Industrialization

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• Industrialization

H. Carter
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Outline

• Industrialization Draft Plan Strategy
• Industrialization Areas Planning
• Industrialization Progress/Accomplishments
• Industrialization Plan for Next 2-3 Years
• SPAFOA
• Response to the Review Charge Regarding
  Industrialization
• Conclusion

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DRAFT US-ILC Industrialization Plan 17dec07

• Developed in response to a recommendation of the
  FY07 SRF Review
• 34 page document in which an overall plan leading
  to industrialization of SRF technology in support
  of the ILC is described
• Work ceased shortly after the Omnibus Bill struck
• Table of Contents (with responsibilities)
• 0. Introduction and Summary Shekhar and Peter
  G.1. Cavity Fabrication Phil Pfund and Harry
  Carter
• 2. Cavity Processing and Dressing Phil and
  Harry3. Cavity Testing Mark Champion
• 4. Cryomodule Fabrication and Integration
  Phil and Harry5. Cryomodule Testing - Mark6.
  Business Model Joe Collins
• 7. Intellectual Property Rights, DOE
  Regulations, and US
• Laws Gary Leonard
• 8. List of Acronyms (needed) Peter Added
  14dec07

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Industrialization Strategy

• Phased Approach
• Phase I RD
• Development and testing of components
• Define and develop processes
• Create specifications and develop procedures
• Establish QC/QA requirements
• Phase II Industry development and qualification
• Finalize and completely specify what it is we
  want
• Identify potential vendors and work with them to
  transfer technology established during the R D
  phase
• Work closely with vendors to facilitate their
  successful development
• Evaluate vendor-produced components and processes
• Phase III Pre-production
• Down select qualified vendors from all
  participants in Phase II
• Award pre-production quantity contracts to
  qualified vendors
• Apply design-for-manufacture and value
  engineering principles
• Phase IV Production
• Award production quantity contracts to qualified
  vendors

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Industrialization Areas of Interest

• Cavities
• Vendor development
• AES
• Roark/Niowave
• Alternatives to conventional construction
• CM Parts
• Vendor development for major components
• Creating multiple sources
• Processing
• Arriving at the standard process
• Alternatives
• Mechanical polish EP to remove damaged layer
  (50µ)
• Value engineering---where and when to apply
• Obvious first target is the high value items
• Second target is high precision, tight tolerance
  items

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Industrialization Alternate Paths

• SBIRs
• AES
• Stainless Steel Helium Vessel Development
• Phase I completed
• Phase II request submitted
• FNAL has agreed to collaborate by providing
  testing
• CRADAs
• Able Electropolish Inc.
• EP vendor development
• Full immersion EP test conducted
• Single cell EP tool for 3.9GHz cavities is
  operational and tests are underway

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Industrialization Progress/Accomplishments

• 1.3GHz Cavity Fabricators Development
• Single Cell
  Nine Cell
• Ordered Recd Ordered
  Recd
• Accel 6 6 20 12
• AES 6 6 12 6
• Roark 3 3 3 0
• Roark (3.9GHz) 7 6 - -
• Niowave 3 3 3 0

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Industrialization Progress/Accomplishments

• Processing
• Cabot
• Small effort in progress to assess their process
  on flat samples
• ARRA funds will enable us to apply this process
  to single cell and 9-cell cavities
• Able Electropolish, Inc.
• CRADA for development of their ability to process
  cavities
• Exploring alternative method of full immersion EP

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Industrialization Progress/Plans

• Cryomodules and CM components
• Titanium helium vessels
• Hi Tech
• GE Mathis
• Ameriflex
• Magnetic shielding
• Amuneal, et. al.
• Blade Tuners
• Vacuum vessels and cold masses
• CM1 CM2 were supplied by DESY and INFN-Milano
  respectively
• Planned procurements from U.S. vendors starting
  with CM3 and beyond

Evaluated prototypes
Selected Hi Tech
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Industrialization Plan for next 2-3 yrs

• Continue with Phase II industrialization efforts
  in the areas of
• Cavities
• CM components development
• Processing development
• ARRA funds will help with our industrialization
  plans in that they will enable us to procure the
  needed CM components for assembly of CM4 and CM5

