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Mikko Karppinen

Mikko Karppinen. Nb3Sn Coil Production for 11 T Dipole Model Magnets. Outline. 11 T Project Introduction Some Nb 3 Sn features Cable insulation Coil Fabrication Winding Curing Reaction Splicing Impregnation Instrumentation Handling Quality control

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Mikko Karppinen

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  1. Mikko Karppinen Nb3Sn Coil Production for 11 TDipole Model Magnets

  2. Outline • 11 T Project Introduction • Some Nb3Sn features • Cableinsulation • Coil Fabrication • Winding • Curing • Reaction • Splicing • Impregnation • Instrumentation • Handling • Qualitycontrol • Long toolingprocurement plan

  3. 11 T Dipole Project • Create space for additional (cryo) collimators by replacing 8.33 T MB with 11 T Nb3Sn dipoles compatible with LHC lattice and main systems. • 119 Tm @ 11.85 kA • Phase 1: IR-1,5, and 2 • 3 x 4 MB => 24 x 5.5 m CM + spares • Phase 2: Point-3,7 • 2 x 4 MB => 16 x 5.5 m CM + spares • Joint development program between CERN and FNAL underway since Oct-2010. MB.B8R/L MB.B11R/L 15,66 m (IC to IC plane) 11 T Nb3Sn 3 m Collim 5.5 m Nb3Sn 5.5 m Nb3Sn 5.5 m Nb3Sn 3 m Collim. 5.5 m Nb3Sn

  4. 11 T Dipole Model Program

  5. 11 T Dipole Magnetic Design • 60 mm bore and straight cold mass • Systematic field errors below the 10-4 level and conductor positioning at 50..100 µm level • 6-block design, 56 turns (IL 22, OL 34) • 14.85-mm-wide 40-strand Rutherford cable, no internal splice • Coil ends optimized for low field harmonics and minimum strain in the cable B0(11.85 kA) = 11.25 T (20 % margin on the load-line @1.9K)

  6. Nb3Sn Superconductor • Nb3Sn critical parameters (Jc, Bc2 and Tc) very attractive for accelerator magnets • Requires (long) heat treatment @ 650..680 °C => Only inorganic insulation materials • Brittle, strain sensitive after reaction • Requires vacuum impregnation with resin => less efficient heat extraction by He • Magneto-thermal instabilities => small filaments, small strands, high RRR • Filaments ~50 µm (NbTi 6 µm) • Persistent current effects • Sensitive cabling compaction to avoid Jc degradation (cable stability) • “Wind and react”-process most commonly used for accelerator magnets • Cost ~5 x NbTi

  7. Cable Insulation E-glass wrapping Mica tape S-2 Glass sleeving

  8. Coil Components • 316L End spacers (Selective Laser Sintering) • ODS (Oxide Dispersion Strengthened) Cu-alloy wedges

  9. Winding • Relativelylowwinding tension of 15..30 kg (cablestability) • End regionsrequiregreat care to avoidinsulationdefects • Outer layer wound on curedinner layer and pre-formed inter-layer insulation

  10. Ceramic Binder • Afterwinding of eachlayerceramicbinder CTD-1202 isapplied on the cableinsulation • Coils are curedatat80°C for 1 h and 150°C for 2h in a closedcavitymold. • Azimuthalcoil pressure isapprox. 20 MPa

  11. Reaction • Coilsize preciselydefined by closedcavitymold • Tooling design allowsfor coil expansion of 3%/1% in azimuthal/radial direction • Reactionwith positive argon pressure in the tooling • Modulartooling for easyscale-up

  12. Reaction.. ~10 days

  13. Splicing • Afterreaction the Nb3Sn leads are carefullycleanedavoidinganymechanicalstrain to the brittlecables • The splicesbetween Nb-Ti and Nb3Sn cables are solderedwithin the reactiontooling.

  14. Impregnation • Reactedcoilistransferredfromreactiontoolinto the impregationmold • All voids are filledwithglassfiber and/or ceramicputty, and possible insulationdefects are repaired • 0.2 mm S2-cloth isapplied on the outer surface • ImpregnationwithCTD101K in the avacuum ovenat 30-50 mm Hg withepoxytemperature of 60° C • Curingat125° C for 21 h

  15. Impregnation..

  16. Instrumentation

  17. Handling

  18. QC: Dimensional Control (CMM) Required accuracy < 20 µm

  19. QC: Photogrammetry

  20. SomeCost Indications 220 m of insulated 40-strand Nb3Sn cable: 40 kCHF A set of 23 end spacers: 10 (SLS) .. 20 kCHF (CNC) Impreg. Tool (2.5 m): 50 kCHF Impreg. System (2.5 m): 200 kCHF Reaction furnace (2.5 m): 250 kCHF Reaction tool (2.5 m): 50 kCHF

  21. Large Magnet Facility in B180 Scaling-up.. Curing press – 15 m Winding machine – 10 m

  22. Long ToolingProcurement Plan • Winding machine available • Needs to beadapted: length, windingmandrel, integration of the additional spool, process control system upgrade • Design work to start in earlyDecember • First winding trials (withdummycable) scheduled as from mid-2013 • Curingpressavailable • Curingmoulds to bedeveloped, design work to start in mid-2013 • Reactionfurnace (6.5 m) • Market Survey completed • Invitation to tender, IT-3861/TE, completed • Contractsignature expected in January 2013 • Delivery to CERN expected in the end of 2013 • Impregnationchamber • Market Survey, MS-3898/TE, completed • IT to belaunched in January 2013 • Contract signature expected in late April 2013 • Delivery to CERN expected in first quarter of 2014

  23. Acknowledgements FNAL: N. Andreev, G. Apollinari, E. Bartzi, R. Bossert, G. Chlachidze, F. Nobrega, I. Novitski, G. Wilson, A. Zlobin,... CERN: B. Auchmann, A. Ballarino, A. Bonasia, N. Bourcey, A. Cherif, S. Clement, L. Bottura, C. Kokkinos, B. Favrat, L. Favre, C. Fernandes, P. Fessia, R. Gauthier, G. Kirby, F. Lackner, G. Maury, J. Mazet, R. Moron-Ballester, J-M. Mucher, L. Oberli, J-C. Perez, L. Rossi, T. Sahner, F. Savary, S. Sgobba, D. Smekens...

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