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LCLS Cavity BPM Production Status

LCLS Cavity BPM Production Status. M1-Tool Works BPM Production. M1 awarded contract for machining bodies and transitions for 20 sets of parts First Production BPM mechanical measured and Pre-lim cold test look very good. First production unit. Cavity Production Status.

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LCLS Cavity BPM Production Status

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  1. LCLS Cavity BPM Production Status

  2. M1-Tool Works BPM Production • M1 awarded contract for machining bodies and transitions for 20 sets of parts • First Production BPM mechanical measured and Pre-lim cold test look very good

  3. First production unit

  4. Cavity Production Status • M1-Tool Works to deliver 11 units 1/22/08 presently on schedule • Exercised the option for additional 20 units order from M1-Tool 1/08 • Parts are on time and in spec so far

  5. Cold Test Set-Up for Pre-Braze test • New production test fixtures for pre-braze testing • First production unit looks good and parts are at Altair waiting to be brazed

  6. Cavity BPM Cold Test Data

  7. First Production Unit Shipped to • Serial # 010 shipped to Altair for brazing 12/21/07 • Unit pending complete braze due to window problem

  8. Production Risks (Presented at FAC 10/30/07) • New End Cap design • New tuning scheme • Window plating problem • Unexpected integration problem • Unexpected vendor problem

  9. The Window Braze Yield Problem • Problem brazing the window into the transition has caused delivery delay • Convergence and down-select of possible solutions pending • Concentration of effort critical

  10. Understanding the Problem • History • Why were ALL the soldered units vacuum tight? 15 for 15 • Why did the units built for the 3-BPM work so well compared to present results 6 small leaks, 9 good NO CRACKING

  11. BPM Window Braze History • Prototype cold test unit, ITS test unit and 3-BPM test unit S/N 01 soldered Sn-Ag-Cu Vacuum tight • 2 test brazes Georo Vacuum tight • 3-BPM S/N R/0 first Georo braze Vacuum tight

  12. Georo Test Braze before 3-BPM units • First test brazes clean and vacuum tight 5/12/07 • No risk at this time so units for 3-BPM testing would be processed with Georo braze material

  13. First Problem Window • 3-BPM test Ser # 03 Georo Braze Results: • 2 out of 5 leaked and the 2 that leaked had “glossy” Ni plating • 3-BPM test Ser # 02 Georo Braze Results: • 4 out of 5 leaked and the 4 that leaked had “glossy” Ni plating

  14. Corrective Action from 3-BPM Window Failures • Start R&D program to identify problem with bright Ni • CPI suggested using gold plating of first trials • First sample failed 10/07 because of apparent cracks and “spattering” • Possible cause was cool down too rapid

  15. Window Problem Status 01/21/08 • Moly retaining ring and retaining outer block • Lower temperature braze (Orotin) with induction heating re-work • CPI supplies transition with window installed • Kovar frame • Two piece transition • Bolt on window • Coax adapter

  16. Cavity BPM Production Recovery Options without changing the design • Option 1 Lower temperature braze (Orotin) and Induction heating re-work plan • Option 2 Work with CPI for a turn-key solution providing completed transition • Option 3 Braze window into a frame (Kovar) with similar expansion coef and weld into transition

  17. CONs Yield not satisfactory Re-work plan needs work Braze with existing/modified parts • PROs • Lowest risk option • Fastest recovery • Re-work plan possible • Lowest cost impact • No risk to qualified BPM system design

  18. Induction Heating • Working with Ameritherm to re-work window after failed braze • Braze can be re-worked by applying additional paste or powder to joint

  19. Receiver Electronics Production Status • All parts on order • Test fixtures developed • Parts to start arriving 2/08

  20. Production Status • M1-tool Works delivered first unit 11/07 on time and in spec • First unit has been QA tested and cold tested with very good results • First unit is at Altair being Brazed less waveguide transitions • ANL to supply Altair with first set of modified window/transitions • Addition 11 BPMs in process at ANL

  21. Production Milestones • Production of 1 BPMs for LTU 02/08 • Production of 11 BPMs for undulator/LTU 03/08 • Production of 12 BPMs for undulator 04/08 • Production of 12 BPMs for undulator 05/08 • Spares 4 BPMs 06/08 • 40 sets of Electronics 08/08

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