May 9, 2012 D. R. Dietderich, LARP CM-18
Cable Fabrication Plans and Experience
D.R. DietderichLawrence Berkeley National Laboratory
bnl - fnal- lbnl - slacUS LHC Accelerator Research Program
May 9, 2012 D. R. Dietderich, LARP CM-18
Outline of the Presentation
• Cable inventory for HQ/LHQ and plans
• Cable R&D – 140mm to 150mm bore– Cable fabrication of 217 stack
• R&D to reduce HQ cable dimensions– Wire diameters 0.778 mm and 0.80 mm
• Cored cable R&D
May 9, 2012 D. R. Dietderich, LARP CM-18
HQ/LHQ Cable Parameters & Processing
• Nominal Parameters– Annealed wire 185-190C for 4 hours– Wire diameter: 0.778 mm – Thickness: 1.375 mm – Width: 14.8 mm – Keystone Angle – 0.75 deg.
• Stainless steel core, biased towards thick edge– Tape composition - 316L stainless steel– 8 mm wide– 0.025 mm thick
May 9, 2012 D. R. Dietderich, LARP CM-18
HQ/LHQ Cable Status• Cable available for coil winding
– “Z” will denote a cable with a core. – 1020Z-D
• 1UL insulated– 1021Z – A1, A2, B (4 UL)
• 1 UL insulated braided on by NEW• Insulation layer thickness 0.104 mm
– Nearly the same thickness as prototype run with 0.103 mm. • Used in HQ coil 17• 3 UL insulated with sleeve from Rev. Comp.
– 1021Z-C – R&D 1UL NOT insulated, PL ~85 mm • 1024Z – 5 UL fabricated,
• 1 UL 1 insulated • 4 UL-HQ (400m) not insulated (Save for HQ for LHQ)• Ti doped • Used HQ coil 18
• 1025Z – 1 UL (300m) LHQ practice cable• Ready to insulate at NEW
May 9, 2012 D. R. Dietderich, LARP CM-18
Next LHQ/HQ Cable Run• May to August
– LHQ cable, fabricate 2 UL (May)• Standard HQ/LHQ cable with core
– HQ cable with RRP 217 stack, 1+ UL (June)• Standard HQ/LHQ cable with core
– MQXF Cable for140-150mm bore (July-August)
• R&D run to define cable parameters• 40 strands• Wire diameter ~0.85 mm
May 9, 2012 D. R. Dietderich, LARP CM-18
Cable for 140-150 mm Bore
May 9, 2012 D. R. Dietderich, LARP CM-18
Possible Cable Parameters for 140 mm
• If wire diameter is 0.85 mm the cable:
• Width: ~18.25 mm
• Thickness: ~1.50 mm
• Keystone angle: ~0.65 deg.
May 9, 2012 D. R. Dietderich, LARP CM-18
Cored Cable 1012 Used in HQ Coil 12
• HQ cable 1012 (old cable parameters)– 35 strands with diameter of 0.80 mm– 1.44 mm mid-thickness,
• Did not increase mid-thickness with core addition
– 15.1 mm wide– 0.75 deg. Keystone angle– 8 mm wide, 0.025 mm thick stainless steel core
• Biased to thick edge of cable
– Core biased toward thick edge of the cable
• No fabrication issue with the addition of a SS core• Addition of the core did not degrade the Ic
– Measurements show a reduction of ~3% which is typical for this cable without a core
Mandrel with slot for adding a core
May 9, 2012 D. R. Dietderich, LARP CM-18
Objective of Cable R&D• To use existing HQ tooling cable dimensions
needed to be reduced to:– Provide more space azimuthally (i.e. thinner cable)– Provide more radial space (i.e. narrower cable)
• Cable R&D targets dimensions: – Reduce HQ cable thickness by 65-100 microns
• To 1.375 mm - 1.340mm
– Width target is < 15mm (14.7mm -15mm) • Accommodates dimensional changes of cable during
reaction• Thicker insulation or more insulation between layers and
tooling
– Keystone angle un-changed at 0.75 deg.
