TQC013 Plans R. Bossert

1
TQC01-3 Plans R. Bossert
US LHC Accelerator Research Program
bnl - fnal- lbnl - slac
LARP Collaboration Meeting October 5-6, 2005
2
TQC01-3 objectives

• TQC01-3 are technological quadrupole models based
  on the collar-yoke-skin mechanical structure
• Design goals
• Achieve Gmaxgt210 T/m.
• Fabricate, test and evaluate 2-layer shell-type
  coil design without internal interlayer splices
• Fabricate, test and evaluate mechanical
  structures based on collar-yoke-skin support
• Develop and evaluate coil fabrication and magnet
  assembly technologies
• Performance study
• magnet quench performance training, re-training,
  SSL
• field quality geometrical harmonics, coil
  magnetization, iron saturation, alignment, field
  quality correction
• quench protection conductor parameters, quench
  heaters
• operating margin thermal model with mid-plane
  heaters
• Compare TQC and TQS designs, technology and
  performance parameters

3
TQ coil

• Coil
• 2-layer shell-type
• Inner-layer wedges
• Inner-layer pole glued into the coil
• Cable
• Strand Nb3Sn, 0.7 mm
• Number of strands 27
• Keystone angle 1 deg
• Width 10.05 mm
• Thickness 1.26 mm
• Insulation 0.125 mm S2-glass sleeve
• Identical to TQS coils.

4
TQC design approach

• TQC design is based on the MQXB mechanical
  structure (collar, yoke, skin, end plate, etc.).
• Two stages
• 2-layer coil with thick collar
• 3-layer coil with thin collar
• TQC uses available coil winding and curing
  tooling (winding tables, mandrels, presses,
  etc.).
• Mechanical structure, tooling and infrastructure
  exist for 1-2 m long and up to 6 m long magnets.

MQXB cross-section.
5
TQC mechanical structure

• Modified MQXB collar blocks with outer-layer
  poles for coil alignment. Inner-layer poles are
  glued into the coil.
• Radial yoke cut per lamination to provide
  symmetrical load.
• Control spacers for collared coil alignment and
  yoke motion control.
• Four shims in the midplanes to control coil-yoke
  interference.
• 12 mm thick stainless steel skin.
• Mechanical structure and coil pre-stress will be
  studied and optimized using short (30 cm)
  mechanical model.

TQ2a cross-section
6
TQC parameters
7
TQC01 Objectives

• Design, fabricate and test a 1m long, 2 layer,
  90mm Nb3Sn quadrupole model using mechanical
  support structure based on 25mm thick SS collars.
  Compare magnet performance with the design
  parameters.
• Provide input for a consistent comparison
  between the properties of a collar-based
  structure and an aluminum shell-based structure
  (TQS model).
• Use the same coil design for both TQS and TQC
  models.

8
TQC01 Schedule and Status
FY05 Design of cable, coil, and tooling
FNALLBNL 01/15/2005 Complete Fabricate and
insulate practice cable LBNL 04/15/2005
Complete Procure coil fabrication tooling/parts
FNAL 05/01/2005 Complete Procure mech
model parts FNAL 07/15/2005
Complete Wind Cure 2 practice coils
FNALLBNL 08/01/2005 Complete React
impregnate 2 practice coils FNAL 09/15/2005
Complete FY06 Assemble and test mechanical
model FNAL 11/10/2005 Wind/cure coils
FNAL 12/20/2005 React/impregnate
coils FNAL 02/10/2006 Assemble
magnet FNAL 03/17/2006 Test magnet
BNL 05/05/2006
9
TQC01 Budget
(in thousands of dollars)
Applied 50 of shared TQS01/C01 effort. Strand
purchase to return to FNAL not included. Cabling
not included.
10
TQC02 Objectives

• Design, fabricate and test a 2nd 1-m long,
  2-layer, 90-mm Nb3Sn quadrupole model using
  mechanical support structure based on 25-mm thick
  SS collar. Compare magnet performance with the
  design parameters and the performance of TQC01.
  Increase the statistical database for TQ short
  models.
• Provide input for a consistent comparison
  between the properties of a collar-based
  structure and an Aluminum shell-based structure
  (TQS models).
• Refine design features based on construction
  experience and/or testing of TQC01.
• Incorporate RRP strand in TQ coils and
  structure.

