WHITE PAPER

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WHITE PAPER ON THE INDUSTRIAL PRODUCTION OF
SEAMLESS 1.3 GHz SUPERCONDUCTING RADIO FREQUENCY
CAVITIES FOR THE ILC E.W. Collings and M.D.
Sumption Center for Superconducting and Magnetic
Materials (CSMM) Dept. of Materials Science and
Engineering The Ohio State University Columbus,
OH 43210 U.S.A.
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Plan Outline
CSMM (Ohio State University) has chosen
manufacturers and institutions (i) that will
convert the bulk Nb into seamless Nb pipe and
seamless bimetallic Nb/Cu pipe, and will also
supply some matching unalloyed Cu pipe for
mechanical-test purposes (Nu-Tech Precision
Metals) (ii) that will characterize the starting
pipes using electron optics and bulge testing
(Ohio State University) (iii) that will build
machines capable of hydroforming 9-cell cavities
in three stages necking, intermediate forming
and final forming (Interlaken Technology) (iv)
that will house, maintain, and operate the
machines and produce hydroformed cavities on
request (Eden Cryogenics). OSUs CSMM is also
offering to provide International Technical
Assessment. This will consist of consulting with
existing experts notably at KEK and DESY to
investigate the scaling of present hydroforming
equipment from 2-4 cells to the final 9-cell
cluster. CSMM is also offering to provide
Technical Oversight throughout the duration of
the program coordinating vender activities,
consulting with KEK, DESY, and domestic
laboratories, and reporting to Fermilab.
3
Cavity Requirements for the
ILC Approximately 35 km in length, the
International Linear Collider (ILC) will require
about 16,000 1-m long nine-cell 1.3 GHz SRF
cavities. Cooled to 1.8 K by superfluid He
these superconducting Nb cavities will be mounted
within some 2000 cryomodules and energized to an
expected field gradient of 35 MV/m by 800
klystron oscillators. The internal surfaces of
the cavities, polished to a mirror-like finish,
must be free of defects and blemishes. To
achieve this condition the cavities experience
combinations of electropolishing (EP), buffered
chemical polishing (BCP), and high pressure water
rinsing (HPR), and are assembled as cryomodules
under clean-room conditions.
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Companies Contacted
Nb Tubing Supply NuTech Precision Metals 460
McCartney Street, PO Box 7 Arnprior, Ontario,
Canada [phone] Eagle Alloys
Corporation 178 West Park Court Talbott, TN
37877 [phone] Explosion Bonding Atlas
technologies 305 Glen Cove Road Port Townsend,
WA 98368 [phone] Metal Spinning Spinmex,
Inc 10628 Dolores Ave South Gate, CA
90280 [phone] Metalspun Products Co.,
Inc 410 Drexel Ave., PO Box 90 Oak Creek, WI
53154 [phone] Glenn Metalcraft Inc
1502 South 14th Street, PO Box 446 Princeton,
MN 55371 [phone] Helander Metal Spinning
Company 931 North Ridge Avenue Lombard, IL
60648 [phone]
Hydroforming Jet Manufacturing Inc 13445
Estelle Street Corona, CA 92879 (951)
736-9316 Metalspun Products Co., Inc 410 Drexel
Ave., PO Box 90 Oak Creek, WI 53154 (414)
762-9080 Interlaken Hydroforming 8175 Century
Boulevard Chaska, MN 55318 (952)
856-4210 HydroDynamic Technologies, Inc 30
Silverdome Industrial Park Pontiac, MI
48342 [phone] Schuler Hydroforming
Inc 7145 Commerce Blvd Canton, MI 48187 (734)
207-7200 Flexicraft Industries 2315 W. Hubbard
Street Chicago, IL 60612-1403 [phone] H
H Tube 108 Garfield Street, PO Box
455 Vanderbilt, MI 49795 [phone]
5
Starting Tube Niobium tubing is not a stock
item and must be fabricated to order. Tube able
to be provided by Company-A was not suitable
it would have been machined out of a sold block
of powder-compacted Nb. Company-B would take
existing Nb and Cu tubing and form the bimetallic
Nb/Cu tube by explosive bonding this is not the
preferred method of bonding and it still leaves
open the question of starting tube. Company-C,
Nu-Tech Precision Metals Inc, provided the most
satisfactory solution. It could not only produce
Cu and Nb tubing of the correct size, but had the
ability to form a bimetallic Nb/Cu tube by
extrusion bonding. Bonding by extrusion is a
well-established technique used routinely, for
example, in the manufacture of low temperature
superconducting composites.
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FORMATION of SOLID Nb AND BIMETALLIC Nb/Cu TUBING
Nu-Tech Precision Metals Inc, 460 McCartney
Street, Arnprior, ON, Canada
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• Solid Nb Pipe
• Purchase 3001 RRR Nb billet from Wah Chang.
• Machine OD and package in copper for piercing.
• Heat to 1800F.
• Pierce billet.
• Machine billet for forward extrusion.
• Pickle to clean.
• Package in copper for extrusion.
• Heat billet to 1800F and extrude.
• Crop each end and pickle to remove Cu cladding.
• Straighten.
• Hone ID to finished size.
• Wall machine OD from ID to ensure wall
  thickness variation is minimal.
• Finish straighten.
• Polish OD ID.
• Inspect final sizes.
• Crate and ship

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• Bimetallic Nb/Cu Pipe
• Purchase 3001 RRR Nb billet from Wah Chang.
• Machine OD and package in copper for piercing.
• Heat to 1800F.
• Pierce Nb billet.
• Machine Nb portion of billet for forward
  extrusion.
• Purchase C10100 or C15000 copper billet.
• Machine OD for piercing.
• Heat to 1500F.
• Pierce cylinder.
• Machine copper cylinder portion of billet.
• Pickle Nb and copper cylinders to clean.
• Assemble Nb and copper cylinder and package in
  copper for extrusion.
• Heat billet to 1500F and extrude.
• Crop each end and pickle ID only to remove Cu
  cladding
• Straighten.
• Hone ID to finished size
• Wall machine OD from ID to ensure wall
  thickness variation is minimal.

