Stycast Insertion Part 3and preliminary glue picture on samples

10-10-06

1. Approx 3/32 hole drilled in plate, holes are counterbored for copper tubing

Stycast will go through and fill around two pins with one entrance hole and the bottom and exit hole at the top

Stycast will go through and fill around one pin with two holes drilled for entrance and exit, respectively

2. Copper tubing glued in with stycast

Small Zerc-like Fittings may be used in the real coil, but stycast works just fine.

3. Sample was carefully installed aligning pins in the middle of the holes.

Sample is then turned on its side for stycast insertion, standard plastic tubing is used. For delivery, a hypodermic syringe is used.

4. To prevent bubbles in stycast, sample is mixed, stirred then placed in a hard vacuum for 3 minutes

Paint pot used as vacuum chamber

Vacuum system and gage (used for QPS racetrack coils)

Stycast after vacuum deairing, notice that it foamed up the sides.

5. Injection of stycast (Vertically)

The stycast was pushed using the syringe from the bottom until it expelled from the top. It flowed with very little resistance at first but became slightly harder once the bottom hole was filled. There was no visible seepage from the sides and no visible air in the line. A vacuum was applied to the top line after stycast was observed coming out of the top. This was followed by further pushing with the syringe. No air bubbles were seen.

6. The other two holes showed similar results with no air bubbles in the line.

Stycast will now be cured at room temp for 24 hrs and will be transported back to ORNL for tensile testing

Strain gage cryo work

Adhesives tested so far on fiber optic wire:

1. Stycast 2850 FT2. Vishay M series AE-103. Norland UV glue

Still awaiting receipt of CTD 540, EPO-TEK

301-2 from Epoxy technology corporation and

standard Torrseal, recommended to us by

SNS. Update we have ctd 540 now

Test bed setup without motor

Testing

The sst samples were sanded to 60 and 120 grit surfaces along with the mirror like surface in the middle of the plate

60 gritAs delivered, mirror like 120 grit

The procedure for these first adhesive tests is to immerse the specimen for 75 mins with about 14.5 lbs of load applied to it, which results in around 800 ue on the center of the specimen in the three point bend fixture.

M bond AE-10 Specimen in LN2

Stycast and AE-10 after test

M Bond AE-10

Cracking and one spot became unbonded on the AE-10 specimen.

There is no degradation of the stycast specimen

Stycast 2850 FT

UV glue

The UV glue was a complete failure as it became unglued in multiple places. Not surprising considering our last effort with the stuff on the TF coil.

Testing of the Fiso gages• 4 gages were attached to a

316 sst sample plate on 60 grit and 220 grit surfaces.

• 2 gages used Stycast 2850 FT

• 2 gages used Vishay M Series AE-10.

• 2 gages (one Stycast one AE10) were also applied to G10.

Static 3 point bend testing in room air

SST (50 grit paper) 1 4 STY,UV,AE,CTD 4SST (as received, mirror like) 1 4 STY,UV,AE,CTD 4g-10 strips 1 4 STY,UV,AE,CTD 4QPS beam 1 4 STY,UV,AE,CTD 4SST, (200 grit, [if needed]) 1 4 STY,UV,AE,CTD 4

total 20

Note: as methods are discounted, more gages will be available

push rod

gages are in red

sample strips

Tension

Compression

Notes

• Fiber optic gages have been attached to both stainless steel and g-10 using stycast and AE-10.

• The AE-10 Gages can be recovered by using a stripping agent if they fail and come off.

• Data Acquisition software is installed for the UMI and FTI-10.

• Room temperature testing (steady state) of the gages and data acquisition system shall commence tomorrow.

Testing of the two sample plates in room temperature

Loading is applied by a tapered rod, which does not extend to the edge of the specimen, errors may be introduced here.

Deflection system is primitive, dial indicator mounted to side of sample. Plate deflection is somewhat curved.

Mass weights were measured to nearest 1/10 gram on scale.

