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Oct. 12, 2006Undulator Breakout
1 Dean R. Walters
Undulator Vacuum System Vacuum System
Dean R. Walters
Soon-Hong Lee, James Bailey, James Morgan, Dana Capatina, Scott Doran, ANL
Lou Ann Tung, LLNL
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2 Dean R. Walters
Beam Finder Wire
Chamber
Vacuum System
Undulator Vacuum System Vacuum System
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BFW In Situ- Short BreakBFW
Undulator
Undulator
Beam
GirderGirder
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BFW Assembly Mounted on Adjustable Support
Adjustable Mounting Support
Vacuum Pump Connector (2.75” Conflat Flange)
Card Position Monitor (Limit switches)
Air Supply Shut Off Valve
Pneumatic Solenoid Valve
Precision Screw
Electrical Connectors for Wire Signals
Vacuum Chamber Connection Flange
(NW-50 CeFix w/Clamp)
Beam Port
Pneumatic Cylinder
Alignment Fiducials
Frame
Compression Spring Positioner
Potentiometer
Housing
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BFW Prototype Setup
Kinematic Stop Plates
Engaged
Precision Screws
Pneumatic Cylinder
“Keyence” Sensors
Supports Read Out
Air Supply Line 70 psi
Vacuum Line
Bellows
Fixed Frame
Movable Assembly
Vacuum Chamber
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BFW Prototype Results
Vertical Repeatability: +/-7 Microns
Horizontal Repeatability: +/- 14 Microns (Extrapolated to account for lever arm)
Adjustability: +/- 2 Microns
Required Force on Kinematic Stop: 20 lbs.
Slide Rod Clearance: 0.020”
Top Locking Screws: Lock Washers OK
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Assemblies and Cross Sections
Assembly
VacuumChamber
Flange
Locating Pins
Bellows Flange
Shielding Cut-out
BFW Flange Seal
VacuumFlange
Beam Tube Spider
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Beam Finder Wire Final Design Review ReportA final design review of the APS/LCLS Beam Finder Wire (BFW) was held on
September 20, 2006 at Argonne National Laboratory.
Recommendations:
The ANL/SLAC team should proceed with the fabrication of the Beam Finder Wire Assembly and the BFW Support Assembly excluding the Wire Card Assembly. The Wire Card Assembly should have a design review after final material selections are complete.
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X-Adjustor
Z-Adjustor Support Assembly
Production Vacuum Chamber Ass’y
Vacuum Chamber Assembly
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Measurement results of magnetic permeability (r)
1. Anneal conditions • Vacuum pressure at 1.0 x 10-4 Torr• 1,750 º F for 30 minute soaking on 20Cb-3 and 1,950 º F for 30 minute soaking on the other types • Rapid Nitrogen gas quenching
2. 316LN had stable permeability values of less than 1.010, even if cold-works and welding.3. 310S and Nitronic 40 had increased in permeability after welding significantly.4. 20Cb-3 had acceptable permeability values less than 1.020 (most less than 1.010) and good welding
characteristics (less heat-affected zone)5. Nitronic 33 and 20Cb-3 had increased in permeability after annealing.
Material As-received condition
After vacuum annealing
After machining & forming
After TIG welding
After final machining
316LN 1.002a (1.004b) 1.003a (1.003b) 1.003a (1.003b) 1.004a (1.003b) 1.008c (1.003d)
310S 1.057e (1.005f) 1.036e (1.003f) 1.033e (1.003f) 1.042e (1.018f) 1.051c (1.007d)
20Cb-3 1.007e (1.008f) 1.008e (1.015f) 1.008e (1.015 f) 1.010e (1.011f) 1.018c (1.009d)
Nitronic 33 (1.002g) 1.022e (1.006f) 1.030e (1.012 f) 1.030e (1.023f) 1.126c (1.033d)
Nitronic 40 1.004e (1.003h) 1.003e (1.004 h) 1.005e (1.004 h) 1.019e (1.052h) 1.081c (1.048h)
Initial Calibration, 1.27±0.01
1.272 1.276 1.275 1.277 1.276
Note on thickness a: 1.99 mm, b: 6.65 mm, c: 0.5 mm, d: 6.0 mm, e: 1.59 mm, f: 6.35 mm, g: 7.94 mm, h: 4.76 mm
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Measurements of the changes of applied magnetic fields Sample chambers under APS undulator "A"
A 3-inch-long sample vacuum chamber was inserted Into a hybrid permanent magnet undulator with a 3.3 cm period and 8 mm min. gap To Investigate high magnetic field influence to the relative magnetic permeability Peak of applied magnetic field: ~ 1.2 T
-0.02
-0.01
0
0.01
0.02
316LN 20Cb-3 Nit-33 Nit-40 310SC
ha
ng
e o
f A
pp
lied
Ma
gn
eti
c F
ield
(%
)
B/B < 1.5 x10-4 Undulator A
8.0 mm
Sample chamber
Hall probe holder
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Fabrication ProcessesSST Plate, End Cap
(144” x 7.5” x 1”) (144” x .5” x.25”) 20Cb-3
Seam Welding
Final Machining
Cleaning/Baking
Milling/Polishing
SST Sheets (144” x .75” x .120”)
316LN SST
Polishing/Milling
Coating