11
TQC02 Schedule
FY06 Conductor available FNALLBNL 11/01/20
05 Fabricate and insulate cable LBNL
01/31/2006 Coil winding complete FNAL 05/01/
2006 Coil impregnation complete FNAL
05/15/2006 Assembly complete FNAL
06/20/2006 Testing and analysis complete
FNAL 08/20/2006
12
TQC02 Budget
(in thousands of dollars)
Cabling not included.
13
TQC03 Objectives

• Design, fabricate and test a 3rd 1-m long,
  2-layer, 90-mm Nb3Sn quadrupole model using
  mechanical support structure based on 25-mm thick
  SS collar. Compare magnet performance with the
  design parameters and the performance of TQC01
  and TQC02. Increase the statistical database
  for TQ short models.
• Provide input for a consistent comparison
  between the properties of a collar-based
  structure and an Aluminum shell-based structure
  (TQS models).
• Refine design features based on construction
  experience and/or testing of TQC01/2. Possibly
  redesign coil cross-section or cable
  configuration.
• Incorporate new RRP strand in TQ coils and
  structure.

14
TQC03 Schedule
FY06 TQC01 and TQS01 analysis complete
FNALLBNL 06/01/2006 Design optimization
FNALLBNL 07/15/2006 Cable fabricated and
insulated LBNL 08/04/2006 Practice coils
wind/cure LBNL 09/15/2006 FY07 Practice
coils react/pot FNAL 10/15/2006 Wind/cure
coils LBNL 01/20/2007 React/impregnate
coils FNAL 02/20/2007 Assemble
magnet FNAL 04/01/2007 Testing and analysis
complete BNL 06/01/2007
15
TQC03 Budget
(in thousands of dollars)
Applied 50 of shared TQS03/C03 effort. Cabling
not included.
16
TQ Current Status

• The TQ coil manufacturing has been very
  successful to date. No major delays or problems
  have occurred. LBL and FNAL have successfully
  collaborated on their completion.

• 4 practice coils have been manufactured.

17
TQ Current Status

• Some minor issues were resolved during the
  practice coil manufacturing process

• Gaps between turns and end parts appeared on
  practice coil 1 due to the necessity of grinding
  parts to place them onto the uncompressed coil
  during winding, a common practice when making
  Nb3Sn coils. This problem has been solved by
  cutting slots into certain end parts to make them
  more flexible.

• Experiments with longitudinal gaps needed for
  differential expansion of pole parts vs. coils
  were completed. Gaps have been established at
  2.5mm.
• Ramp area between inner and outer coils deformed
  during curing on early practice coils. New
  tooling, incorporated in practice coil 4,
  alleviated stresses in this area and eliminated
  the deformations.

• Some instances of de-cabling during winding have
  been controlled with winding techniques,
  primarily reducing winding tension at critical
  moments, adding a 360 degree twist between the
  cable tensioning device and the coil during
  winding, and changing the system which measures
  tension, allowing the cable to take a straight
  path directly from the tensioner to the coil,
  rather than passing through a series of rollers.

18
Current Status

• The first set of practice coils were reacted and
  impregnated at Fermilab. Impregnation looks good,
  techniques are documented.

• The remaining two are currently being reacted,
  and will be impregnated, at LBNL.

19
Current Status

• Work on the TQC mechanical model has begun, with
  warm and cold test using an aluminum tube to
  replicate the coils. The model will now be built
  with the first two impregnated practice coils,
  cut in half to allow 4 pieces of straight section
  to be installed. When testing is done at FNAL,
  the coils will be sent to LBNL to be used in a
  TQS mechanical model with the second two practice
  coils.

20
Current Status

• Coils for TQS01 are currently being fabricated.
  The first two coils are complete, with the third
  and fourth scheduled to closely follow. Coil
  winding is on schedule.

• 7 UL of cable for TQS01/TQC01 are insulated and
  on hand at FNAL. The remaining 3 UL have been
  fabricated by LBNL. One UL (for TQS01) will be
  insulated and shipped by next week. The
  remaining two will be insulated when the material
  arrives.