Tension layer winding of cable-in-conduit conductor

A 710 mm i,d. by 440 mm long, 6 layer Cable-in-Conduit (CIC) coil was precision tension layer wound with Incoloy 908 jacketed conductor to model winding technology that will be used for the Nb3Sn outsert coils of the 45 Tesla Hybrid Magnet Project at the U.S. National High Magnetic Field Laboratory, This paper reports on the set up of a new winding facility with unique capabilities for insulating and winding long length CIC conductor and on special procedures which were developed to wind and support layer to layer transitions and to safely form conductor into and out of the winding. Analytical methods used to predict conduit keystoning, springback and back tensioning requirements before winding are reported in comparison to results obtained during winding and actual winding build-up dimensions on a layer by layer basis in comparison to design requirements.