Willard_Flex Strap Test Status Update 10-28-10

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Willard_Flex Strap Test Status Update 10-28-10 Powered By Docstoc
					NSTX Flex Strap Development
    Tests Status Update
          10-28-10
       Flex Strap and Bolted Joint Design Verification Tests

  • Tests Performed at 4 Different Levels
        – Material Level
            • C15100 H04 fatigue strength (R0) before and after soldering                         
            • Coupon-stack solder cycle development tests                                         
        – Single Lamination Level
            • Roll-formability                                                                     
            • In-plane bending stiffness                                                           
            • Cyclic, simulated maximum combined loads                                              0
        – Stub Joint Level
            • Tap-lok insert pull-out strength in C18150 copper stub, static and fatigue            0
            • Inconel 718 custom Superbolt nut/ stud fatigue strength                               0
        – Flex Strap Assembly Level
            • Manufacturability                                                                    
            • In-plane bending stiffness                                                           IW
            • Cyclic, simulated maximum combined loads
            • Contact pressure distribution
                 – Bolt pretension only                                                               0
                 – Bolt pretension + simulated maximum combined-load                                  0
            • Superbolt nut tensioned in umbrella segment mock-up                                     0


  5
NSTX                                    NSTX Center Stack Upgrade PDR Review               June 23 & 24, 2010   5
Cost-Optimized Design Flex Strap Assembly: Deformation and Force
                   Assembly: 31X .078” Thick Laminations
       NSTX CSU Flex Strap Assembly and Applied Boundary
                          Conditions

                                                                                              Rout = 5.688”


       31 Laminations:
       - .078” thick
       - .007” gap between laminations
        - Mat’l: Full-Hard C15100 H04 Cu-
       Zr

       Vertical Legs Vacuum Brazed


                                                                     Rin = 3.255”                                       Upper Umbrella Assy
                                            7.5”




                                                                   Bvert= .24 T                               8x 5/8” Bolt Hole




                             Uvert thermal = .3 in




                                                                                        5”
                                                                                                       I = 130 kA

                           Utor twist = .10 in
                                                     Urad thermal = .018 in




  7
NSTX                                                   NSTX Center Stack Upgrade PDR Review                                       June 23 & 24, 2010   7
   ANSYS Static Structural Results: Lamination Tresca Stress
             Current Scenario #82, 31 Laminations/ Strap, Center Strap




  8
NSTX                          NSTX Center Stack Upgrade PDR Review       June 23 & 24, 2010   8
                                        Estimated C15100 H04 CuZr Fatigue S-N Curve
                                       Olin Brass: Room Temperature; 40% CW; Reverse Bending (R-1)
                     70

                                                             Su = 58 ksi
                                                             Sy = 57.6 ksi
                     60




                     50


                                20x Cycles
S - Strength (ksi)




                     40




                     30
                                  2x Stress



                     20


                                                       Ctr Flex Peak Stress
                     10




                       0
                     1.00E+03            1.00E+04      1.00E+05               1.00E+06   1.00E+07    1.00E+08

                                                         N - Number of Cycles




                                                                                                                23
                                            Modified Goodman Diagram: C18150 TL04 CuCrZr Thread
                                                               Tresca Stress
                                  60

                                                                     Su = 79 ksi
                                                                     Sy = 75 ksi
                                  50       2/3 Sy
     Stress Amplitude, sa (psi)




                                  40




                                  30
                                   Se

                                  20




                                  10



                                                                                2/3 Sy               Su
                                   0
                                       0            10   20   30      40       50          60   70    80   90

                                                                   Mean Stress, sm (psi)
10
                                       Modified Goodman Diagram: Inconel 718 AMS 5663 5/8" Bolt
                                                            Tension Stress
                             160
                                                                 Su = 180
                             140
                             .9 Sy

                             120
Stress Amplitude, sa (psi)




                             100



                              80
                               Se

                              60



                              40



                              20



                               0
                                   0     20     40    60    80      100      120 .9   Sy 140   160      S
                                                                                                     180 u   200

                                                            Mean Stress, sm (psi)
                     11
       Flex Joint Design using Superbolt Jack-Screw
                      Tensioned Nuts




  12
NSTX                 NSTX Center Stack Upgrade PDR Review   June 23 & 24, 2010   12
       ANSYS Static Structural Results: Joint Tresca Stress
          Current Scenario #82, 31 Laminations/ Strap




  19
NSTX                     NSTX Center Stack Upgrade PDR Review   June 23 & 24, 2010   19
NSTX Flex Strap Friction Stir Weld Reaction Loads: Joint B Forces
        Note: Direction of reactions must be reversed when applied as loads to stub faces
NSTX Flex Strap Friction Stir Weld Reaction Loads: Joint B Moments
         Note: Direction of reactions must be reversed when applied as loads to stub faces
ANSYS Static Structural Results: 5/8” Bolted Contact Pressure
                            Current Scenario #82, 31 Laminations/ Strap




 Min. Pressure ~ 4500 psi
  23
NSTX                                  NSTX Center Stack Upgrade PDR Review   June 23 & 24, 2010   23
Pressurex® is a unique, affordable and easy to use tool that reveals the distribution and magnitude of pressure between any two
contacting, mating or impacting surfaces. pressure indicating sensor film is extremely thin (4 to 8 mils) which enables it to conform
to curved surfaces. It is ideal for invasive intolerant environments and tight spaces not accessible to conventional electronic
transducers.

How It Works
Pressurex® is a mylar based film that contains a layer of tiny microcapsules. The application of force upon the film causes the
microcapsules to rupture, producing an instantaneous and permanent high resolution "topographical" image of pressure variation
across the contact area.
Simply place Pressurex® between any two surfaces that touch, mate or impact. Apply pressure, remove it and immediately the film
reveals the pressure distribution profile that occurred between the two surfaces. Like Litmus paper, the color intensity of the film is
directly related to the amount of pressure applied to it. The greater the pressure, the more intense the color.
Pressurex® has a wide array of uses. For example, Pressurex® can be used in a bolted joint interface, composite layup, heat sealing
and lamination or press. Our pressure indicating film acts as a force sensing resistor. It can measure surface pressure distribution
whether it is used as an impact force sensor, seat pressure sensor, as a strain gauge or even as nip impression paper.

				
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