Novel use of water soluble “Aquapour” as a temporary spacer during coil winding for the NSTX-U centerstack

A major facility upgrade to the National Spherical Torus eXperiment (NSTX-U) is currently underway at Princeton Plasma Physics Laboratory (PPPL). A key component of NSTX-U is the fabrication of a new, higher field centerstack (CS). In order to simultaneously provide robust joints between the inner and outer legs of the Toroidal Field Coils (TF) and minimize radial build, the NSTX-U CS design requires that the Ohmic Heating solenoid (OH) be wound directly on the inner TF bundle. To protect the OH against thermal expansion stress during scenarios where the inner TF bundle is hot but the OH is relatively cool, the completed CS will have a 0.100 inch annular gap between the outer diameter of the TF bundle and the inner diameter of the OH solenoid. “Aquapour”, a proprietary material produced by the Advanced Ceramics Manufacturing Company will be used during manufacture to produce this gap. After the TF bundle is vacuum pressure impregnated and cured, a cylindrical “clam shell” mold will be assembled around it, and a slurry of powdered Aquapour and water will be pumped into the annular space between the mold and TF bundle. Subsequent baking will turn the Aquapour solid, and a protective layer of wet lay-up fiberglass and resin will be added. The OH solenoid will be wound directly on this wet lay-up shell. After vacuum pressure impregnation of the OH, the water soluble Aquapour will be washed away, leaving the required radial clearance between the TF and OH. This paper will describe prototyping and testing of this process, and plans for use on the actual CS fabrication.