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Prototype Vacuum ChambersCompound screws (Brass Screws & SST )
Vacuum Chamber
NW 50 Flange -Clamp Type (316L SST)
Top & Bottom Strips (316LN)
Chamber Strong-back (20Cb-3)
End Cap (20Cb-3)
Prototype A
Prototype B
Top & Bottom Strips (20Cb-3)
Chamber Strong-back (316 SST)
End Cap (20Cb-3)
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SUT Machining Results Material: Austenite stainless steel 316Supplier: Walco Tool & EngineeringParallelism of chamber surfaces (0.100 mm): 0.250 mmThickness of chamber (6.00 ~ 6.08 mm) : max. 6.15 mmStraightness of chamber edge (± 0.200 mm) : max. 0.406mm bowedVibratory or thermal stress relief is required, which may restore the original properties of the base metal
E
H
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Prototype B Machining ResultsMaterial: Austenite stainless steel 316Supplier: Dial Machine Inc. (measured Aug. 8, 06)No attempt was made to tweak in, or adjust, the constrained condition to improve the results.Flatness of nose bottom surface in the clamped condition (0.100mm): 0.314mmParallelism of nose bottom surface to strongback bottom in the clamped condition (0.100mm): 0.198 mmParallelism of nose top surface to nose bottom surface in the clamped condition (0.100mm): 0.107 mmStraightness of chamber edge (180.0± 0.20mm) : 179.54~179.70mm (0.160mm bowed) Thickness of chamber every 12” in the clamped condition (5.0±.08mm) : 4.945~5.112mmFlatness of the surface of machining fixture in the strongback clamped condition: 0.04mmFlatness of the bottom surface of strongback in the free state: 1.143mm
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Polishing of Stainless SteelSamples of True #8 stainless steel sheets from Pacific Plus Inc. of Dallas, TX / Hwa Yang Stainless Steel Group in China.
True #8 and super #8 are trademarks of Pacific Plus International, Inc.1.5 mm thick 316 SST sheets (1 ft x ft) and 0.5 mm thick 304 SST sheet (4 ft x 8 ft) were bought to evaluate the impact of manufacturing operation on the surface finish.
Samples were polished at Fine Art Inc. and Polished Metals Limited.Measurements
Used Tencor Alpha-Step to obtain a 2D surface profile.Used MicroXAM RTS surface profiler (White light interferometry)
MicroXAM RTS from www.ade.com
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Sample: #PLM 2 Mode: PM Objective: 50x Size: 0.244 x 0.244 mm2
# 8r(z): -1867 mm; hrms: 27.9 nm
x’rms: 14.4 mrad; z’rms: 3.6 mrad
Sampled Data (1024x1024)Sampled Data (1024x1024)
Lineout (x: #200; z: #300-#400)Lineout (x: #200; z: #300-#400)
Full Spectrum (1024x1024)Full Spectrum (1024x1024)
Sampled Data (500x500)Sampled Data (500x500)
Lineout (x: #200; z: #300-#400)Lineout (x: #200; z: #300-#400)
Full Spectrum (500x500)Full Spectrum (500x500)
Sample: #PLM 2 Size: 0.130 x 0.130 mm2
WLI
AFM r(z): -907 mm; hrms: 13.5 nm
x’rms: 24.4 mrad; z’rms: 8.2 mrad
Evaluation of Roughness Scans - Polished
For wakefield considerations, the beam- (or z-) direction is the most important and all measurement results are within tolerance, i.e., have rms derivatives in z of less than 10 mrad.
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CO2 Laser Weld PrototypingInspection Results for Sample 3
Seal weld
Intermittent weld
Groove
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Laser Welding/Final Machining Prototyping
42” Prototype After Laser Welding and Before Final Machining
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CO2 Laser Weld Prototyping42” Vacuum Chamber Prototype
Fixturing for end
cap welding
Welding end cap
Fixturing for strong back
welding
Welding strong back
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Final Machining PrototypingMachined to red line
both sides
Vacuum Chamber Gap
Six Inch Long Prototypes
Actual Weldment
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Final Machining Prototyping
Machining of 6” Long Prototypes
1” Dia. End Mill
Dial Indicator
T/C Measurement
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Final Machining Prototyping Preliminary Inspection Results for the 42” Prototype
<0.002” Flatness & <0.002” Tolerance on Thickness
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Pictures of test set up operating
Coating in a 35 mm SST Tube
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Test set up operatingCoating inside a 12.7 mm Glass tube Coating inside a 7.9 mm Glass tube
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Measurements of samples
Samples
Measure thickness of 560 nm, 240 nm, & 130 nm
Deposition Rate of 23 nm per minute
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Prototype Development
Strongbk.