Stainless Steel Specimens at room temperature

GAGE 1 GAGE 2 GAGE 3 GAGE 4adhesive AE10 AE11 STY STYgage number 6442 6443 6444 6445Location Bottom Top Bottom Topgrit 60 GRIT 220 GRIT 60 GRIT 220 GRIT

AE10 Specimen #1 had problems

Errors on Stycast < 20%

Return strains were a few micro-strain typically

Gage readings are very repeatable

MEASURED DEFLECTION

(IN)

MEASURED LOAD (lbs)

% error (load)PREDICTED

STRAINGAGE 1 GAGE 2 GAGE 3 GAGE 4 GAGE 1 GAGE 2 GAGE 3 GAGE 4

0.022 2.06 5.25 117.56 80.25 -96.00 111.75 -102.00 31.74 18.34 4.94 13.240.04525 4 0.64 241.80 161.50 -194.25 224.75 -198.25 33.21 19.67 7.05 18.010.06925 6 2.61 370.05 241.75 -271.75 344.00 -298.25 34.67 26.56 7.04 19.400.1695 14.65 2.85 905.77 587.00 -663.50 843.50 -723.25 35.19 26.75 6.87 20.15

return strain -3.67 -2.33 9.67 -3.67

MEASURED DEFLECTION

(IN)

MEASURED LOAD (lbs)

% error (load)PREDICTED

STRAINGAGE 1 GAGE 2 GAGE 3 GAGE 4 GAGE 1 GAGE 2 GAGE 3 GAGE 4

0.022 2.06 5.25 118 -108.00 98.5 -118.25 103.25 8.13 16.21 -0.58 12.170.045 4 0.09 240 -189.67 205.75 -234.75 205.5 21.13 14.44 2.38 14.54

0.06875 6 1.90 367 -269.33 309 -356.25 306.25 26.69 15.89 3.03 16.640.169 14.65 2.56 903 -699.33 793.5 -864.25 758 22.56 12.14 4.30 16.07

return strain -538.25 8.75 -10.25 12.5

% error

% errorTEST AVERAGES (1-4) Strain (ue)

TEST AVERAGES (5-8) Plate Flipped Strain (ue)

G-10 Specimens at room temperature

GAGE 5 GAGE 7adhesive AE10 stycastLocation Top top

Errors on Stycast < 8%

Return strains were a few micro-strain typically

Pattern suggests loading may not be centered

MEASURED DEFLECTION

(IN)

MEASURED LOAD (lbs)

% error (load)

PREDICTED STRAIN

GAGE 5 GAGE 7 Gage 5 Gage 7

0.1615 2.06 7.12 946.29 -1018.00 -965.25 -7.58 -2.000.20225 2.51 9.63 1185.06 -1274.50 -1205.25 -7.55 -1.70

0.238 2.96 9.44 1394.53 -1499.25 -1415.25 -7.51 -1.490.32225 3.95 10.74 1888.18 -2028.50 -1914.50 -7.43 -1.39

return strain 1.75 1.25

MEASURED DEFLECTION

(IN)

MEASURED LOAD (lbs)

% error (load)

PREDICTED STRAIN

GAGE 5 GAGE 7 Gage 5 Gage 7

0.1625 2.06 7.69 952.15 946.75 1015.25 0.57 -6.630.203 2.51 9.96 1189.45 1196.75 1280.50 -0.61 -7.65

0.2405 2.96 10.38 1409.18 1403.75 1503.50 0.39 -6.690.3235 3.95 11.09 1895.51 1886.75 2021.25 0.46 -6.63

return strain 33.67 22.00

% errorStrain (ue)TEST AVERAGES (1-4)

TEST AVERAGES (5-8) Plate Flip % errorStrain (ue)

First attempt at Cryo testing

Cooling of cryo box

Dial indicator yields very poor measurements in present location. Cryo LVDT under design.