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LCFOA SPAFOA

• .. Industrialization requires early and
  meaningful engagement of the industrial community
  in government sponsored science programs too
  often in the past industrial capability has not
  been integrated in the early stages of major
  government science projects which resulted in
  higher manufacturing costs and schedule
  slippages. It also results in a lag in technology
  transfer into the commercial applications. The
  ultimate success of incorporating SCRF technology
  into both government and commercial programs
  requires a continuous laboratory-university-indust
  rial partnership throughout its development.
  Therefore, the SPAFOA was established to
  facilitate the integration of the broad spectrum
  of U.S. and Canadian industry into these
  programs.Kenneth O. Olsen, P.E.PresidentSuper
  conducting Particle Accelerator Forum of the
  Americas

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Excerpts from SPAFOA Mission Statement

• The SPAFOA provides a partnership between its
  industry members and government funded SCRF
  programs during their design, component
  prototyping, manufacturing, siting and
  installation.
• Planned activities and interactions include, but
  are not limited to the following
• Serving as an advocate for early and meaningful
  industry participation in government supported
  SCRF programs,
• Facilitating two-way technology transfer between
  SCRF programs and industry to make the Americas
  more competitive in the global marketplace,
• Conducting and/or contributing to
  industrialization studies to reduce component
  manufacturing costs and schedules, examine
  commercial applications for the technology, and
  evaluate innovative construction practices,
• Supporting the Americas Regional Teams bid to
  host the International Linear Collider

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Response to the Charge Regarding Industrialization

• Are the available resources effectively utilized
  to engage U.S. industries?
• Yes. We are providing appropriate levels of
  support to industry, both in manpower and
  funding, at this stage of the ILC RD program.
• We are engaging many of the members of the SPAFOA
  in this limited industrialization process, though
  we are not limiting ourselves to only the SPAFOA
  as the only source for vendors.

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Conclusions

• Historically, industrialization has been a
  difficult process to implement during the RD
  phase of our program due to
• Limited funds available to support it
• Lack of fully developed items to
  industrialize---often we dont know what we want
• No industry out there to create the object of
  interest
• No assurances that a program will become a
  project--- discourages industrial participation
  due to a perceived lack of commitment on our
  funding institutions (the government) part
• No follow up business for the industrial
  participant
• Nevertheless,

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Conclusions

• We have made progress in our preliminary
  industrialization efforts in the areas of
• Cavity fabrication
• Cavity processing
• Dressed cavity components fabrication
• G3 helium vessel assemblies
• Cryomodule components fabrication
• Planned during T4CM parts procurements
• We will continue these efforts and expand them as
  we approach project status for ILC and synergetic
  programs (e.g. Project X)

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• Supporting Slides

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Industrialization Strategy (from R. Kephart Talk)

• Both ILC and Project X require industrialization
  but the Project scales and timing are quite
  different
• 50 vs 1800 cryomodules
• SRF vendor development requires that labs and
  industry work closely together we are doing just
  that
• FNAL organized a U.S. industrial group for ILC
  (LCFOA)
• This group remains active (LCFOA? SPAFOA)
• Uncertainty about the ILC lowered industrial
  interest
• Renewed interest in Project X
• Timing is important for project
  industrialization. It is expensive to maintain
  unused capability in Industry

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Industrialization (from R. Kephart Talk)

• Our Strategy for Project X
• Focus on cavity fabrication and surface
  processing
• well done by industry, other customers
• Develop vendors for cryomodule parts
• Cavity and cryomodule testing requires large
  capital outlay for RF and cryogenic
  infrastructure. Not well suited for Industry
• Assembly of Cryomodules number of CM is small,
  valued added during assembly is also small
  infrastructure, risk, and required expertise are
  all high. Best done at labs for Px
• but perhaps with industrial labor
• Fabrication of RF Power equipment well suited for
  industry
• Goal Develop capability, specifications, QC
  procedures, etc, well in advance of the Project X
  construction start
• Thus far U.S. SRF Industrialization has been
  limited by funding, ARRA funds will really help!
• More from Carter