1 of 35

Elytt experience:

Iter TF Double Pancake conductor insulation and DP Impregnation

DP: 15 m long, 9 m wide

Calle Orense 11, 2 º B - 28020 Madrid - Spain - Phone: +34 91 411 09 63 - Fax: +34 91 411 09 64 - www.elytt.com

NSTX-U TF-OH Bundle FDR. Elytt manufacturing plan and prototype testing

2 of 35

Elytt experience:

Iter TF Double Pancake conductor insulation and DP Impregnation

Calle Orense 11, 2 º B - 28020 Madrid - Spain - Phone: +34 91 411 09 63 - Fax: +34 91 411 09 64 - www.elytt.com

NSTX-U TF-OH Bundle FDR. Elytt manufacturing plan and prototype testing

3 of 35

Elytt experience:

Iter TF Double Pancake conductor insulation and DP Impregnation

Calle Orense 11, 2 º B - 28020 Madrid - Spain - Phone: +34 91 411 09 63 - Fax: +34 91 411 09 64 - www.elytt.com

NSTX-U TF-OH Bundle FDR. Elytt manufacturing plan and prototype testing

4 of 35

Elytt experience:

Iter PF Double Pancake and Winding Pack Impregnation

DP: up to 25 m diameter, 0,1 m height
WP: up to 25 m diameter, 1 m height

Calle Orense 11, 2 º B - 28020 Madrid - Spain - Phone: +34 91 411 09 63 - Fax: +34 91 411 09 64 - www.elytt.com

NSTX-U TF-OH Bundle FDR. Elytt manufacturing plan and prototype testing

5 of 35

Elytt experience:

Most critical point for good VPI: compaction and resin paths
Mock ups needed
Important but easier to achieve:

Inclination
Resin degassing
Resin and mold temperature
Pumping speed
Resin back and forth
Vacuum level

Calle Orense 11, 2 º B - 28020 Madrid - Spain - Phone: +34 91 411 09 63 - Fax: +34 91 411 09 64 - www.elytt.com

NSTX-U TF-OH Bundle FDR. Elytt manufacturing plan and prototype testing

6 of 35

Elytt Design review and manufacturability:

Design review recommendations (implemented):

Eliminate Kapton as much as possible as it causes delamination (only Kapton in OH conductor co-wound tape)
Eliminate G11 as much as possible to get continuous fiber wrap
Change blade length for G11 at ends (unique G11)
Round area and avoiding sharp corners
OH conductor terminals machined, not casted

Manufacturability

Difficult to achieve:

Wrapping: blades wrapping configuration
Impregnation:

Controlled compaction of fiber glass
Resin pads with resin paths in appropriate places

Less difficult to achieve (based on Elytt experience):

Other insulations (OH inner ground, OH conductor, OH outer ground, B stage, Inter Quadrant)
Vacuum level
Avoiding resin rich areas (use of tedlar)
All areas Resin wet (use of compaction tools, resin paths, inclination, resin degassing, resin and mold temperature, pumping speed, resin back and forth)

Strongly recommended: mock ups

Calle Orense 11, 2 º B - 28020 Madrid - Spain - Phone: +34 91 411 09 63 - Fax: +34 91 411 09 64 - www.elytt.com

NSTX-U TF-OH Bundle FDR. Elytt manufacturing plan and prototype testing

7 of 35

Manufacturing Plan:

Compaction test (as calculation input)

Final tooling preliminary design

Final tooling calculation (thermal and structural)

Final tooling design

Design mock up tooling adapting final tooling

Manufacture mock ups tooling

Manufacture & test mock up

Manufacture Final tooling

Manufacture & test TF-OH

Modify Final tooling if needed

Define Final manufacturing procedures

Define Final IP

Modify Final IP

Modify Final manufacturing procedures

Risk analysis

TIME

Calle Orense 11, 2 º B - 28020 Madrid - Spain - Phone: +34 91 411 09 63 - Fax: +34 91 411 09 64 - www.elytt.com

NSTX-U TF-OH Bundle FDR. Elytt manufacturing plan and prototype testing

8 of 35

Manufacturing Plan:

1 m Quadrant mock up. Grit blasting and prime

TF-OH first quadrant Blades grit blasting and prime

1 m Quadrant Blades stacking

TF-OH first quadrant Blades stacking

1 m Quadrant VPI and tests

TF-OH first quadrant VPI

4 quadrant mock up

TF-OH TF 4 quadrant integration and wrapping

TF compaction mock up

TF VPI mock up

TF-OH TF VPI

OH mock up. B stage

TF-OH OH B stage

OH mock up. Winding

TF-OH OH winding

OH mock up. VPI

TF-OH OH VPI

TIME

Calle Orense 11, 2 º B - 28020 Madrid - Spain - Phone: +34 91 411 09 63 - Fax: +34 91 411 09 64 - www.elytt.com

