C-1 casting (MCWF#1) continues at Major Tool. They are still in 3-axis operations and expect to flip the part to the second side last night or today. The prototype winding form is on the 5-axis machine, where it is being used to develop the 5-axis machining program before the C-1 reaches the 5-axis machine.
  

• EIO and Major Tool continue to forecast that the C-1 will ship to PPPL on July 30, although the three-axis operations are taking longer than expected.  Appropriate actions are being taken to maintain schedule for the upcoming 5-axis operations and final inspection and release. Nonetheless, our assessment of the schedule is the same as we reported to OFES on June 24, namely that it is likely to slip further due to the continuing need for machining development.
  

• The foundry portion of the C-1 documentation package was formally submitted to PPPL. At the Major Tool meeting, plans were developed for PPPL engineering and QA staff to support the final inspection and test activities and perform concurrent review of the final set of documents at Major Tool in order to avoid unnecessary delays in releasing the part for shipment.
  

• The C-2 casting (MCWF#2) was shipped from MetalTek and arrived at Major Tool on June 28.
  

• The A-1 (MCWF#3) casting has returned from radiographic testing and the films are currently under review. There were issues with the laser scanning dimensional check that was done last week so the subcontractor will be brought back in to repeat some of the measurements.
  

• The C-3 (MCWF#4) casting has been heat treated and visually inspected. It appears to be of very good quality, reportedly the best to date. It may be the next to ship to Major Tool.
  

• Some components of the Type B pattern (the third and last) have been fabricated and the assembly process has started.
  

2. VVSA procurement

• Both 60-degree fixtures are complete and are being used for sector fabrication.
  

• The first ten panels, the so-called development panels, are complete.  All the production panels have now completed the “skin” removal process. Thirteen of these have been through the first pressing operation and are in process.
  

• Fabrication of the first 60-degree sector has started. Five panels have been mounted on the fixtures and seam welding is in progress.
  

Hutch Neilson