May June July Aug. Sept. Oct. Nov. Dec. Jan. Feb.2006 2007
MayApr.
P.O.
End Cap
Side Walls
Weldment
Strongbk.
End Cap
Side Walls
Weldment
Strongbk.
End Cap
Side Walls
Weldment
Strongbk.
End Cap
Side Walls
Weldment
Prototype A
Strongbk.
End Cap
Side Walls
Weldment
Prototype B
Strongbk. Proc. 316 L & Initial Mach.P.O.
End Cap Proc. 20Cb-3 & Initial Mach.
Side Walls Polish Sheet Intl. Mach.
Weldment
Fab. Fix. & Weld Mach/ Coat
20Cb-3 Mach.
Proc. 20Cb-3 & Initial Mach.
Intl. Mach. Polish Sheet
Fab. Fix. & Weld Mach/ Coat
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Prototype DevelopmentMay June July Aug. Sept. Oct. Nov. Dec. Jan. Feb.
2006 2007MayApr.
42” Prototype
Parts Proc. 304 SS & Mach.
Fixtures (Weld) Design & Fab.
Assembly Weld Mach Coat
Laser Weld Development
6” Samples YAG @ ANL
18” Samples CO2 @ Vendors
Final Mach. Development
6” Samples Mach. @ ANL
Fixtures (Mach) Design & Fab.
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Bench Test
Prototype DevelopmentMay June July Aug. Sept. Oct. Nov. Dec. Jan. Feb.
2006 2007MayApr.
Equipment Design
Consultant
Coating Development
Agreement Place PO 1St
Procure Assy
Power Supply Loan Agr Ship Install
Process Dev 42” Prt
Full Size Setup
Part #2
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Chamber Design Review
The LCLS undulator vacuum chamber and system were reviewed by a committee composed of John Grimmer, APS, Nadine Kurita, SLAC, Allan Rowe, FNAL, and John Noonan, ANL, chair on September 27 and 28, 2006
ScheduleThe schedule for fabrication and delivery of vacuum chambers for the undulator vacuum system is tight, especially for the undulator vacuum chamber. This is a complex part with stringent physics requirements, especially the surface finish. Aspects of the chamber are demonstrated, but a full-size prototype will not be complete until December, 2006.
The Undulator Vacuum ChamberThere are no technical barriers to fabrication of the chambers. However, there are tooling and detailed fabrication issues that need to be answered in order for production to proceed. Successful chamber fabrication will be a significant accomplishment. The physics are stringent
Fabrication of the full size prototype chamber is essential and the engineers should have all the APS and LCLS support that they need to complete the fabrication. The full size prototype will determine vacuum integrity, outgassing rates for the chamber, coating surface finish, and dimensional straightness. It is important to perform a test in which the full size chamber is installed in an undulator and its straightness measured. The survey groups need to be involved in the tests and certify that the installation procedure is reasonable.
Magnetic measurements need to be repeated on the 20Cb-3 steel. The 20Cb-3 material has no apparent pedigree in demanding vacuum and magnetic applications. The prototype has not yet been welded leak tight and will clearly be "worse" than 316LN in magnetic performance, although the effect of the difference is debatable.
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Vacuum System CalculationsIn past hand vacuum calculations have been used to estimate the vacuum system performanceRecently a collaboration with LLNL has been established to provide calculations. Below are the results obtained at this point.The next analysis will include:
-Add in the turbo and roughing pumps (with S(p)) in the long breakand an ion pump in all three breaks-Put in the time-dependent outgassing rate for stainless steel (already have fit)-Put in the different rates for copper and aluminum
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Long break layout(Short break is the same but without the valve spool)
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Pressure profile with one ion pump on the long break with one undulator section
z = 1 cmAll surfaces outgas at1.6 x 10-11 T-l/s/cm2
cm
One undulator section Long break
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Conclusions
BFWDesign, testing, and review have been completed.Committee has agreed that it is ready to enter production
ChambersThis has not progressed as expected. The Strongback delay has rippled through the prototype schedule and it impacts the production schedule.The Design Review Committee has agreed that the Strongback can enter production, but testing is needed on the full sized prototypes to continue with the production of the whole weldment. These Prototypes must be done before the end of January so that the production units are not impacted.
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CO2 Laser Weld Prototyping42” Vacuum Chamber Prototype
Results in Constraint Condition
0.002” 0.000” 0.001” 0.001” 0.000” 0.000” 0.000” 0.001”
0.000” 0.001” 0.001” 0.000” 0.000” 0.002” 0.001” -0.001”
Flatness Variation Along Center of Wall Sheet
Across Sheet Flatness <0.001”
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Vertical Adjustment Screws (14)
Vacuum Chamber alignment
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Test Set upCathode GuidesStraightening of CathodesTensioning of CathodesVertical positioning
42” chamber
Full size setupVertical Coating Stand
On Going Work