NSTX-U TF-OH Bundle FDR. Elytt manufacturing plan and prototype testing

9 of 35

Mock ups:

Title/Description	Objective	Material & Tooling	Configuration & Procedure	Completion Schedule
SOW 2.1.2 A: TF Wrapping Tests (3D Printed Parts)	Define wrapping technique Define fabric patterns (.dxf files for Co2 Laser machine)	Blade 3 D printed Legacy PPPL roll tape 50mm width (no fabric available) Elytt property Woven clothes from Tisstech (thickness 0.2mm and width 400mm)	Preliminary layer configuration and sequence with legacy tape and Elytt fabric Preliminary Blade wrapping procedure	June 2022
SOW 2.1.2 B: TF Conductor Wrapping Tests (PPPL Conductor Sample)	Confirm wrapping technique Confirm geometry of fabric patterns Full coverage of copper check Tacking material test	Legacy PPPL Blade Legacy PPPL tape Elytt property Woven clothes from Tisstech (thickness 0.2mm and width 400mm) 2 tackifiers (Hunstman Araldite 2011 and CTD-BDR-1.0)	Final layer configuration and sequence with legacy tape and Elytt fabric Final Blade wrapping procedure Preliminary IP procedure	August 2022

Calle Orense 11, 2 º B - 28020 Madrid - Spain - Phone: +34 91 411 09 63 - Fax: +34 91 411 09 64 - www.elytt.com

NSTX-U TF-OH Bundle FDR. Elytt manufacturing plan and prototype testing

10 of 35

Mock ups:

Title/Description	Objective	Material & Tooling	Configuration & Procedure	Completion Schedule
SOW 2.1.2 C-1: TF Flat Mock-Up and Compaction. Preliminary	Define pressure for 20% compression on the S-2 glass for tooling calculation (security factor to be applied)	Legacy PPPL tape (no fabric available)	Similar to final configuration but with tape Preliminary Report of S-2 fiberglass insulation compaction	June 2022
SOW 2.1.2 C-1: TF Flat Mock-Up and Compaction. Final	Confirm pressure to obtain 20% compression	Final S2 tape Final S2 fabric	Final configuration Final compaction value Final Report of S-2 fiberglass insulation compaction	September 2022

Calle Orense 11, 2 º B - 28020 Madrid - Spain - Phone: +34 91 411 09 63 - Fax: +34 91 411 09 64 - www.elytt.com

NSTX-U TF-OH Bundle FDR. Elytt manufacturing plan and prototype testing

11 of 35

Mock ups:

Title/Description	Objective	Material & Tooling	Configuration & Procedure	Completion Schedule
SOW 2.1.2 D: 1 Meter Quadrant Mock-Up and VPI (Extruded Coolant Channel s/Surplus PPPL Conductors)	Blade grit blasting and clean	Legacy Blade with scallop machined Final grit Final cleaning agent Nitrogen Gas Final Grit blasting machine Final portable crane Final blade lifting tool and lifting beam Portable Surface Roughness Tester	Final grit blasting procedure Final cleaning procedure Final IP procedure	October 2022
	Blade prime and cure	Final primer CTD-450 Final cleaning agent Final priming station Final prime curing station Final portable crane Final blade lifting tool and lifting beam Coating Thickness Gauge	Final primer applied according to specs Final primer application procedure Final primer curing procedure Final cured prime cleaning procedure Final IP procedure	October 2022
	Blade wrapping	Final S2 tape Final S2 fabric Final G11 Final connection area masking plate and bolts Final tackifier Final wrapping station Final portable crane Final blade lifting tool and lifting beam	Almost Final S2 tape/S2 fabric/G11/tacking configuration (legacy blade) Final tacking procedure Almost Final wrapping procedure (legacy blade) Final IP procedure	November 2022

Calle Orense 11, 2 º B - 28020 Madrid - Spain - Phone: +34 91 411 09 63 - Fax: +34 91 411 09 64 - www.elytt.com

NSTX-U TF-OH Bundle FDR. Elytt manufacturing plan and prototype testing

12 of 35

Mock ups:

Title/Description	Objective	Material & Tooling	Configuration & Procedure	Completion Schedule
SOW 2.1.2 D: 1 Meter Quadrant Mock-Up and VPI (Extruded Coolant Channel s/Surplus PPPL Conductors)	Blade stacking and shrinkage tape wrap	Final de-moulding shrinkage tape Final tackifier Final Blade stacking and quadrant wrapping station Final fillers, parker plugs and resin pads Final portable crane Final blade lifting tool and lifting beam Elytt 10tn lifting beam	S2 tape/tacking final configuration Almost Final Blade stacking procedure (legacy blade) Final tacking procedure Final IP procedure	November 2022
	Quadrant VPI and cure	Final resin CTD-425 Specific compaction and VPI mold and support based on Final design Final impregnation station Final curing station with some adjustments Elytt crane Elytt 10tn lifting beam Trumpf TruTool nibller (casing cutting)	Almost Final compaction procedure Almost final impregnation mould (casing) assembly and welding procedure Final VPI and cure procedure Almost Final de-moulding procedure Final IP procedure Visual inspection of impregnated areas and cooling holes (no resin inside) Dimensional control Electrical tests	December 2022
	Testing		Cut Macrographic inspection Mechanical tests	December 2022

Calle Orense 11, 2 º B - 28020 Madrid - Spain - Phone: +34 91 411 09 63 - Fax: +34 91 411 09 64 - www.elytt.com

NSTX-U TF-OH Bundle FDR. Elytt manufacturing plan and prototype testing

13 of 35

Mock ups:

Title/Description	Objective	Material & Tooling	Configuration & Procedure	Completion Schedule
SOW 2.1.2 E: 2.5 Meter Cylindrical TF Mock-Up Compaction Test	Compaction of TF bundle ground insulation and shrinkage tap wrap	Final S2 tape Final de-moulding shrinkage tape Final TF bundle wrapping station Final TF bundle compaction tooling Elytt crane Elytt 10tn lifting beam	Final S2 tape configuration Final TF ground insulation procedure Final compaction procedure Final IP procedure	December 2022

SOW 2.1.2 F: 2.5 Meter Cylindrical TF Mock-Up VPI (on 2.5m TF compaction mock up)	VPI and cure	Final resin CTD-425 Specific VPI mold and Support Final impregnation station Final curing station with some adjustments Elytt crane Elytt 10tn lifting beam	Final VPI and cure procedure Final IP procedure	December 2022

Calle Orense 11, 2 º B - 28020 Madrid - Spain - Phone: +34 91 411 09 63 - Fax: +34 91 411 09 64 - www.elytt.com

NSTX-U TF-OH Bundle FDR. Elytt manufacturing plan and prototype testing

14 of 35

Mock ups:

Title/Description	Objective	Material & Tooling	Configuration & Procedure	Completion Schedule
SOW 2.1.2 H: 2.5 Meter OH Coil Mock-Up Compaction VPI (using 2.5 TF mockup VPIed)	B stage and shrinkage tape wrap	Final B stage tape Final de-moulding shrinkage tape Specific compaction and curing mold based on final design Final curing station with some adjustments Elytt crane Elytt 10tn lifting beam PPPL winding line	Final B stage configuration Final B stage winding procedure Final B stage compaction procedure Final B stage curing procedure Final IP procedure	January 23
	Teflon	Final Teflon tape Teflon fixing tooling	Final Teflon configuration Final Teflon wrapping and fixing procedure Final IP procedure	January 2023
	Inner Ground wrapping	Final S2 tape Final TF wrapping station Elytt crane Elytt 10tn lifting beam	Final S2 tape configuration Final OH inner ground insulation procedure Final IP procedure	January 2023

Calle Orense 11, 2 º B - 28020 Madrid - Spain - Phone: +34 91 411 09 63 - Fax: +34 91 411 09 64 - www.elytt.com

NSTX-U TF-OH Bundle FDR. Elytt manufacturing plan and prototype testing

15 of 35

Mock ups:

