Several problems must be solved in the construction, design, and operation of a nuclear fusion reactor. One of the chief problems in the manufacture of high-powered copper/polymer composite magnets is the difficulty to precisely control the fiber volume fraction. In this thesis, the effect of variations in fiber volume fraction on thermal stresses in copper/cyanate ester composite cylinders is investigated. The cylinder is a composite that uses copper wires that run longitudinally in a cyanate ester resin specifically developed by Composite Technology Development, Inc. This composite cylinder design is commonly used in magnets for nuclear fusion reactors. The application of this research is for magnets that use cylindrical coil geometry such as the Mega Amp Spherical Tokamak (MAST) in the UK. However, most stellarator magnet designs use complex geometries including the National Compact Stellarator Experiment (NCSX), and the Quasi-Poloidal Stellarator (QPS). Even though the actual stresses calculated for the cylindrical geometry may not be directly applicable to these projects, the relationship between fiber volume fraction and stresses will be useful for any geometry. The effect of fiber volume fraction on stresses produced by mechanical, thermal and magnetic loads on cylindrical magnet coils is studied using micromechanics with laminate plate theory (LPT) and finite element analysis (FEA). Based on the findings of this research, variations in volume fraction do significantly affect the stress experienced by the composite cylinder. Over a range of volume fractions from 0.3 to 0.5, the LPT results demonstrate that thermally induced stresses vary approximately 30% while stresses due to pressure vary negligibly. The FEA shows that magnetic stresses vary much less at around only 5%. FEA results seem to confirm the LPT model. It was also concluded that the stress in the insulation layers due to all types of loadings is significant and must be considered when using this system in fusion applications.

Several problems must be solved in the construction, design, and operation of a nuclear fusion reactor. One of the chief problems in the manufacture of high-powered copper/polymer composite magnets is the difficulty to precisely control the fiber volume fraction. In this thesis, the effect of variations in fiber volume fraction on thermal stresses in copper/cyanate ester composite cylinders is investigated. The cylinder is a composite that uses copper wires that run longitudinally in a cyanate ester resin specifically developed by Composite Technology Development, Inc. This composite cylinder design is commonly used in magnets for nuclear fusion reactors. The application of this research is for magnets that use cylindrical coil geometry such as the Mega Amp Spherical Tokamak (MAST) in the UK. However, most stellarator magnet designs use complex geometries including the National Compact Stellarator Experiment (NCSX), and the Quasi-Poloidal Stellarator (QPS). Even though the actual stresses calculated for the cylindrical geometry may not be directly applicable to these projects, the relationship between fiber volume fraction and stresses will be useful for any geometry. The effect of fiber volume fraction on stresses produced by mechanical, thermal and magnetic loads on cylindrical magnet coils is studied using micromechanics with laminate plate theory (LPT) and finite element analysis (FEA).Based on the findings of this research, variations in volume fraction do significantly affect the stress experienced by the composite cylinder. Over a range of volume fractions from 0.3 to 0.5, the LPT results demonstrate that thermally induced stresses vary approximately 30% while stresses due to pressure vary negligibly. The FEA shows that magnetic stresses vary much less at around only 5%. FEA results seem to confirm the LPT model. It was also concluded that the stress in the insulation layers due to all types of loadings is significant and must be considered when using this system in fusion applications.

The manufacture, laminate design, and modeling of a part with complex geometry are explored. The ultimate goal of the research is to produce a model that accurately predicts part stiffness. This is validated with experimental results of composite parts, which refine material properties for use in a final prototype part model. The secondary goal of this project is to explore manufacturing methods for improved manufacturability of the complex part. The manufacturing portion of the thesis and feedback into material model has incorporated a senior project team to perform research on manufacturing and create composite part to be used for experimental testing. The senior project was designed, led, and managed by the author with support from the committee chair. Finite element modeling was refined using data from coupon 3-point bend testing to improve estimates on material properties. These properties were fed into a prototype part model which predicted deflection of composite parts with different layups and materials. The results of the model were compared to experimental results from prototype part testing and 3rd party analysis. The results showed that an accurate mid-plane shell element model could be used to accurately predict deflection for 2 of 3 experimental parts. There are recommendations in the thesis to further validate the models and experimental testing.