Fabrication of new joints for SST-1 TF coil winding packs

The Toroidal Field (TF) magnet system of SST-1 has sixteen NbTi/Cu based coils with about one hundred Inter-Pancake (IP) and Inter-Coil (IC) joints. New box type helium leak tight, low DC resistance joints have been designed, fabricated and tested at 5 K temperature and 10 kA DC transport current. The prototype of this joint has been validated in laboratory as well as on spare TF coil winding pack. Moreover, the performance of these joints has been realised and validated on actual sixteen TF winding packs, the joint resistance of ∼0.5 nΩ repeatedly measured on hundreds of IP joints. The quality of terminations and joints was ensured at various stages of fabrication. The quality of joint box material was ensured by visual inspection, chemical analysis, radiography test, ultrasonic test, eddy current test, etc. This paper describes joint design drivers, joint design detail, prototype joint fabrication processes, quality assurance (QA)/quality control (QC) adopted during prototype and actual joint fabrication process, joint resistance measurement on actual TF coils and analysis of measured joint resistance in detail.