Title/Description	Objective	Material & Tooling	Configuration & Procedure	Completion Schedule
SOW 2.1.2 H: 2.5 Meter OH Coil Mock-Up Compaction VPI (using 2.5 TF mockup VPIed)	OH conductor winding+bending+pancake brazing+terminal brazing	Legacy OH conductor Final S2-Kapton co-wound tape Final G11 termination area fillers Final G11 terminal box and fillers Final terminals Final brazing material PPPL S2-Kapton co-winding station PPPL winding station and tools with configuration of legacy OH conductor G11 terminal box fixing tool Final bending tools with some adaptations Final brazing tools with some adaptations	Final S2-Kapton co-wound tape configuration Final OH conductor winding configuration Final termination configuration Final G11 termination area with fillers configuration Final G11 terminal box and fillers configuration Final co-wound tape manufacturing procedure Final winding procedure Final bending procedure Final termination brazing procedure Final pancake brazing procedure Final G11 termination filler installation procedure Final G11 terminal box and filler installation procedure	February 2023
	Outer Ground wrapping	Final S2 tape Final tacking Final TF wrapping station Elytt crane Elytt 10tn lifting beam	Final S2 tape/tacking configuration Final tacking procedure application Final OH outer ground procedure application Final IP procedure application	February 2023

Calle Orense 11, 2 º B - 28020 Madrid - Spain - Phone: +34 91 411 09 63 - Fax: +34 91 411 09 64 - www.elytt.com

NSTX-U TF-OH Bundle FDR. Elytt manufacturing plan and prototype testing

16 of 35

Mock ups:

Title/Description	Objective	Material & Tooling	Configuration & Procedure	Completion Schedule
SOW 2.1.2 H: 2.5 Meter OH Coil Mock-Up Compaction VPI (using 2.5 TF mockup VPIed)	OH solenoid VPI and cure	Final resin CTD-425 Specific compaction and VPI mold based on Final design Final impregnation station Final curing station with some adjustments Elytt crane Elytt 10tn lifting beam	Almost Final caps installation procedure Almost Final compaction procedure Final VPI and cure procedure Final demoulding procedure TF-OH layers extraction procedure Final IP procedure Visual inspection of impregnated areas and TF-OH gap (no resin interlayer) Dimensional control Electrical tests	March 2023
	Testing		Cut Macrographic inspection	March 2023

Calle Orense 11, 2 º B - 28020 Madrid - Spain - Phone: +34 91 411 09 63 - Fax: +34 91 411 09 64 - www.elytt.com

NSTX-U TF-OH Bundle FDR. Elytt manufacturing plan and prototype testing

17 of 35

Mock ups:

Title/Description	Objective	Material & Tooling	Configuration & Procedure	Completion Schedule
SOW 2.1.2 G: Four Quadrant VPI Simulation	Inter quadrant Ground insulation	Final S2 fabric Final tacking G11 inner tube Final TF wrapping station Elytt crane	Final inter quadrant S2 fabric/tacking configuration Final tacking procedure Final inter quadrant ground insulation procedure Final IP procedure	January 2023
	Quadrant VPI and cure	Final resin Specific compaction and VPI mold and support based on Final design Final impregnation station Final curing station with some adjustments Elytt crane	Almost Final caps installation procedure Almost Final compaction procedure Final VPI and cure procedure Final IP procedure	February 2023
	Testing		Cut Macrographic inspection

Calle Orense 11, 2 º B - 28020 Madrid - Spain - Phone: +34 91 411 09 63 - Fax: +34 91 411 09 64 - www.elytt.com

NSTX-U TF-OH Bundle FDR. Elytt manufacturing plan and prototype testing

18 of 35

Mock ups:

Title/Description	Objective	Material & Tooling	Configuration & Procedure	Completion Schedule
SOW 2.1.2 I: Deep Gun Drilling Prototype Back-Up Source	Blade deep drilling	Legacy blade Final Drill bit Almost Final Drilling tool (legacy blade) Subcontractor crane Subcontractor lifting beam	Final drilling procedure Final IP procedure	July 2022

Calle Orense 11, 2 º B - 28020 Madrid - Spain - Phone: +34 91 411 09 63 - Fax: +34 91 411 09 64 - www.elytt.com

NSTX-U TF-OH Bundle FDR. Elytt manufacturing plan and prototype testing

19 of 35

Blade wrapping proposal:

Calle Orense 11, 2 º B - 28020 Madrid - Spain - Phone: +34 91 411 09 63 - Fax: +34 91 411 09 64 - www.elytt.com

NSTX-U TF-OH Bundle FDR. Elytt manufacturing plan and prototype testing

20 of 35

Blade wrapping proposal:

Calle Orense 11, 2 º B - 28020 Madrid - Spain - Phone: +34 91 411 09 63 - Fax: +34 91 411 09 64 - www.elytt.com

NSTX-U TF-OH Bundle FDR. Elytt manufacturing plan and prototype testing

21 of 35

Blade wrapping proposal:

Calle Orense 11, 2 º B - 28020 Madrid - Spain - Phone: +34 91 411 09 63 - Fax: +34 91 411 09 64 - www.elytt.com

