HWR for PXIE: Proposed fabrication technology P.N. Ostroumov - - PowerPoint PPT Presentation

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HWR for PXIE: Proposed fabrication technology P.N. Ostroumov - - PowerPoint PPT Presentation

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HWR for PXIE: Proposed fabrication technology P.N. Ostroumov Physics Division October 26, 2011 Project X Collaboration Meeting, October 25-27, 2011 Content Recent activities of our Group Fabrication steps Purchase of Nb sheets and

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SLIDE 1

HWR for PXIE: Proposed fabrication technology

P.N. Ostroumov Physics Division October 26, 2011 Project X Collaboration Meeting, October 25-27, 2011

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SLIDE 2

September 23, 2011

P.N. Ostroumov QWR&HWR Workshop, September 23-24, 2011 2

Content

  • Recent activities of our Group
  • Fabrication steps

– Purchase of Nb sheets and bar stock – Nb forming – Brazed SS-Nb transition – Nb machining, wire EDM – BCP – EBW – SS vessel – Alignment fiducials

  • HWR for PXIE specs
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SLIDE 3

Development and construction of a new 162.5 MHz HWR

  • EM Design - B. Mustapha
  • Mechanical design and engineering analysis – Z. Conway
  • Fabrication steps

– Nb forming – Brazed SS-Nb transition – Nb machining, wire EDM – EBW – Frequency tuning – SS vessel – ASME pressure vessel code

  • Cavity Sub-systems: RF coupler, slow and fast tuners – M. Kelly, G. Zinkann
  • RF surface processing – M. Kelly
  • Cryomodule: assembly, alignment – Z. Conway and M. Kelly
  • Operational experience with SC ion linac – G. Zinkann
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SLIDE 4

Recent Experience of ANL Linac Development Group

  • In the past 26 months

– Prototype 72.75 MHz QWR has been developed, built and tested – 6 production cavities have been built – Just finished construction of super-high gradient 72.75 MHz QW

  • Peak magnetic fields are expected to exceed 120 mT

– New 322 MHz, β=0.285 HWR for the MSU/FRIB has been developed

  • Complete engineering and mechanical design

– New super-high gradient 325 MHz HWR resonator has been developed

  • Being constructed, die forming of Nb parts is in progress
  • Will be completed in the summer of 2012

– Optimized EM design of SC cavities for several other applications

  • 162.5 MHz HWR for FNAL
  • Low-β (0.085) and high-β (0.15) 176 MHz HWRs for SARAF
  • Low-β (0.085) and high-β (0.15) 109 MHz QWRs for SARAF
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SLIDE 5

September 23, 2011

P.N. Ostroumov QWR&HWR Workshop, September 23-24, 2011 5

Overall design philosophy of SC cavities

  • Incorporate into the cavity design the following features and

sub-systems

– RF coupler – Slow tuner – Fast tuner – RF surface processing – Facilitate integration into the cryomodule

  • Cavity alignment
  • Fabrication is being done under close supervision of ANL

experts

– EBW by an ANL engineer – Wire EDM set up by an ANL engineer – Helium vessel work - under ANL engineer guidance

  • RF surface processing, assembly, testing

– ANL experts

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SLIDE 6

Example: 72.75 MHz QWR

  • Exploded view of Nb and SS parts
  • Nb purchase: 1/8” sheets and bar stocks
  • SS helium vessel
  • Nb-SS brazed joints
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SLIDE 7

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HWR: exploded view (preliminary)

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SLIDE 8

September 23, 2011

P.N. Ostroumov QWR&HWR Workshop, September 23-24, 2011 8

Fabrication Steps: QWR Nb parts

30 cm 30 cm 30 cm

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SLIDE 9

September 23, 2011

P.N. Ostroumov QWR&HWR Workshop, September 23-24, 2011 9

Niobium parts for production cavities, formed from flat sheets and machined from bar stocks

Central conductor halves Toroids with gussets Bottom domes and extension tubes Cylinder housing Brazed Nb-SS transitions Tapered sections (coupling ports, beam ports)

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SLIDE 10

Cavity Fabrication by Wire EDM

September 23, 2011

P.N. Ostroumov QWR&HWR Workshop, September 23-24, 2011 10

Center Conductor Cavity Bottom Dome

  • Essentially no possibility for inclusions
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SLIDE 11

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Sinker EDM of the Toroid center conductor mating surface

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SLIDE 12

Wire EDM

  • Recast layer only 5 microns thick

– Oxide of brass and niobium – Completely removed with a 5 minute BCP; not removed easily by EP

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SLIDE 13

BCP etch after Machining, EDM, 24 hours prior EBW

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SLIDE 14

Electron Beam Welding

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AFTER THE PARTS WELD SEAMS ARE EDMed OR MACHINED TO SIZE THEY RECEIVE A 5 MICRON BCP ETCH AND WITHIN 24 HOURS OF ETCH ARE WELDED.

Central Conductors Cylindrical Housing

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SLIDE 15

Electron Beam Welding of multiple parts

September 23, 2011

P.N. Ostroumov QWR&HWR IMP Workshop, September 23-24, 2011 15

Tapered sections

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Welding of each part requires well-designed support fixturing

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SLIDE 17

Electron Beam Welding

September 23, 2011

P.N. Ostroumov QWR&HWR IMP Workshop, September 23-24, 2011 17

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SLIDE 18

Niobium welds completed

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SLIDE 19

Stainless steel jacket is assembled to complete cavity fabrication

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SLIDE 20

September 23, 2011

P.N. Ostroumov QWR&HWR Workshop, September 23-24, 2011 20

Stainless Steel LHe Vessel, TIG welding

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SLIDE 21

September 23, 2011

P.N. Ostroumov QWR&HWR Workshop, September 23-24, 2011 21

Final Step: connect beam ports to the SS helium vessel using Electron Beam Welding

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SLIDE 22

Fiducials for the cavity alignment

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SLIDE 23

Current status of the 162.5 MHz, β=0.11 HWR

  • EM design is nearly complete
  • Detailed procedures for the mechanical design and

engineering analysis have been developed

– is being started as I speak

  • Detailed fabrication procedure exists
  • Beam aperture – 33 mm
  • RF coupler will be capable either to transmit 10 kW RF power

to the beam or withstand full reflection

  • Will be built in compliance with the ASME pressure vessel

code

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SLIDE 24

First “Cold Test” of the new ATLAS Superconducting Quarter Wave Resonator, December 14, 2010