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

BNL - FNAL - LBNL - SLAC. Long Quadrupole (LQ) Coil Fabrication Status & Plans Fred Nobrega. 12 th LARP Collaboration Meeting April 8-10, 2009. Fabrication Status Overview Coil Status Winding and Curing Reaction Impregnation FY10 Proposals. LQ01 copper cable Al- bronze pole pieces

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

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  1. BNL - FNAL - LBNL - SLAC Long Quadrupole (LQ) CoilFabrication Status & PlansFred 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

  2. 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 LQ Practice Coil Fabrication Overview All coils wound and cured at FNAL LQ Status & Plan for FY09 Fred Nobrega

  3. 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 LQ Production Coil Fabrication Overview All coils wound and cured at FNAL LQ Status & Plan for FY09 Fred Nobrega

  4. 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 LQ Status & Plan for FY09 Fred Nobrega

  5. Coil winding gaps LQ03- LQ10 Coil Winding Gap # gap (mil) post HT (mil) *Began using anchor system to introduce gaps during winding.  Release anchor system results into near zero winding tension. * * Revised anchor tooling (stiffer). LQ Status & Plan for FY09 Fred Nobrega

  6. 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 LQ Status & Plan for FY09 Fred Nobrega

  7. LQ08 Thermocouple Location on Reaction Tooling Furnace Door Lead End Return End T/C 11* T/C 12 T/C 1 Witness samples argon flow thru T/C 14 T/C 10 T/C 15 T/C 9 T/C 4 T/C 13* T/C 2 Coil Heat TreatmentLQ-05, 06, 08, 10 LQ Status & Plan for FY09 Fred Nobrega

  8. Coil Reaction CycleLQ01-03, 05, 06, 08, 10, (BNL LQ04, 07, 09) LQ Heat Treatment Cycle • 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 Measurement Program Days LQ Status & Plan for FY09 Fred Nobrega

  9. Coil ReactionLQ01-03, 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 programs Coils 4 and 5 will be used for practice assembly Coils 6 to 9 will be used for LQS01 LQ Status & Plan for FY09 Fred Nobrega

  10. Coil Reaction with MicaLQ03-06, 08, 10 & subsequent, (BNL LQ04, 07, 09) LQ Status & Plan for FY09 Fred Nobrega

  11. Coil ReactionLQ01-03, 05, 06, 08, 10, (BNL LQ04, 07, 09) • 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 LQ Status & Plan for FY09 Fred Nobrega

  12. 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 LQ Status & Plan for FY09 Fred Nobrega

  13. 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 cure Problem: O-ring diameter too small Fix: increase O-ring diameter LQ Status & Plan for FY09 Fred Nobrega

  14. 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 LQ Status & Plan for FY09 Fred Nobrega

  15. LQ05 & 06 2nd Impregnation LQ06 process schedule 24 hr Max per CTD 17.5 hr soak LQ Status & Plan for FY09 Fred Nobrega

  16. LQ05 & LQ06 2nd Impregnation LQ06 LQ05 LQ Status & Plan for FY09 Fred Nobrega

  17. LQ05 2nd LQ05 1st LQ06 1st LQ06 2nd LQ05 & LQ06 CMM Measurements of 1st& 2ndImpregnation 1664 mm from LE One square = 100 microns LQ Status & Plan for FY09 Fred Nobrega

  18. LQ Coil Ground Insulation LQ Status & Plan for FY09 Fred Nobrega

  19. LQ CoilGround Insulation LQ Status & Plan for FY09 Fred Nobrega

  20. 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 Status & Plan for FY09 Fred Nobrega

  21. LQ Up Ender Fixture Assy LQ COIL-COLLAR ASSY MANDREL ME-461301 • FNAL internal review complete • Action items complete • Collaboration review LQ Status & Plan for FY09 Fred Nobrega

  22. LQC Vertical Collaring Collaring is done incrementally in many passes. Collaring Direction Collaring Direction LQ Status & Plan for FY09 Fred Nobrega

  23. LQ Coil Assembly Table LHC MQXB Coils During Assembly LQ Status & Plan for FY09 Fred Nobrega

  24. Main vertical press force Side Key Pushers FY10 Proposal: Dipole Collar-based LQ Structure • 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 Collaring can be done along the full magnet in a single pass, eliminating degradation risk and reducing construction time. Horizontal collaring uses weld press and dipole-symmetric collar laminations. LQ Status & Plan for FY09 Fred Nobrega

  25. Dipole Collar TQ Dipole Collars Could be used for LQ LQ Status & Plan for FY09 Fred Nobrega

  26. 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 LQ Status & Plan for FY09 Fred Nobrega

  27. FY10 Proposal: Bolted Skin • Use 4m bolted skin for both LQM and LQC Where C= vertical or horizontal collaring) LQ Status & Plan for FY09 Fred Nobrega

  28. 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 LQ Status & Plan for FY09 Fred Nobrega

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