20060823 NCSX weekly update

From: Hutch Neilson
Sent: Wednesday, August 23, 2006 4:17 PM
To: Hutch Neilson; Jeffrey Makiel; Barry Sullivan; Ronald L. Strykowsky; Jim Lyon; Sam Barish
Cc: James H. Chrzanowski; Michael E. Viola; Pamela Hampton; Phil Heitzenroeder; Wayne T. Reiersen; Richard J. Hawryluk; Robert J. Goldston; Gene Nardella; Bradley E. Nelson; Michael R. Kalish; Gregory Pitonak
Subject: 20060823 NCSX weekly update
We will have our usual Thursday telecon at 9:30 a.m. Call 1-877-653-7764, 361326#. Hutch

NCSX Weekly Update of 08/23/06

1. Modular Coil fabrication (PPPL)

MC Fabrication summary status:

3 coils through VPI to date
1 in VPI operations
2 coils in winding form prep and winding operations
2 in the queue

C-2 Coil

In queue for post-VPI cleanup.

C-3 Coil

In post-VPI cleanup. Permanent clamps are being installed.

C-4 Coil

Successfully VPI’d this week. Currently in the cure cycle as of this writing.

C-5 Coil

Winding pack dimensional adjustments and final pack measurements complete.
VPI prep completion milestone is August 16. Currently 18 working days behind schedule.

A-1 Coil

Initial ground wrap installation complete. Placement of lacing strips in progress.
VPI prep completion milestone is October 2. Currently 9 working days behind schedule.

A-2 Coil

In the queue for winding operations.
VPI prep completion milestone is November 10. Currently on schedule.

A-3 Coil

In the queue for winding operations.

2. MCWF procurement (Energy Industries of Ohio)

MCWF summary status:

All 18 castings have completed foundry operations
5 in active machining operations
5 in the machining queue
8 shipped to PPPL

Machining operations (Major Tool and Machine):

B-1

The B-1 spent most of last week in 3-axis operations in the Mitsu-30. Programming changes were needed to deal with some difficult, but localized problem areas on the winding form. After several days’ delay, it moved to the U-5 on Saturday 8/19, whereupon 5-axis machining operations immediately began. These problems and the associated delays are normal for the first casting of a Type. Additional time was needed to develop solutions that are expected to save time on the remaining Type B’s.
Some overstocked areas on the B-1 as-cast surfaces were identified. It will likely require machining by MTM to remove the excess material. Currently under evaluation.
A mid-September B-1 delivery is still expected. The project’s delivery milestone is September 20.

B-2

The B-2 is in 3-axis machining operations on the Mitsu-40.
The project’s delivery milestone is November 29 for B2.

A-4

The A-4 has completed Lucas 40T operations and is in the queue for the Mitsu-40.
The project’s delivery milestone is October 24 for A-4.

B-3, B-4, and B-5

The B-3, B-4, are rotating through rough machining operations on the Lucas 40T.
The project’s delivery milestone is January 11 for B-3.
The project’s delivery milestone is February 14 for B-4.
The project’s delivery milestone is March 20 for B-5.

The expected delivery sequence for the next few coils is B-1, B-2, A-4, B-3, B-4. All are on or ahead of schedule.

A-5, A-6, B-6, and C-6

The A-5, A-6, B-5, B-6, and C-6 are in the queue for machining.

3. VVSA procurement (Major Tool and Machine)

VVSA #3: The ports are being temporarily re-attached for final alignment. Still on track for September 15 delivery.

4. TF Assemblies procurement (Everson Tesla, Incorporated)

Clean room construction progressing.

Winding fixture fabrication is progressing. Completion expected by 9/15.

Fabrication of the braze coil for the Robitron is progressing. Expected to ship 8/28.

Hutch Neilson