NSTX-U TF-OH Bundle FDR. Elytt manufacturing plan and prototype testing

22 of 35

Blade wrapping proposal:

Calle Orense 11, 2 º B - 28020 Madrid - Spain - Phone: +34 91 411 09 63 - Fax: +34 91 411 09 64 - www.elytt.com

NSTX-U TF-OH Bundle FDR. Elytt manufacturing plan and prototype testing

23 of 35

Blade wrapping proposal:

Calle Orense 11, 2 º B - 28020 Madrid - Spain - Phone: +34 91 411 09 63 - Fax: +34 91 411 09 64 - www.elytt.com

NSTX-U TF-OH Bundle FDR. Elytt manufacturing plan and prototype testing

24 of 35

Blade wrapping proposal:

Calle Orense 11, 2 º B - 28020 Madrid - Spain - Phone: +34 91 411 09 63 - Fax: +34 91 411 09 64 - www.elytt.com

NSTX-U TF-OH Bundle FDR. Elytt manufacturing plan and prototype testing

25 of 35

Blade wrapping proposal:

Calle Orense 11, 2 º B - 28020 Madrid - Spain - Phone: +34 91 411 09 63 - Fax: +34 91 411 09 64 - www.elytt.com

NSTX-U TF-OH Bundle FDR. Elytt manufacturing plan and prototype testing

26 of 35

Blade wrapping proposal:

Calle Orense 11, 2 º B - 28020 Madrid - Spain - Phone: +34 91 411 09 63 - Fax: +34 91 411 09 64 - www.elytt.com

NSTX-U TF-OH Bundle FDR. Elytt manufacturing plan and prototype testing

27 of 35

Blade wrapping proposal:

Calle Orense 11, 2 º B - 28020 Madrid - Spain - Phone: +34 91 411 09 63 - Fax: +34 91 411 09 64 - www.elytt.com

NSTX-U TF-OH Bundle FDR. Elytt manufacturing plan and prototype testing

28 of 35

Blade wrapping proposal:

Calle Orense 11, 2 º B - 28020 Madrid - Spain - Phone: +34 91 411 09 63 - Fax: +34 91 411 09 64 - www.elytt.com

NSTX-U TF-OH Bundle FDR. Elytt manufacturing plan and prototype testing

29 of 35

Blade wrapping proposal:

Calle Orense 11, 2 º B - 28020 Madrid - Spain - Phone: +34 91 411 09 63 - Fax: +34 91 411 09 64 - www.elytt.com

NSTX-U TF-OH Bundle FDR. Elytt manufacturing plan and prototype testing

30 of 35

Blade wrapping proposal:

Calle Orense 11, 2 º B - 28020 Madrid - Spain - Phone: +34 91 411 09 63 - Fax: +34 91 411 09 64 - www.elytt.com

NSTX-U TF-OH Bundle FDR. Elytt manufacturing plan and prototype testing

31 of 35

Blade wrapping proposal:

Calle Orense 11, 2 º B - 28020 Madrid - Spain - Phone: +34 91 411 09 63 - Fax: +34 91 411 09 64 - www.elytt.com

NSTX-U TF-OH Bundle FDR. Elytt manufacturing plan and prototype testing

32 of 35

Blade wrapping proposal:

Calle Orense 11, 2 º B - 28020 Madrid - Spain - Phone: +34 91 411 09 63 - Fax: +34 91 411 09 64 - www.elytt.com

NSTX-U TF-OH Bundle FDR. Elytt manufacturing plan and prototype testing

33 of 35

Blade wrapping proposal:

Calle Orense 11, 2 º B - 28020 Madrid - Spain - Phone: +34 91 411 09 63 - Fax: +34 91 411 09 64 - www.elytt.com

NSTX-U TF-OH Bundle FDR. Elytt manufacturing plan and prototype testing

34 of 35

Blade wrapping proposal:

Calle Orense 11, 2 º B - 28020 Madrid - Spain - Phone: +34 91 411 09 63 - Fax: +34 91 411 09 64 - www.elytt.com

NSTX-U TF-OH Bundle FDR. Elytt manufacturing plan and prototype testing

35 of 35

Blade wrapping proposal:

Calle Orense 11, 2 º B - 28020 Madrid - Spain - Phone: +34 91 411 09 63 - Fax: +34 91 411 09 64 - www.elytt.com

NSTX-U TF-OH Bundle FDR. Elytt manufacturing plan and prototype testing