May 9, 2012 D. R. Dietderich, LARP CM-18
HQ Cable Parameters of R&D Cables
Width vs. Thickness for cables 1014 and 1015
14.70
14.75
14.80
14.85
14.90
14.95
15.00
1.32 1.33 1.34 1.35 1.36 1.37 1.38 1.39 1.40 1.41 1.42
Thickness (mm)
Wid
th (
mm
)
1014
1015
1014- P2 1014- P1
1014- R51014- S
TQ LQ
New HQ cable
HQ Box
Zone with Too much damage
May 9, 2012 D. R. Dietderich, LARP CM-18
Critical Current Cable 1014 with 0.80 mm
Un-deformed Round Wire
ExtractedStrands
May 9, 2012 D. R. Dietderich, LARP CM-18
RRR 1014 – 0.80 mm wire
RRR of 1014
0
20
40
60
80
100
120
140
160
180
1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65
Cable mid-Thickness
RR
R
LBL 1014 RRR
BNL 1014 RRR Wide Rolls
BNL 1014 RRR Narrow Rolls
Un-deformed Round Wire
May 9, 2012 D. R. Dietderich, LARP CM-18
Critical Current Cable 1015 – 0.778 mm wire
Un-deformed Round Wire
Extracted strands
1st Production cable 1017
May 9, 2012 D. R. Dietderich, LARP CM-18
Cable 1015 Sections I & L
• No significant sub-element damage is observed in the wire cross-sectional images
1015-L
1015-I
May 9, 2012 D. R. Dietderich, LARP CM-18
Summary
• HQ and LHQ cabling process established• Target cable parameters for MQXF presented• The critical current variation can be due to:
– Sample handling while preparing for Jc testing?
– Or localized damage in some strands during cabling? – Suggests that a cable testing facility is needed for
accurate cable critical current measurements.
• A stainless steel core can be added to the standard HQ cable without significant loss of critical current
May 9, 2012 D. R. Dietderich, LARP CM-18
Extra slides
May 9, 2012 D. R. Dietderich, LARP CM-18
1 Pass Cable with Stainless Steel Core
Frequency, f, Hz
0.00 0.02 0.04 0.06 0.08 0.10
To
tal
per
-cy
cle
loss
, Qt,cal,
104 J
/m3
0
5
10
15
20
25
Cable 1 Cable 2 Cable 1A
FO
EO
May 9, 2012 D. R. Dietderich, LARP CM-18
LARP Cable Fabrication • 2 pass process was developed to reduce dimensional changes
of a cable during coil processing and reaction– A cable is fabricated oversize in thickness, annealed (200C for 2-4 hrs),
and re-rolling to final thickness.• Very important -- Cable is permitted to get wider during the second pass • The anneal reduces the residual stress in the cable and the cable shortens
by 0.20 – 0.25%.
• 1 pass process has been developed for adding stainless steel (SS) cores to cables– Strand is annealed (190C for 4 hrs) prior to cabling – Cable is made to final dimensions
• Due to the mechanical differences between the strand and the SS core a 2 pass process is not possible.
• However, other core materials such as S-glass tape or MgO paper tapre with a SS core
May 9, 2012 D. R. Dietderich, LARP CM-18
Cable R&D to Reduce Cable Size
• The next slide shows the thickness and width of several cable samples – Cable 1014
• 34 strands with a diameter of 0.80 mm– Cable 1015
• 35 strands with a diameter of 0.778 mm
• “Blue Box” denotes the target parameters needed to accommodate the cable dimensional changes in the present tooling.– Dash line are the deduced parameters from R&D on
TQ and LQ coils• “Red Circle” denotes the new HQ parameters
with the 0.778 mm diameter strand
May 9, 2012 D. R. Dietderich, LARP CM-18
R&D to Reduce HQ Cable Dimensions
• New cable parameters: – Mid-thickness 1.375 mm from 1.44 mm– Width 14.80 mm from 15.10 mm– Keystone angle 0.75 deg. Unchanged
• New cable designs will provide more space in tool for cable dimensional changes– Have made the first production cable 1017 with new parameters
• HQ coil 14 has been fabricated and is ready to test in a mirror.
– Have just made a cored cable with the new cable parameters with a strand diameter of 0.778mm.
• Coil winding with the cored cable was OK – However, popped strands were produced going around the pole
• They are pushed back into position as winding continues
– Planning to cut HQ coil 12 into sections for inspection.