Long Quadrupole (LQ) Coil Fabrication Status & Plans Fred Nobrega

BNL - FNAL - LBNL - SLAC

Long Quadrupole (LQ) Coil Fabrication Status & Plans

Fred Nobrega

12th LARP Collaboration Meeting April 8-10, 2009

• Fabrication Status Overview

• Coil Status»Winding and Curing

»Reaction

»Impregnation

• FY10 Proposals

LQ Status & Plan for FY09 Fred Nobrega 212th LARP Collab. Meeting – Napa, Apr. 8-10, 2009

LQ Practice Coil Fabrication Overview

• LQ01» copper cable» Al- bronze pole pieces

• LQ02» Nb3Sn unusable sharp corners» pole design change to Ti» reaction tooling bow

• LQ03» short unit length of cable

now practice coil» high cable tension after

reaction» introduced mica

reduce friction during HT» introduced stiffener plate

reduce bow (HT)

• LQ04» shortened pole pieces after

coil curing as a result of LQ03

» shipped to BNL for practice reaction and impregnation

• LQ05» impregnation problem practice coil » used 2nd impregnation

technique to find solution for LQ06 (already wound and cured)

» used for quench heater test in LN2

» shipped to LBL for practice shell structure assembly

All coils wound and cured at FNAL


LQ Production Coil Fabrication Overview

• LQ06 – 1st production coil» internal production readiness

review» impregnation problem, dry S2» used 2nd impregnation

technique from LQ05 to repair coil

» shipped to LBL for the LQS01 magnet

• LQ07 – 2nd production coil» shipped to BNL for reaction

and impregnation

• LQ08 – 3rd production coil» reacted at Fermi» being prep’ed for

impregnation

• LQ09 – 4th production coil» shipped to BNL for reaction

and impregnation

• LQ10 – 1st production coil for second magnet series» waiting for reaction tooling

from LQ08 for HT» this coil is also the spare coil

for LQS01

• LQ11 – 2nd production coil for second magnet series» cable paid out onto 2 spools

waiting for winding mandrel used by LQ10

All coils wound and cured at FNAL


Coil winding & curing LQ01- LQ10

• Controlled process» modified with input from reacted coils

• Well documented» drawings» travelers» discrepancy reports

• Coil studies» LQ03 high cable tension after HT CTE of Ti pole WRT

tooling• result reduce/eliminate cable tension after curing• Added mica to reduce friction

– LQ04 after curing pole shortened– LQ05 and subsequent coils anchor system, releases

winding tension after curing


Coil winding gaps LQ03- LQ10

* Began using anchor system to introduce gaps during winding. Release anchor system results into near zero winding tension.

3 no

4 no

5 yes*

6 yes*

7 yes*

8 yes*

9 yes*

10 yes**

11-13 yes**

Coil Winding Gap # gap (mil) post HT (mil)

no

no

no

no

no

no* * Revised anchor tooling (stiffer).


Coil winding & curing LQ01- LQ10

• Coil studies (continued)» LQ04 midplane Fuji pressure film of cured coil in

reaction tooling• results indicate higher layer 2 coil stress than layer 1

• possible cause double cure of inner layer

– being studied by R. Bossert

» LQ05 used to for quench heater test with LN2 • successfully passed


Coil Heat TreatmentLQ-05, 06, 08, 10

LQ08 Thermocouple Location on Reaction Tooling

Witness samples

argon

flow thru

Lead End

Return End

T/C 11*

T/C 14

T/C 13*

T/C 12

T/C 10

T/C 2

T/C 1

T/C 15

T/C 4

T/C 9

Furnace Door


Coil Reaction CycleLQ01-03, 05, 06, 08, 10, (BNL LQ04, 07, 09)

• LQ03 » High cable tension after reaction in LQ03

» Added stiffener plate to reaction tooling and mica to coil to eliminate tooling bow and reduce friction respectfully