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Hydrostatic extrusion press at Nu-Tech
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Bimetallic Nb/Cu pipe fabricated by Nu-Tech
Precision Metals Inc -- as supplied to DESY
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Cavity Formation by Hydroforming A company well
known to the SRF community uses hydroforming to
manufacture SRF half-cells. But as with their
deep-drawn or spun counterparts the next
fabrication step is EB welding. Information on
seamless multicell cavity requirements was
exchanged with five possible providers of
hydroforming services -- Companies I,
J,K,L, and M. Of them only two (L and
M) expressed interest in the SRF program. The
forming die envisioned by Company-L although very
large was seemingly dedicated to the formation of
just a single cell the setup being not directly
adaptable to multicell production. Company-M,
Interlaken Technology Corporation, communicated
to us a clear understanding of multicell cavity
fabrication issues and seems to have had some
prior experience related to small cavity
formation. Interlaken has expressed a strong
interest in participating in the proposed
seamless-cavity production program.
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Interlaken Technologies (ILT) envisions an
arrangement similar to a convolute manufacturing
process where the necked blank and tools are
placed in a cylinder and feed forces and
pressures are applied from the ends. When the
process and tooling concepts are validated in the
simulation ILT would proceed with the design and
fabrication of the machines and tooling. Once
assembled and calibrated the machines would be
tested and any required modifications made.The in
house tests would also validate the process
parameters. Upon completion the equipment
would be installed at Eden Cryogenics.
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MANUFACTURE OF HYDROFORMING TOOLING
Interlaken Hydroforming, 8175 Century Boulevard,
Chaska, MN 55318
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Simulation of hydroforming a single cavity
Installed at Interlaken, a high speed
hydroforming system for producing 40 copper
fittings per minute.
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MAINTENANCE OF TOOLING, MANUFACTURE OF CAVITIES
AND CRYOMODULES Eden Cryogenics, LLC
Eden is interested not only in hydroforming the
nine-cell cavities but also the enclosing
cryogenic vessels. As also stated in their
letter of participation Edens experience in
the engineering, design and fabrication of vacuum
jacketed pressure vessels and cryogenic equipment
is in-line with the requirements for the ILC.
Eden has the capability in engineering and
fabrication to produce the cryomodules for the
ILC project and has a high interest in
manufacturing these units.
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MAINTENANCE OF TOOLING, MANUFACTURE OF CAVITIES
AND CRYOMODULES
Eden Cryogenics, LLC, 8445 Rausch Drive, Plain
City OH 43064
17
Manufacture of cryogenic components at Eden
Cryogenics
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Companies Contacted
Nb Tubing Supply NuTech Precision Metals 460
McCartney Street, PO Box 7 Arnprior, Ontario,
Canada [phone] Eagle Alloys
Corporation 178 West Park Court Talbott, TN
37877 [phone] Explosion Bonding Atlas
technologies 305 Glen Cove Road Port Townsend,
WA 98368 [phone] Metal Spinning Spinmex,
Inc 10628 Dolores Ave South Gate, CA
90280 [phone] Metalspun Products Co.,
Inc 410 Drexel Ave., PO Box 90 Oak Creek, WI
53154 [phone] Glenn Metalcraft Inc
1502 South 14th Street, PO Box 446 Princeton,
MN 55371 [phone] Helander Metal Spinning
Company 931 North Ridge Avenue Lombard, IL
60648 [phone]
Hydroforming Jet Manufacturing Inc 13445
Estelle Street Corona, CA 92879 (951)
736-9316 Metalspun Products Co., Inc 410 Drexel
Ave., PO Box 90 Oak Creek, WI 53154 (414)
762-9080 Interlaken Hydroforming 8175 Century
Boulevard Chaska, MN 55318 (952)
856-4210 HydroDynamic Technologies, Inc 30
Silverdome Industrial Park Pontiac, MI
48342 [phone] Schuler Hydroforming
Inc 7145 Commerce Blvd Canton, MI 48187 (734)
207-7200 Flexicraft Industries 2315 W. Hubbard
Street Chicago, IL 60612-1403 [phone] H
H Tube 108 Garfield Street, PO Box
455 Vanderbilt, MI 49795 [phone]
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Summary
CSMM has chosen manufacturers and institutions
(i) that will convert the bulk Nb into seamless
Nb pipe and seamless bimetallic Nb/Cu pipe, and
will also supply some matching unalloyed Cu pipe
for mechanical-test purposes (Nu-Tech Precision
Metals) (ii) that will characterize the starting
pipes using electron optics and bulge testing
(Ohio State University) (iii) that will build
machines capable of hydroforming 9-cell cavities
in three stages necking, intermediate forming
and final forming (Interlaken Technology) (iv)
that will house, maintain, and operate the
machines and produce hydroformed cavities on
request (Eden Cryogenics). OSUs CSMM is also
offering to provide International Technical
Assessment. This will consist of consulting with
existing experts notably at KEK and DESY to
investigate the scaling of present hydroforming
equipment from 2-4 cells to the final 9-cell
cluster. CSMM is also offering to provide
Technical Oversight throughout the duration of
the program coordinating vender activities,
consulting with KEK, DESY, and domestic
laboratories, and reporting to Fermilab.
20
The End --thank you