Sample plate in LN2

Stainless Steel Specimens at 77 K

MEASURED LOAD (lbs)

PREDICTED STRAIN

GAGE 1 GAGE 2 GAGE 3 GAGE 4 GAGE 1 GAGE 2 GAGE 3 GAGE 4

2.06 107.60 #DIV/0! 92.00 -101.50 66.50 #DIV/0! 14.50 5.67 38.204 208.93 #DIV/0! 162.00 -204.25 161.75 #DIV/0! 22.46 2.24 22.586 313.39 #DIV/0! 217.00 -277.75 230.75 #DIV/0! 30.76 11.37 26.37

14.65 765.19 #DIV/0! -308.00 -566.50 471.00 #DIV/0! 59.75 25.97 38.45return strain 0.00 #DIV/0! 237.00 -2.67 6.67

MEASURED LOAD (lbs)

PREDICTED STRAIN

GAGE 1 GAGE 2 GAGE 3 GAGE 4 GAGE 1 GAGE 2 GAGE 3 GAGE 4

2.06 107.5970855 #DIV/0! #DIV/0! 108 -96.5 #DIV/0! #DIV/0! -0.37 10.314 208.9263796 #DIV/0! #DIV/0! 196.25 -169.5 #DIV/0! #DIV/0! 6.07 18.876 313.3895694 #DIV/0! #DIV/0! 295.25 -275.75 #DIV/0! #DIV/0! 5.79 12.01

14.65 765.1928652 #DIV/0! #DIV/0! 633.75 -551.5 #DIV/0! #DIV/0! 17.18 27.93return strain #DIV/0! #DIV/0! 15.75 -13.25

TEST AVERAGES (1-4)

TEST AVERAGES (5-8)

Strain (ue) % error

Strain (ue) % error

GAGE 1 GAGE 2 GAGE 3 GAGE 4adhesive AE10 AE11 STY STYgage number 6442 6443 6444 6445Location Bottom Top Bottom Topgrit 60 GRIT 220 GRIT 60 GRIT 220 GRIT

We lost gage 1 during cooldown,

Gage 2 went out after we applied 14 lbs to it.

Force may have been off due to sticking in bearings. No reasonable deflection was taken

Stycast gages survived and had very good return strain. Both AE10 gages were unreadable

G-10 Specimens at 77 K

MEASURED LOAD (lbs)

PREDICTED STRAIN

GAGE 5 GAGE 7 Gage 5 Gage 7

2.06 696.22 #DIV/0! -578.50 #DIV/0! 16.912.51 848.30 #DIV/0! -634.00 #DIV/0! 25.262.96 1000.39 #DIV/0! -775.00 #DIV/0! 22.533.95 1334.98 #DIV/0! -998.75 #DIV/0! 25.19

MEASURED LOAD (lbs)

PREDICTED STRAIN

GAGE 5 GAGE 7 Gage 5 Gage 7

2.06 696.22 #DIV/0! 621.50 #DIV/0! 10.732.51 848.30 #DIV/0! 766.75 #DIV/0! 9.612.96 1000.39 #DIV/0! 868.00 #DIV/0! 13.233.95 1334.98 #DIV/0! 1096.25 #DIV/0! 17.88

TEST AVERAGES (1-4)

TEST AVERAGES (5-8)

Strain (ue) % error

Strain (ue) % error

We lost gage 5 during cooldown,

Again, Force may have been off due to sticking in bearings. No reasonable deflection was taken. Also, plate support pins may have been rubbed.

Stycast gages survived and had very good return strain. The AE10 gages was unreadable

E for G10 = 5 Mpsi at 77 K (assumption)

The results observed from the AE10 gages was eerily similar to those seen on the TF beam last year. With sporadic nonsense readings at times after they became lost contact with the UMI data acquisition system.

Gages after testing

Cracking

“Reciprogator” three point bend tester

30 RPM motor (approximately same period as a coil pulse) and cam have been assembled. This provides for approximately .06 in of vertical deflection of the rod.

What is the modulus of SS. ?

In our case, Small changes in deflection load, produce large changes in modulus and thus predicted strain.

Such a wide array of data for the modulus of stainless steel.

Source:

participants