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BNL - FNAL - LBNL - SLAC
LARP Model Magnet RD DOE Review of the LHC
Accelerator Research Program June 1-2,
2005 Gian Luca Sabbi
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Model Magnet RD Guidance

• Programmatic issues
• Approach as RD program, not as a construction
  project (DOE)
• Investigate Nb3Sn technology options for IR
  upgrades (DOE)
• Concentrate on quadrupole magnets first (CERN,
  LAPAC)
• Down-select options prior to experimental
  investigation (LAPAC)
• Collaboration issues
• Coordinate program and effort across
  laboratories (DOE, LAPAC)
• Compare technologies, develop common procedures
  (LAPAC)
• Technical objectives
• Investigate performance limits, as input for IR
  design (DOE, CERN)
• Demonstrate long Nb3Sn magnets as soon as
  feasible (CERN, LAPAC)

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Magnet Program Goals
Overall goal Provide options for future
upgrades of the LHC Interaction Regions
FY09 Milestone Demonstrate viability of
Nb3Sn technology for Quad-first option
1. Capability to deliver predictable,
reproducible performance TQ (Technology
Quads) D 90 mm, L 1 m, Gnom gt 200 T/m 2.
Capability to scale-up the magnet length
LQ (Long Quads) D 90 mm, L 4 m, Gnom gt 200
T/m 3. Capability to reach high gradients in
large apertures HQ (High Gradient Quads) D
90 mm, L 1 m, Gnom gt 250 T/m
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Program Plan FY05-FY09
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Technology Quads Features and Goals

• Objective develop the technology base for LQ and
  HQ
• evaluate conductor and cable performance
  stability, stress limits
• develop and select coil fabrication procedures
• select the mechanical design concept and support
  structure
• demonstrate predictable and reproducible
  performance
• Implementation two series, same coil design,
  different structures
• TQS models shell-based structure
• TQC models collar-based structure
• Magnet parameters
• 1 m length, 90 mm aperture, 11-13 T coil peak
  field
• Nominal gradient 200 T/m maximum gradient
  215-265 T/m

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TQS01 TQC01 Conductor Coil

• Strand
• OST-MJR, 0.7 mm diameter
• Jc 2 kA/mm2 (12 T, 4.2 K)
• Is gt 1 kA w/optimized HT
• Cable
• 27-strand, 10.05 mm width
• Mid-thickness 1.26 mm
• Keystone angle 1.0 deg
• Insulation S-2 glass sleeve
• Coil
• double-layer, shell-type
• one wedge/octant (inner layer)

• MJR strand
• same strand for both models
• 70 kg borrowed from FNAL
• replacement order in FY06

Coil cross-section
Coil end (inner layer)
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TQS models Shell-based Structure

• Concept
• Aluminum shell over iron yoke
• Assembly w/hydraulic bladders
• Advantages
• Can deliver high pre-stress
• Pre-stress increases at cool-down
• Easy disassembly/reassembly
• Issues
• Coil alignment (RD w/SQ series)
• Length scaling (RD w/LR series)

Shell transverse strain vs key interference
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TQC models Collar-based Structure

• Concept
• Support by thick SS collars
• Assembly w/external press
• Advantages
• Proven coil positioning
• Proven length scale-up
• Issues
• Maximum pre-stress delivered
• Pre-stress overshoot at assembly
• Flexibility for RD

• Modified MQXB (LHC IR quad) collar blocks
• Outer-layer poles provided by the collars
• Inner-layer poles are glued into the coil
• Pole spacers for alignment and yoke gap control
• Mid-plane shim to control coil-yoke interference

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Short Sample Parameters
MJR strand Jc 2 kA/mm2 (12 T, 4.2 K) 48 Cu
RRP strand Jc 3 kA/mm2 (12 T, 4.2 K) 50 Cu
Gradient range 215-265 T/m depending on
conductor and operating temperature
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FY05 Progress on TQS01 TQC01

• Finalized cable and coil design 2D 3D
  magnetic analysis completed
• Completed coil parts design procurements are in
  progress
• Completed winding tooling design and procurement
• Completed structure designs, procurements are in
  progress
• Reaction/potting tooling 2 sets needed for
  schedule 1 procured, 1 in order
• Finalized inter-lab coil fabrication plan and
  agreed on procedures
• Fabricated cable for practice coils finalized
  strand map for production cable
• Winding of first practice coil has started, with
  good results

