Material Property R

1
Material Property RD Review of remaining tests

• Single conductor torsion tests
• Transverse compression at LN2
• 4 turn racetrack fatigue tests
• Multi-turn beam bending and torsion tests,
  including fatigue
• Mod coil casting material fatigue property tests-
  2 welded, 9 non-welded from EIO -
• 2-D glass/epoxy tests (for TF,PF coils only) and
  need for 3-D
• Compile material property database

Kozub, Chrzanowski Kozub, Chrzanowski Nelson,
Cole Heitzenroeder Kalish HM Fan
2
Material Property RD Review of remaining tests

• Single conductor torsion tests 40 hours 2 wks
  cal. time
• Transverse compression at LN2 8 hours couple
  days
• Dogbone test - 8 hours _at_RT, can we do LN2?
  not easy
• 4 turn racetrack fatigue tests 200 hours left
  -
• pull long coil to failure, find out max load,
  resistance vs strain at room temperature week
  or two, done by Oct 15
• Increase cyclic load in 1st short coil to 20000
  lbs at LN2 and run to appropriate number for 33
  load increase, start by Oct 19
• Increase cyclic load in short coil to 25000 lbs
  at LN2 and run appropriate number of cycles for
  67 load increase
• Increase load to 30000 lbs and run to failure,
  end by Nov 10
• Review plan, then run 2nd coil (e.g. max load not
  to exceed failure strain at RT, or some other
  test, must end by Nov 24 or start after Dec 15

3
Full scale beam bending and torsion test

• 3-point bend / torsion test in 4-column MTS load
  frame
• RT or LN2 temp
• 5 extensiometers
• Left, right ends,
• Left, right midpts
• Center
• Tests for
• Load / deflection
• Fatigue
• 3 specimens
• Original 18 turn beam
• 40 turn beam
• 40 turn beam with crossovers

4
Full scale beam bending and torsion test - Status

• Complete
• Beams on site and prepped for test (cut to 42 in
  long)
• All fixtures completed (except insulation)
• 5 extensiometers on hand
• FEA of original beam completed for bending only
• Original beam loaded for testing
• To Do
• Write test / safety procedure for LN2 operation
  (part of 1403-42F, 24k total in plan)
• Procure approved insulation system (part of
  1403-42F)
• Perform deflection and fatigue tests 2 wks from
  start (part of1403-42F)
• Perform FEA analysis of new beams, incl leads (in
  plan 22k-1403-42G)

5
Beam FEA model 18 turn sample 1

• ½ of beam (one side 9 turns) modeled
• E-cable/epoxy 9.5 e6 psi
• E-epoxy/glass insulation 1.5 e6 psi
• Supported at ends and loaded in center
• Loads and supports through small pads

6
Vertical Deflection, 2000 lb load 0.05 inches
7
Von Mises stress, 2000 lb load peaks at load point
8
XX (lateral) Stress, 2000 lb load, 0 except load
pt
9
YY(vertical) Stress, 2000 lb load, 0 except
load pt.
10
ZZ (axial) Stress, 2000 lb load, 7.5 ksi tension
11
YZ (Shear) stress, 2000 lb load
12
Hand calculation E effective for .05 in.
defl6.3 Msi