LQ Heat Treatment CycleStep # Type Start Rate/time

1 Ramp 20C 25C/hour

2 Soak 210C 72 hours

3 Ramp 210C 25C/hour


5 Ramp 400C 50C/hr


7 Ramp 640C -100C/hrDays

Program

Measurement


Coil Reaction LQ01-03, 05, 06, 08, 10, (BNL LQ04, 07, 09)

• Found problem after coil #3 heat treatment• Performed analysis further analysis needed

• Developed solution for LQS01 coils LQ02 coils

Further analysis by core programsCoil Layer Starting Gap Gap Pole parts Load

gap before HT after HT ave. DL/partmil mil mil mil lbs

3 OL 0 0 0 -3.6 03 IL 0 0 0 -17.2 12004 OL 128 18 1.5 1.2 04 IL 270 182 22 05 OL 120 15 0 -3.7 <1005 IL 230 157 0 -6.7 200-3006 OL 179 102 206 IL 225 147 07 OL 179 07 IL 225

Notes 1, 2 4 5 3

1 for coil 4 and 5: material removed from pole parts; for coil 6: gaps during winding2 in coil 6 and 7 the OL gaps depend on the IL gaps3 computed by measuring pole parts: 1-4, 6-10 (no central part)4 time between measurement and HT vary from coil to coil (==> possible error)5 Coil 4 outer layer gap: 1.5 mil at the last gap at the NLE (RE), all other gaps closed

Coils 4 and 5 will be used for practice assembly

Coils 6 to 9 will be used for LQS01


Coil Reaction with MicaLQ03-06, 08, 10 & subsequent, (BNL LQ04, 07, 09)

10 milceramicand bindersheet

titanium outer pole

titanium inner pole

10 mil ceramic and binder sheet

20 mils

10 mils

10 mils

LQ with Mica

During Reaction5 mil micasheet

5 mil micasheet

5 mil mica sheet


• LQ04» L1 center pole length reduced by 0.270” (6.86mm) and L2

center poll shortened by 0.124” (3.15mm) to reduce cable tension.

Note: Tension was reduced by removing material from L2 (part #461135) and then L1 (part # 461133) Center Pole Spacers.

• LQ05 » L1 pole shorten by.073” (1.85mm) & L2 by 0.101” (2.57mm) to

remove winding tension in cable before HT.» Also used anchor system on winding mandrel that effectively

introduced gaps longitudinally between pole pieces during winding. Anchors released after winding closing gaps and reduces nearly all the cable winding tension. Used on LQ06 and subsequent coils without shortening center pole pieces.

• LQ06 - LQ09 successful reaction• LQ10 - LQ13 not reacted,

» LQS02 coils with LQ10 spare for LQS01

Coil Reaction LQ01-03, 05, 06, 08, 10, (BNL LQ04, 07, 09)


Coil ImpregnationLQ05, LQ06, LQ08 (BNL LQ04, 07, 09)

• LQ05» filled in one hour (4 times faster than design) and had epoxy

leak» used for quench heater test in LN2 pool, no visible damage to

coil or heaters» used to successfully develop and demonstrate a 2nd

impregnation of a potted coil (pictures & details in following slides)

» shipped to LBL for practice assembly of LQS01• LQ06

» successfully potted a second time (pictures & details in following slides)

» shipped to LBL for assembly into LQS01• LQ08

» being prepared for impregnation complete and ship to LBL by the end of April for assembly into LQS01


LQ05 1st Impregnation

• rapid epoxy fill flow Problem: low visibility of epoxy in vacuum oven

Fix: add Pyrex clear glass tube at fill end of coil

• O-ring leak during coil cureProblem: O-ring diameter too small

Fix: increase O-ring diameter


LQ06 1st Impregnation

• Same impregnation process as LQ02» changed 7 mil ceramic cloth to 5 mil S2 glass after LQ02