Practice coil winding
Coil curing cavity
Winding tooling
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TQS01 TQC01 Schedule
Q3 2005 Q4 2005 Q1 2006 Q2 2006
Practice coils mech. models
TQS01 Fab/Test
TQC01 Fab/Test
Spare coils
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TQS01-TQC01 Sub-tasks Cost
FNAL
LBNL
BNL
FY04 FY05 FY06
FY04 FY05 FY06
FY05 FY06

• Coil design
• Tooling parts
• Coil winding/curing
• 0.67 M

• Coil design
• Tooling parts
• Coil reaction/potting
• 0.46 M

Shared TQ1a/2a 1.14 M
Test setup 0.01 M

• TQS01 design
• TQS01 structure
• TQS01 assembly
• 0.46 M

TQ1a Specific 0.53 M
TQS01 test 0.06 M

• TQC01 design
• TQC01 structure
• TQC01 test
• 0.48 M

Conductor and cabling cost are not
included! (covered by Materials)
TQ2a Specific 0.48 M
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TQ program following TQS01/TQC01

• 1. Additional tests using the same coil design
• TQS02 reconfigure/optimize based on TQS01
  results
• Increase preload? (e.g. 4.2 K to 1.9 K) Modify
  structure? (as for HD1)
• Replace quadrant with spare? (if localized
  quenches observed)
• TQC02 new coils (w/RRP conductor) in
  collar-based structure
• Feedback from TQC01 can be incorporated at
  assembly
• Coils might be redirected to TQS depending on
  test results
• TQE01 coil-structure exchange
• Disassemble TQC01 coil and test in TQS01
  structure
• Some technical issues to be addressed decision
  after TQS01/TQC01 tests
• 2. Coil iteration and fabrication of TQS03
  TQC03 coils

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TQ schedule following TQS01 and TQC01
Q1-06 Q2-06 Q3-06 Q4-06
Q1-07
TQS02
TQC02
TQE01
Coil iteration practice coil
TQS03 TQC03 Coils
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Coil Design Iteration

• Depending on test results, changes may be
  implemented
• Adjust cable parameters (new conductor etc.)
• Increase keystone angle (better radial
  positioning)
• Redesign or eliminate wedge
• Modify end design (magnetic, mechanical)
• Modify insulation scheme (reliability, cost,
  length scale-up)
• Several factors need to be taken into account
• Performance issues and optimization
• Reproducibility goal
• Length scale-up goal

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Mechanical Support

• The design selection requires addressing a
  complex set of issues
• Pre-load targets to achieve design performance
  w/minimum training
• Maximum allowed stress in the coils
• Trade-offs between stresses in the coil and
  structure
• End support, axial pre-load requirements
• Field/gradient/aperture scale-up
• Maximum pre-stress delivered (collar-based
  structure)
• Length scale-up and alignment (shell-based
  structure)
• A combined effort of the magnet program is
  required
• Design studies (analysis and comparisons of
  different approaches)
• Supporting RD (simplified tests using SQ and
  LR)
• Model magnet RD (full scale testing and
  validation)

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FY08-09 Long Quads (LQ)

• RD issues
• long cable fabrication and insulation
• stress control during coil reaction, cable
  treatment, pole design
• coil impregnation procedure, handling of reacted
  coils
• support structures, assembly issues
• reliability of design and fabrication

Plan scale-up the TQ design to 4 meter length
(LQ)

• FY06 fundamental scale-up issues addressed by
  Supporting RD
• general infrastructure and tooling
• long racetrack coil fabrication and test
• scale-up and alignment issues for shell-based
  structure

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FY08-09 High-gradient Quads (HQ)
3-layer G260-290 T/m
4-layer G280-310 T/m
FY06 conceptual design studies (DS),
conductor/cable RD (MAT)
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FY06 Tasks and Budget
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Summary

• The RD plan being developed is consistent with
  LARP guidance
• All three labs provide contributions
• TQ models will test coil fabrication and
  mechanical issues
• Moving forward with first two quads TQS01 and
  TQC01
• Converged on the same coil design for both
  models
• Converged on fabrication procedures and plan
• Winding of practice coil has started

Rate of progress and successful completion of
TQS01 and TQC01 are essential benchmarks towards
meeting the FY09 milestone