» process has short soak time

» increase soak time in LQ08 (next week), more similar to BNL process


LQ05 & 06 2nd ImpregnationDAY DATE TIME HRS DESCRIPTION

FRIDAY 3/6/2009 7:00 A.M. 0 started vacuum pump down and heating @ 60 C

SATURDAY 3/7/2009 12:00 P.M. 29 continue vacuum pump down

SUNDAY 3/8/2009 12:00 P.M. 53 continue vacuum pump down

MONDAY 3/9/2009 7:59 A.M. 61 total pre epoxy impregnation pump down time8:00 A.M. 0 start mixing, heating and out gassing10:00 A.M 2 start flowing epoxy to magnet 1 CM/sec

12:30 P.M. 4.5 see epoxy in overflow tube1:30 P.M. 5.5 fill 3 feet of overflow hose, time estimated1:30 P.M. 5.5 clamp off epoxy input hose, stop vacuum and start soak time

10:00 P.M. 14 remove from vacuum vessel and remove .010 shim11:30 P.M. 15.5 completed shim removal and retightened bolts12:00 P.M. 16 start 60 C overnight heating in oven

TUESDAY 310/2009 7:00 A.M. 23 start 110 C ramp8:30 A.M. 0 begining of 110 C for 5 hours cycle 1:30 P.M. 5 start 125 C ramp2:30 P.M. 1 beginning of 125 C for 16 hours cure cycle

WEDNESDAY 3/11/2009 6:30 A.M. 16 end of cure cycle oven door auto opens, need to shut off fans

24 hrMaxper

CTD17.5 hr

soak

LQ06 process schedule


LQ05 & LQ06 2nd Impregnation

LQ05

LQ06


LQ05 & LQ06 CMM Measurements of 1st & 2nd Impregnation 1664 mm

from LE

LQ05 1st

LQ05 2nd

LQ06 1st

LQ06 2nd

One square = 100 microns


LQ Coil Ground Insulation


LQ CoilGround Insulation


FY10 Vertical Collaring• Coil assembly is up

righted with the up-ender tooling. The picture to the left is the MQXB in ICB. This scheme requires 2 cranes. (LQ design uses 1)

• Collar keying is done in several passes while coil strain gauges are monitored

• Coil is brought to horizontal using the up right process in reverse


LQ Up Ender Fixture Assy

LQ COIL-COLLAR ASSY MANDREL ME-461301

FNAL internal review completeAction items completeCollaboration review


LQC Vertical Collaring

Collaring is done incrementally in

many passes. Col

lari

ng

Dir

ecti

on

Col

lari

ng

Dir

ecti

on


LQ Coil Assembly Table

LHC MQXB CoilsDuring Assembly


FY10 Proposal: Dipole Collar-based LQ Structure

Main vertical press force

Side Key Pushers

Collaring can be done along the full magnet in a single pass, eliminating degradation risk and reducing construction time.

• Use Dipole Collaring – if TQC with dipole style collars is successful then propose to LARP their use for LQC

• Use Up-Ender – if dipole collaring is unsuccessful» Design complete» Internal review complete» Drawing package ready for release and procurement

Horizontal collaring uses weld press and dipole-symmetric collar laminations.


Dipole Collar

TQ Dipole CollarsCould be used for LQ


FY10 Proposal: LQ Mirror

• Use Mirror Magnet - if LQS is unsuccessful to further evaluate issue

OR

• Commit to LQ mirror now and begin iron part procurement before we have results merge with TQM parts


FY10 Proposal: Bolted Skin

• Use 4m bolted skin for both LQM and LQC

Where C= vertical or horizontal collaring)

3/16 in.

3/32 in.


Conclusions

• Many problems overcome to reach long coil production

• 50% of LQS01 coils complete and shipped to LBL with remaining coils complete within 2-3 weeks

• Possible changes to LQ dipole style collar design depending on TQC02Eb & TQC03E test results

• Changing welded shell design to long bolted shell saves money and time if more than one LQC magnet and/or LQ mirror is built

Documents

Long Quadrupole (LQ) Coil Fabrication Status & Plans Fred Nobrega